N61CX

Part: UNKNOWN — ODOR (COCKPIT)

EN ROUTE FROM AVB TO RMS, THE FLIGHT CREW SENSED AN ODOR IN THE COCKPIT WHEN THE OVER HEAD FLORESENT LIGHTING SYSTEM WAS ILLUMINATED. THE CREW TURNED THE LIGHTS OFF AND THE ODOR SUBSIDED, THE FLIGHT CONTINUED TO RMS FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECT THE LIGHTING SYSTEM CIRCUITRY AND OPERATED THE SYSTEM WITH NO DEFECTS NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UPLATCH — LACK OF LUBE (LT MLG WW)

AFTER TAKEOFF FROM AVB EN ROUTE TO FRA, WHEN THE LANDING GEAR WAS RETRACTED THE MAIN GEAR DOOR NOT LATCHED LIGHT REMAINED ILLUMINATED. THE FLIGHT CREW CYCLED THE LANDING GEAR WITH THE WARNING INDICATION REMAINING THE SAME. THE FLIGHT CONTINUED TO FRA FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT GEAR DOOR WARNING SYSTEM AND LUBRICATED THE LEFT GEAR DOOR UPLATCH MECHANISM AND PERFORMED A SUCCESSFUL GEAR SWING IN ACCORDANCE WITH THE MAINTENANCE MANUAL.

Part: RETRACT MECH — MALFUNCTIONED (NLG DOOR)

AFTER TAKEOFF FROM MSP, EN ROUTE TO TOL, WHEN THE GEAR WAS RETRACTED, THE FLIGHT CREW NOTICED A LOUD NOISE AND SLIGHT VIBRATION COMING FROM THE NOSE WHEEL WELL AREA. THE CREW PERFORMED A GEAR UPLATCH CHECK WHICH PASSED, THEN CYCLED THE GEAR. THE VIBRATION CONDITION WAS STILL PRESENT AND THE AIRCRAFT CONTINUED AT A REDUCED AIRSPEED IN ACCORDANCE WITH THE COMPANY OPERATIONS MANUAL TO TOL. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE FORWARD NOSE GEAR DOORS WERE OPEN. MAINTENANCE SECURED THE NOSE GEAR DOORS AND PERFORMED A GEAR SWING IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL WITH NO DISCREPANCIES NOTED, THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: RETRACT MECH — LACK OF LUBE (NLG DOORS)

AFTER TAKEOFF WHEN THE GEAR WAS RETRACTED, THE FORWARD NOSE GEAR DOORS REMAINED OPEN. THE CREW CYCLED THE GEAR WITH NO HELP. THE FLIGHT CONTINUED TO TOL, MAKING AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE NOSE GEAR DOOR LATCH MECHANISMS, WITH NO DISCREPANCIES NOTED. MAINTENANCE CLEANED AND LUBRICATED THE DOOR LATCH MECHANISMS AND RETURNED THE AIRCRAFT TO SERVICE FOLLOWING A SUCCESSFUL GEAR SWING IN ACCORDANCE WITH THE DOUGLAS DC-8 MAINTENANCE MANUAL.

Part: REGULATOR VALVE — DEFECTIVE (NR 1 ENGINE)

DURING CLIMBOUT, THE NUMBER ONE AND TWO ENGINE PNEUMATIC MANIFOLD OVER TEMPERATURE INDICATING LIGHTS ILLUMINATED, VERIFIED BY TEMPERATURE INDICATOR. THE FLIGHT ENGINEER SECURED THE NUMBER ONE AND TWO ENGINE BLEED SYSTEMS FOLLOWING COMPANY EMERGENCY PROCEDURES. THE FLIGHT RETURNED TO TOL FOR AN UNEVENFUL LANDING. MAINTENANCE PERFORMED A GROUND RUN IN ACCORDANCE WITH COMPANY JRH WHICH REVEALED THE NUMBER ONE BLEED REGULATOR VALVE DEFECTIVE, WHICH WAS REPLACED. MAINTENANCE PERFORMED A SUCCESSFUL OPERATIONAL TEST.

