N68060

Part: FITTING — LEAKING (HYDRAULIC SYS)

LAX - FLT 32 - NR 1 SYSTEM HYDRAULIC FAILURE. DIVERTED TO LAX, WHERE AN UNEVENTFUL LANDING WAS MADE. FOUND NR 1 SYSTEM HYDRAULIC LINE AT THE UNION TO THE STAB TRIM BRAKE LEAKING. ALSO, PRECAUTIONARY CHECKED ENGINE DRIVEN HYDRAULIC MODULE AND SYSTEM RETURN FILTER, NO CONTAMINATION FOUND. SERVICED NR 1 HYDRAULIC RESERVOIR AFTER MAINTENANCE COMPLETED, LEAK CHECK OF FILTER OK. (M)

Part: CHARGER — INOPERATIVE (CABIN) · airframe 90,070 hrs · 14,897 cycles

THE FORWARD SECTION OF D-ZONE EMERGENCY LIGHTS WENT DIM WHILE CHECKING CABIN EMERGENCY LIGHTS WITH SHIP''S POWER ON. THE D-ZONE FORWARD SECTION BATTERY CHARGER AND BATTERY WERE REPLACED.

Part: VANE — CRACKED (RT WING FLAP) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND A 2.5 INCH CRACK IN THE RT WING I/B FLAP VANE SKIN WITH THE EXTERNAL SUPPORT TRACK DAMAGED. THE FLAP VANE WAS REMOVED AND REPLACED IAW MM 27-51-03.

Part: BEAM — CORRODED (FUSELAGE) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND RT CABIN FITTING PANEL BEAM CORRODED AT STA 421 - 449. A REPAIR WAS INSTALLED IAW SRM 51-31-01.

Part: BRACKET — CRACKED (NR 3 PYLON) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND A 2 INCH CRACK IN RT WING NR 3 PYLON PANEL NR 487DR ANGULAR BRACKET. A NEW ANGLE BRACKET WAS INSTALLED IAW SRM 51-31-01.

Part: BOTTLE — DISCHARGED (PAX DOOR) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND THE R-2 DOOR POWER ASSIST BOTTLE PRESSURE LOW. THE R-2 DOOR POWER ASSIST BOTTLE PRESSURE WAS RESTORED IAW MM 52-11-07.

Part: BOTTLE — DISCHARGED (PAX DOOR) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND THE R-1 DOOR POWER ASSIST BOTTLE PRESSURE LOW. THE POWER ASSIST BOTTLE PRESSURE WAS RESTORED IAW MM 52-11-07.

Part: SUPPORT BRACKET — CRACKED (TE FLAP) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND A 1 INCH CRACK IN RT WING O/B HINGE I/B FLAP SUPPORT. A NEW SUPPORT WAS INSTALLED IAW DOUGLAS DRAWING ARC2594-3 AND SRM 51-33-01.

Part: INTERCOSTAL — CRACKED (NR 2 PACK DOOR) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND THE NR 2 AIR CONDITIONING PACK DOOR INTERNAL STRUCTURE CRACKED IN TWO PLACES. THE CRACKS WERE 3 AND 7 INCHES LONG. THE INTERCOSTALS WERE REPLACED IAW DOUGLAS DRAWING ACA 3820.

Part: BEAM — CORRODED (FUSELAGE) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND LT CABIN LONGITUDINAL BEAM UNDER LAV CORRODED AT STA 401. THE BEAM WAS REPLACED IAW MM 20-50-02.

Part: GALLEY TRACK — CORRODED (FUSELAGE) · airframe 89,130 hrs · 14,676 cycles

INSPECTION FOUND CENTRAL GALLEY SUPPORT CORRODED AT STA 449. THE SUPPORT WAS REPLACED IAW SRM 51-31-01.

Part: SKIN — DENTED (LT TE FLAP VANE)

INSPECTION FOUND LEFT WING I/B FLAP VANE EXTERNAL SKIN DENTED. THE FLAP VANE WAS REMOVED AND REPLACED IAW MM 27-50-03.

Part: SKIN — WORN (RT TE FLAP VANE)

INSPECTION FOUND RT WING I/B FLAP VANE UPPER SKIN WORN. THE FLAP VANE WAS REPLACED IAW MM 27-50-03.

Part: SKIN — DENTED (BS 339)

INSPECTION FOUND LOWER FUSELAGE SKIN DENTED AT FORWARD AVIONICS COMPARTMENT DOOR CUTOUT, LEFT FORWARD CORNER AT FRAME 339.

Part: FLOORBEAM — CORRODED (BS 1921)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 1921 ON RT SIDE UNDER LAV J. A NEW FLOORBEAM WAS INSTALLED IAW SRM 51-30-00.

Part: LONGERON — CRACKED (NR 2 ENG COWL)

INSPECTION FOUND A 1 INCH CRACK IN NR 2 ENGINE LEFT CORE COWL LONGERON. REPAIRED IAW ECRA 7110-01511.

Part: SKIN — CRACKED (LT WING)

INSPECTION FOUND A 2 INCH CRACK IN LT WING DROOPED LEADING EDGE SKIN. A REPAIR WAS PERFORMED IAW SRM 57-10-00.

Part: CLIP — CORRODED (BS 1721)

INSPECTION FOUND CENTER CARGO COMPARTMENT SHEAR CLIP CORRODED AT STA 1721 FROM LONGERON 47-48R. REPLACED SHAER CLIP IAW SRM 51-31-01.

Part: ANGLE — CRACKED (WS 486)

INSPECTION FOUND A 2 CRACK IN RT WING TRAILING EDGE ANGLE AT XORS 486. THE ANGLE WAS REPLACED IAW SRM 51-30-00.

Part: SKIN — CRACKED (NR 1 PYLON)

INSPECTION FOUND A 1 INCH CRACK IN NR 1 PYLON SKIN AT UPPER SURFACE OF FORWARD PYLON. A REPAIR WAS INSTALLED IAW ECRA 5431-01006.

Part: SEAT TRACK — CORRODED (BS 421-459)

INSPECTION FOUND LEFT SEAT TRACK CORRODED AT Y421 TO Y459, X72.50. THE SEAT TRACK WAS REPLACED IAW SRM 51-30-00.

Part: SKIN — DENTED (RT TE FLAP)

INSPECTION FOUND THE RT WING O/B FLAP LOWER SKIN DENTED. A REPAIR WAS INSTALLED IAW SRM 57-00-01.

Part: ANGLE — CRACKED (LT WING)

INSPECTION FOUND A .25 INCH CRACK IN ANGLE AT LT WING DROOPED LEADING EDGE. REPAIRED IAW SRM 57-00-01.

Part: SKIN — CRACKED (LT WING)

INSPECTION FOUND A 1 INCH CRACK IN LEFT WING TRAILING EDGE LOWER SKIN NEXT TO O/B HINGE OF O/B FLAP. A REPAIR WAS INSTALLED IAW SRM 57-00-01.

Part: SKIN — DENTED (RT TE FLAP)

INSPECTION FOUND RT WING I/B FLAP UPPER SKIN DENTED. THE SKIN WAS REPAIRED IAW SRM 57-00-01.

Part: SKIN — CRACKED (RT TE FLAP)

INSPECTION FOUND A 1 INCH CRACK IN RT WING O/B FLAP SECTION NR 1 UPPER SKIN AT STA 458. THE FLAP SECTION WAS REPAIRED IAW SRM 51-31-01 AND 57-10-00.

Part: SEAT TRACK — CORRODED (BS 72.5&421)

INSPECTION FOUND CABIN SEAT TRACK CORRODED AT STA Y421 AND X72.50. THE SEAT TRACK WAS REPLACED IAW SRM 51-31-01 AND MM 51-30-00.

Part: CHANNEL — CRACKED (LT WING)

INSPECTION FOUND A 1 INCH CRACK IN LEFT WING UPPER FUEL ACCESS DOOR NR 534CT CHANNEL. THE CHANNEL WAS REPLACED IAW SRM 51-30-00.