Part: SMOKE DETECTOR — DIRTY (CARGO COMPT)

EN ROUTE FROM EDDF TO OKBK, THE MAIN CARGO COMPART SMOKE DETECTION LIGHT ILLUMINATED ACCOMPANIED BY THE WARNING HORN. THE CREW SILENCED THE HORN AND THE A/C DIVERTED TO IST FOR AN UNEVENTFUL LANDING. THE CARGO WAS OFF LOADED AND INSPECTED WITH NO EVIDENCE OF A FIRE. THE CREW REPORTED THE A/C WAS LOADING IN HEAVY RAINS IN EDDF. MX INSPECTED THE SMOKE DETECTION SYSTEM WHICH REVEALED MOISTURE WITHIN THE SYSTEM. MX CLEANED AND DRIED ALL SMOKE DETECTORS AND A SUCCESSFUL OPERATIONAL TEST WAS PERFORMED IAW WITH THE MX MANUAL. THE CARGO WAS LOADED AND THE A/C RETURNED TO SERVICE.

Part: WIRE — CHAFED (NR 4 ENGINE)

ON SHORT FINAL INBOUND EDDF FROM KWI, THE NUMBER 4 ENGINE FIRE BELL SOUNDED AND THE FIRE WARNING LIGHT ILLUMINATED. CAPTAIN RESET MASTER FIRE WARNING SWITCH WHICH SILENCED THE BELL. THE LIGHT REMAINED ILLUMINATED FOR 3 TO 4 SECONDS AND EXTINGUSHED. AN UNEVENTFUL LANDING WAS ACCOMPLISHED. MAINTENANCE INSPECTED THE ENGINE FIRE WARNING WIRING AND FOUND A CHAFED WIRE ON THE UPPER LOOP CONTACTING A PNEUMATIC BLEED DUCT. THE WIRE WAS REPAIRED IAW DAC M/M CHAPTER 20. SYSTEM PASSED A SUCCESSFUL GROUND OPERATIONAL CHECK IAW DAC M/M 26-10-1.

Part: CONTROL CABLE — OUT OF ADJ (MLG DOOR)

AFTER TAKEOFF WHEN THE GEAR WAS RETRACTED, THE LANDING GEAR AND DOOR UNSAFE LIGHT REMAINED ILLUMINATED. THE AIRCRAFT RETURNED TO KWI, MAKING AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE MAIN GEAR DOOR FOLLOW-UP CONTROL MECHANISM OUT OF RIG. MAINTENANCE CORRECTED THE FOLLOW-UP SYSTEM RIGGING IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL. A SUCCESSFUL GEAR SWING WAS PERFORMED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: CONTROL CABLE — MISRIGGED (LT MLG DOOR)

AFTER TAKEOFF WHEN THE LANDING GEAR WAS RETRACTED, THE DOOR UNSAFE LIGHT REMAINED ILLUMINATED. THE CREW RECYCLED THE LANDING GEAR AND THE INDICATION REMAINED THE SAME. THE AIRCRAFT RETURNED TO FRA, MAKING AN UNEVENFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE MAIN GEAR DOOR UPLATCH CABLE SYSTEM MISRIGGED. MAINTENANCE CLEANED UPLATCH SWITCHES AND CORRECTED THE CABLE SYSTEM RIGGING IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL PROCEDURES.

Part: CONTAINER — LEAKING (NR 1 CARGO COMPT)

SHORTLY AFTER TAKEOFF, CREW NOTICED FUMES ENTERING THE COCKPIT. FLIGHT ENGINEER WAS DISPATCHED TO INVESTIGATE MAIN CARGO DECK TO DETERMINE ORIGIN OF FUMES. THE FLIGHT ENGINEER CONFIRMED FUMES EMANATING FROM THE CARGO PALLET LOCATED IN THE NR 1 POSITION. CREW DUMPED FUEL AND RETURNED TO DTW. CREW REQUESTED EMERGENCY RESPONSE HAZ MAT TEAM BE DISPATCHED. THE RESPONSE TEAM MET THE AIRCRAFT AND CONFIRMED THE SOURCE OF THE FUMES TO BE A CONTAINER WITHIN THE NR 1 CARGO PALLET CONTAINER. THE SPILL WAS VERIFIED TO HAVE BEEN CONTAINED WITHIN THE CARGO PALLET. THE AIRCRAFT WAS RETURNED TO SERVICE FOLLOWING REMOVAL OF THE NR 1 CARGO PALLET.