Part: SHEAR CLIP — CORRODED (BS 1781)

INSPECTION FOUND SHEAR CLIP CORRODED IN CENTER CARGO COMPARTMENT AT STA 1781, LONGERON 48L. THE SHEAR CLIP WAS REPLACED IAW SRM 53-30-00.

Part: FLOOR — CORRODED (BS 2007)

INSPECTION FOUND CABIN FLOOR CORRODED AT STA 2007. REPAIRED IAW SRM 53-40-00.

Part: SKIN — CORRODED (R4 DOORWAY)

INSPECTION FOUND FUSELAGE SKIN CORRODED AT NR 4 RT CABIN DOOR LOWER AFT CORNER UNDER THE THRESHOLD. THE SKIN WAS REPLACED IAW SRM 51-31-01.

Part: SHEAR CLIP — CORRODED (BS 1661)

INSPECTION FOUND CENTER CARGO COMPARTMENT LONGERON SHEAR CLIP CORRODED AT STA 1661, LONGERON 48R. THE SHEAR CLIP WAS REPLACED IAW SRM 51-31-01.

Part: SKIN — CRACKED (WS 118)

INSPECTION FOUND A 1.5 INCH CRACK IN LEFT WING TRAILING EDGE SKIN IN ZONE 541 STA XW 118. THE SKIN WAS REPLACED IAW SRM 51-31-01.

Part: STRIP — CRACKED (WS 506)

INSPECTION FOUND A 2 INCH CRACK IN RT WING LEADING EDGE STRIP AT STA XORS 506. THE LEADING EDGE STRIP WAS REPLACED IAW SRM 51-30-00.

Part: LONGERON — CRACKED (BS 2033)

INSPECTION FOUND A 4.5 INCH CRACK IN LONGERON 9R AND 6R. ALSO, 8 INCH CRACK WAS FOUND IN LONGERON 4L, AT STA 2033. THE CRACKED AREAS OF LONGERON WERE REPAIRED IAW SRM 53-10-00, FIGURE 3.

Part: LONGERON — CRACKED (BS 2122)

INSPECTION FOUND 11 INCH CRACK IN LONGERON 13L AT STA 2122. THE LONGERON WAS REPAIRED IAW SRM 53-10-00, FIGURE 3.

Part: BEAM — CORRODED (RT WING)

INSPECTION FOUND CORROSION IN UPPER HOLES OF RT MLG WING ATTACH BEAM. REPAIRED IAW DOUGLAS DRAWINGS 90-57-1017 AND 90-57-1018.

Part: ANGLE — CORRODED (BS 1894)

INSPECTION FOUND FLOORBOARD SUPPORT ANGLES CORRODED AT STA 1894. REPAIRED IAW SRM 53-60-01.

Part: BEAM — CORRODED (LT WING)

INSPECTION FOUND CORROSION IN BOLT HOLES OF LT MLG ATTACH BEAM. REPAIRED IAW DOUGLAS DRAWINGS 90-57-1017 AND 90-57-1018.

Part: ENGINE — FLAME-OUT (NR 1)

THE NR 1 ENGINE SHUTDOWN IN FLIGHT DUE TO FLAME-OUT. A RESTART ATTEMPT WAS UNSUCCESSFUL. THE ABNORMAL CHECKLIST WAS COMPLIED WITH AND THE AIRCRAFT LANDED AT EWR WITHOUT INCIDENT. THE FUEL PUMP AND MEC WERE REMOVED AND REPLACED. A POWER ASSURANCE RUN WAS PERFORMED WITH LEAK AND OPERATIONAL CHECKS GOOD. *S/D* THE MEC WAS TESTED AT WOODWARD GOVERNER CO AND THEY WERE NOT ABLE TO CONFIRM THE REPORTED PROBLEM. THE MAIN FUEL PUMP WAS TESTED AT CHANDLER EVANS AND ALL PARAMETERS WERE WITHIN LIMITS. ENGINEERING WAS UNABLE TO CONCLUDE THE REASON FOR UNCOMMANDED SHUTDOWN OF THIS ENGINE.

Part: HYD PUMP — LEAKING (NR 2 ENGINE)

THE NR 2 HYDRAULIC QUANTITY DECREASED TWO GALLONS AT FIVE HOURS INTO FLIGHT DESTINED FOR EWR. THE HYDRAULIC QUANTITY LOSS AND SINGLE HYDRAULIC SYSTEM FAILURE EMERGENCY CHECKLISTS WERE COMPLETED AND THE AIRCRAFT LANDED AT EWR WITH 2 GALLONS REMAINING IN NR 2 SYSTEM. MAINTENANCE FOUND THE NR 2 ENGINE LT HYDRAULIC PUMP AND THE LT OUTBOARD ELEVATOR DAMPER LEAKING. THE HYDRAULIC PUMP AND ELEVATOR DAMPER WERE BOTH REMOVED AND REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD. PART TOTAL CYCLES, 631.

Part: HYD PUMP — LEAKING (NR 2 ENGINE)

THE NR 2 HYDRAULIC QUANTITY DECREASED TWO GALLONS AT FIVE HOURS INTO FLIGHT DESTINED FOR EWR. THE HYDRAULIC QUANTITY LOSS AND SINGLE HYDRAULIC SYSTEM FAILURE EMERGENCY CHECKLISTS WERE COMPLETED AND THE AIRCRAFT LANDED AT EWR WITH 2 GALLONS REMAINING IN NR 2 SYSTEM. MAINTENANCE FOUND THE NR 2 ENGINE LT HYDRAULIC PUMP AND THE LT OUTBOARD ELEVATOR DAMPER LEAKING. THE HYDRAULIC PUMP AND ELEVATOR DAMPER WERE BOTH REMOVED AND REPLACED . LEAK AND OPERATIONAL CHECKS WERE GOOD. PART TOTAL CYCLES, 5,418.

Part: COALESCER BAG — DIRTY (NR 3 PACK)

SMOKE ENTERED CABIN WHILE EN ROUTE. THE NR 3 PNEUMATIC SUPPLY AND NR 3 AIR CONDITIONING PACK WERE SHUTDOWN IAW CHECKLIST AND THE SMOKE CEASED. THE FLIGHT CONTINUED TO IAH WITHOUT FURTHER PROBLEM. MAINTENANCE REPLACED THE NR 3 PACK COALESCER BAG. THE PACK WAS RUN WHILE OPERATING THE NR 3 ENGINE AND APU AND OPERATION CHECKED GOOD WITH NO SMOKE NOTED. THE AIRCRAFT COMPLETED FIVE FLIGHTS WITHOUT REPORTS OF CABIN SMOKE SINCE THIS CORRECTIVE ACTION WAS IMPLEMENTED.

Part: CHARGER — INOPERATIVE (CABIN)

THE EMERGENCY LIGHT SYSTEM FAILED TO TEST PROPERLY. THE MID-SECTION POWER SUPPLY AND BATTERY WERE REMOVED AND REPLACED.

Part: OVEN — INOPERATIVE (AFT GALLEY)

SMOKE BEGAN TO APPEAR FROM THE TOP OF THE NR 625 AFT GALLEY OVEN WHILE INFLIGHT. THE OVEN WAS TURNED OFF AND ASSOCIATED CIRCUIT BREAKERS WERE PULLED. THE SMOKE CEASED AND THE FLIGHT WAS CONTINUED WITHOUT FURTHER PROBLEM. MAINTENANCE PLACARDED THE NR 625 AFT GALLEY OVEN INOPERATIVE, NO OTHER DEFECTS WERE NOTED.

Part: O-RING — LEAKING (PROBE PLATE)

A FUEL LEAK WAS REPORTED COMING FROM TOP OF RIGHT WING. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND FUEL LEAK AT RT WING FAULT ISOLATION PROBE PLATE. A NEW O-RING WAS INSTALLED AND SEALED IAW MM 28-00-00, LEAK CHECKS WERE GOOD.