Part: TRACK BEARINGS — FAILED (TE FLAPS)

ON LANDING ROLLOUT BGTL, WITH ALL ENGINES IN REVERSE, NR 2 ENGINE EPR DROPPED AND THE REVERSER LEVER MOVED FORWARD OUT OF REVERSE. ON INSPECTION, THE TRANSLATING RING OF THE REVERSER WAS FOUND TO BE MISSING AND TWO AREAS OF DAMAGE WERE NOTED AT THE INBOARD SECTION OF THE OUTBOARD FLAP. INVESTIGATION REVEALS FAILURE OF THE LOWER TRACK ASSEMBLY FORWARD ROD END BEARINGS. THE TRACK THEN DROPPED AND CONTACTED THE RUNWAY AND SEPARATED THE TRANSLATING RING. INTERIM REPAIRS WERE ACCOMPLISHED FOR FERRY FLIGHT TO HEAVY MAINTENANCE. THE THRUST REVERSER WAS REPLACED AND PERMANENT REPAIRS WERE MADE TO THE OUTBOARD FLAP ASSEMBLY. PART TOTAL CYCLES, 20,167.

Part: SKIN — CORRODED (LT AILERON)

DURING ROUTINE C-CHECK INSPECTION, THE LEFT OUTBOARD AILERON LOWER PLATING SURFACE WAS FOUND TO BE CORRODED BETWEEN STATIONS XW500 AND 577. THE PLATING WAS REPLACED IAW THE STRUCTURAL REPAIR MANUAL 51-1-21 AND FAA DER APPROVED SKETCH A89-R05. (M)

Part: SPAR — CRACKED (RT WING RT)

WHILE ACCOMPLISHING THE REPLACEMENT OF THE RIGHT MAIN LANDING GEAR FITTING, THE RIGHT LOWER REAR SPAR WAS FOUND TO BE CRACKED BETWEEN WING STATION S XRS 13 AND XRS 20. THE REPAIR OF THE SPAR WAS ACCOMPLISHED IAW DOUGLAS DRAWINGS 5613917, 5613918, 5613919, 5613920, 5613921 AND THE SRM. (M)

Part: SKIN — CORRODED (BS 1495)

DURING ROUTINE C-CHECK INSPECTION, THE EXTERNAL PLATING WAS FOUND TO BE CORRODED AT FUSELAGE STATION 1495 AND LONGERON 32 RIGHT. REPAIR OF THE PLATING WAS ACCOMPLISHED BY CUTTING OUT THE DAMAGED AREA, FABRICATING AND INSTALLING REPAIR FILLERS AND DOUBLERS IAW THE STRUCTURAL REPAIR MANUAL AND FAA DER APPROVED DRAWING A89-R06. (M)

Part: SKIN — CRACKED (CARGO DR OPENING)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND IN THE EXTERNAL FUSELAGE PLATING AT THE FORWARD UPPER CORNER OF THE FORWARD LOWER CARGO DOOR OPENING. THE CRACK WAS REMOVED BY CUTOUT, AND FABRICATION AND INSTALLATION OF A FILLER AND REPAIR DOUBLERS IAW THE STRUCTURAL REPAIR MANUAL 53-2-0, FIGURE 20. (M)

Part: BUS LINKS — CRACKED (RT AILERON)

DURING ROUTINE C-CHECK INSPECTION, THE RIGHT INBOARD AILERON, INBOARD BUS LINKS WERE FOUND TO BE CRACKED. THE BUS LINKS WERE REPLACED IAW THE DOUGLAS SRM AND MM. (M)

Part: PLATING — CORRODED (RT AILERON)

DURING ROUTINE C-CHECK INSPECTION, THE RIGHT OUTBOARD AILERON LOWER PLATING ON THE INBOARD SIDE WAS FOUND TO BE CORRODED. REPAIR TO THE AREA WAS ACCOMPLISHED IAW THE STRUCTURAL REPAIR MANUAL 57-10-0. (M)

Part: PLATING — CRACKED (RT WING)

DURING ROUTINE C-CHECK INSPECTION, THE RIGHT WING LEADING EDGE PLATING WAS FOUND CRACKED AT THE INBOARD STUB WING, INBOARD END. THE CRACK WAS REPAIRED IAW THE DOUGLAS SRM 57-2-1. (M)

Part: PLATING — CRACKED (FS 225)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND IN THE EXTERNAL PLATING A FUSELAGE STATION 225 BETWEEN LONGERONS 29 AND 30 LEFT. THE CRACK WAS REPAIRED IAW THE STRUCTURAL REPAIR MANUAL. (M)