Part: FAIRING — DETACHED (NR 1 LE SLAT)

THE NR 1 RT SLAT FILLET FAIRING DEPARTED AIRCRAFT ON DEPARTURE. NO ABNORMAL INDICATIONS WERE NOTED IN COCKPIT. MAINTENANCE VERIFIED THE NR 1 RT SLAT FILLET FAIRING WAS MISSING. THE FAIRING WAS RECOVERED ON THE RUNWAY IN FCO. ALSO, FOUND DAMAGE TO THE NR 1 RT SLAT. THE NR 1 RT SLAT WAS REMOVED AND REPLACED, THE MISSING SLAT FAIRING WAS REPLACED. *S/D* INVESTIGATION REVEALED THAT A .375 FASTENER HAD FAILED SOMETIME IN THE PAST DUE TO STRESS CORROSION AND THE FILLET WAS BEING HELD IN PLACE WITH THE 3 REMAINING FASTENERS. AN FCD WAS ISSUED TO INSPECT THE FILLET FAIRING INSTALLATION FOR INTEGRITY ON ALL AFFECTED DC-10 AIRCRAFT.

Part: VALVE — LEAKING (HORIZ STAB)

FLT NR 41 - EWR - THE NR 1 HYDRAULIC SYSTEM QUANTITY DROPPED SLOWLY WHILE EN ROUTE FROM FCO TO EWR. THE SYSTEM WAS SHUTDOWN IN FLIGHT AND RESTARTED PRIOR TO LANDING. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LOWER PRIMARY TRIM CONTROL VALVE LEAKING. THE VALVE WAS REMOVED AND REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD. (M)

Part: DOOR FRAME — CORRODED (BS 895.7)

KUL - INSPECTION FOUND THE FORWARD CARGO LOWER DOOR FRAME CORRODED AT STATION 895.7. THE CORRODED AREA WAS REPAIRED IAW ECRA 5330-02320 AND SRM 53-13-01. (M)

Part: SKIN — CRACKED (VERT STAB)

KUL - INSPECTION FOUND A 1.5 INCH CRACK IN SKIN UPPER SURFACE FORWARD OF VERTICAL STABILIZER REAR SPAR ON RIGHT SIDE. THE SKIN WAS REPAIRED IAW ECRA 5530-01159. (M)

Part: AOA SENSOR — INOPERATIVE (LEFT)

FCO - FLT 0041 - THE STALL WARNING SYSTEM ACTIVATED AFTER SLATS WERE RETRACTED DEPARTING FCO. THE SLAT/FLAPS WERE DROPPED THREE TIMES, BUT THE WARNING CONTINUED. THE FLAP/SLAT INDICATOR DISAGREE LIGHT ALSO ILLUMINATED. THE AIRCRAFT WAS RETURNED TO FCO WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LT INBD FLAP POSITION TRANSMITTER SHAFT FROZEN AND THE CANNON PLUG WAS CORRODED. THE TRANSMITTER AND CANNON PLUG WERE REMOVED AND REPLACED. THE LEFT AOA SENSOR WAS ALSO FOUND AT FAULT. THE LEFT AOA SENSOR WAS REMOVED AND REPLACED. AT/SC AND AOA SELF-TESTS WERE PERFORMED PER MM 22-33-01 AND OPERATION CHECKED NORMAL. (X)

Part: OVEN — DIRTY (FWD GALLEY)

EWR - FLT 0041 - THE FORWARD GALLEY CENTER OVEN EMITTED SMOKE MOMENTARILY WHILE AT CRUISE. MAINTENANCE FOUND HEATING ELEMENTS AND BOTTOM OF OVEN CONTAMINATED WITH GREASE AND OIL. THE OVEN WAS CLEANED. OVEN OPERATION CHECKED GOOD WITH NO SMOKE PRODUCED AND NO OTHER DISCREPANCIES FOUND. (X)