Part: FITTING — CRACKED (RT MLG WW)

DURING ROUTINE C-CHECK INSPECTION, THE RIGHT MAIN LANDING GEAR FITTING WAS FOUND CRACKED. THE FITTING WAS REPLACED IAW THE DOUGLAS SRM AND FITTING REPLACEMENT GUIDE. (M)

Part: BULKHEAD — CRACKED (BS 680)

DURING ROUTINE C-CHECK INSPECTION, THE PRESSURE BULKHEAD (CABLE FEED THROUGH) AT FUSELAGE STATION 680 WAS FOUND TO BE CRACKED AT LONGERON 27 LEFT. THE BULKHEAD WAS REPLACED IAW THE AIRCRAFT SRM. (M)

Part: LONGERON — CRACKED (LT MLG WW)

DURING ROUTINE C-CHECK INSPECTION, THE LEFT LONGERON 24 WAS FOUND CRACKED IN THE WING ATTACH BOTTLE BOLT AREA. THE LONGERON WAS REPLACED IAW THE DOUGLAS REPLACEMENT GUIDE AND THE SRM. (M)

Part: FITTING — CRACKED (RT MLG WW)

DURING ROUTINE C-CHECK INSPECTION, THE RIGHT MAIN LANDING GEAR TORQUE TUBE SUPPORT FITTING WAS FOUND TO BE CRACKED. THE FITTING WAS REPLACED IAW THE STRUCTURAL REPAIR MANUAL. (M)

Part: TURBOCOMPRESSOR — MALFUNCTIONED (NR 1)

RJTY/RJOI - EN ROUTE BETWEEN RJTY AND RJOI, NR 1 CABIN TURBOCOMPRESSOR BECAME NOISY AND PRODUCED AN OILY SMELL. THE NR 12 TC WAS SHUT OFF, AND WAS DEFERRED AT RJOI. THE NR 12 TC WAS SCHEDULED FOR REPLACEMENT DUE TO POSSIBLE BEARING/OIL SEAL FAILURE. (X)

Part: EEL WIRE — FAILED (CABIN)

MAINTENANCE FOUND THE FOUR FORWARD FLOOR EMERGENCY TRACK LIGHTS TO BE INOPERATIVE. THE POWER SUPPLY PROVIDING POWER TO THESE LIGHTS WAS BLOWING PICOFUSES FOR THAT SET OF LIGHTS. TROUBLESHOOTING INDENTIFIED A SHORT IN THE POWER WIRE BETWEEN THE POWER SUPPLY AND THE LIGHT SET. THE SHORTED WIRE WAS REPAIRED, RETURNING THE SYSTEM TO NORMAL OPERATION.

Part: WIRE — FAILED (RT MLG)

WSAP - ON DEPARTURE DURING UPLATCH CHECK, THE GEAR LIGHT STAYED ON WITH THE MAIN GEAR DOOR LIGHT OUT. THE LANDING GEAR WAS CYCLED ONCE, AND THE UPLATCH CHECK WAS SUCCESSFUL. INSPECTION OF THE SYSTEM IN RJTY REVEALED AN INTERMITTENT GROUND WIRE ON THE RT MLG UPLATCH SWITCH. AN OPERATIONAL CHECK OF THE LANDING GEAR WAS ACCOMPLISHED WITH NORMAL OPERATION NOTED ON SIX RETRACTIONS. THE AIRCRAFT WAS RETURNED TO SERVICE. (X)

Part: UPLOCK ASSY — LACK OF LUBE (MLG DOORS)

ON DEPARTURE OUT OF RJTY, THE UPLATCH CHECK WAS ACCOMPLISHED AND BOTH THE GEAR DOOR AND GEAR WARNING LIGHTS ILLUMINATED. THE AIRCRAFT RETURNED TO RJTY FOR MAINTENANCE. MAINTENANCE JACKED THE AIRCRAFT, CLEANED AND LUBRICATED BOTH THE LANDING GEAR AND THE GEAR DOOR UPLATCHES. THE GEAR DOOR LATCHES WERE ADJUSTED PER THE DC-8 MM. THE LANDING GEAR WAS OPERATIONALLY CHECKED, AND THE AIRCRAFT RETURNED TO SERVICE. (M)