N784AL

Part: BLEED VALVE — STUCK (NR 1 ENGINE) · airframe 81,747 hrs · 26,411 cycles

LOG PAGE NR 128276. NR 1 ENGINE WOULD NOT ACCELERATE TO TAKE-OFF POWER; REJECTED TAKE OFF AT 80 KTS. - RETURNED TO GATE. FOUND NR 1 COMPRESSOR BLEED VALVE STUCK IN OPEN POSITION. R&R NR 1 ENGINE COMP. BLEED CONTROL VALVE IAW DC-8 M/M 75-30-3; OPS CHECK NORMAL IAW M/M 5-50-0 UNSCHEDULED MX CHECK, NO DEFECTS NOTED.

Part: CONTROL CABLE — BROKEN (STABILIZER) · airframe 81,629 hrs · 26,348 cycles

ON DESCENT LONG TRIM SUITCASE HANDLE, RIGHT SUITCASE HANDLE JAMMED. FOUND BROKEN CABLE RUNNING NR 49B. REMOVED AND REPLACED 1/16 CONTROL CABLE RUNNING NR 49B IN ACCORDING WITH DC-8 MAINTENANCE MANUAL 27-40-01. RIGGING AND OPERATION CHECKED, FOUND NORMAL IN ACCORDING WITH DC-8 MAINTENANCE MANUAL 27-40-01.

Part: CYLINDER — MALFUNCTIONED (TE FLAPS) · airframe 81,488 hrs · 26,273 cycles

ON APPROACH INTO MROC THE FLAPS WOULD NOT EXTEND BEHOND 23 DEGREES. FOUND OUTBOARD FLAP LOCKOUT CYLINDER RETRACTED; SERVICE FLAP LOCKOUT CYLINDERS IAW MM 27-51-10. OPERATIONAL CHECK FOUND NORMAL IAW MM 27-50-00.

Part: UNKNOWN — SPARKS (MLG AREA)

AIR TURNBACK REPORTED SPARKS COMING FROM RT MAIN GEAR. DECLARED EMERGENCY AND RETURNED TO MIA. (S)

Part: LIMIT SWITCH — MALFUNCTIONED (TE FLAPS) · airframe 81,086 hrs · 26,061 cycles

DURING TAKEOFF ROLL, TAKEOFF WARNING HORN CAME ON. REMOVED AND REPLACED SI-278 FLAP UPLIMIT SWITCH IN ACCORDANCE WITH M/N 27-52-1 AND SI-177 AND 176 SPOILERS SWITCH IN ACCORDANCE WITH 27-63-1, SYSTEM GROUND TEST NORMAL.

Part: SNAP RING — LOOSE (NR 2 TC DEFUSER) · airframe 80,926 hrs · 25,977 cycles

DURING CLIMB-OUT, UNABLE TO CONTROL THE CABIN PRESSURIZATION, NEITHER WITH AUTO OR MANUAL (WITH 4 T.C. ON). FOUND NR 2 TC DISFUSER SNAP RING LOOSE. REINSTALLED SNAP RING AT NR 2 TC IN ACCORDANCE WITH DC-8 M/M 21-10-6. PRESSURIZATION CHECK FOUND NORMAL IN ACCORDANCE WITH DC-8 M/M 21-31-0.

Part: BELLCRANK — BROKEN (NLG) · airframe 80,457 hrs · 25,742 cycles

ON POST FLIGHT FOUND NOSE GEAR DOOR BROKEN LINK. REMOVED TORQUE TUBE AND BELL CRANK IN ACCORDANCE WITH M/M 32-22-2. INSTALLED BELL CRANK AND REINSTALLED NOSE GEAR DOOR LINKAGE IN ACCORDANCE WITH M/M 32-33-2; OPERATIONAL CHECK IN ACCORDANCE WITH M/M 32-22-1 AND 32-30-0, FOUND NORMAL.

Part: WIRE — DAMAGED (HYD TRANSMITTER) · airframe 80,439 hrs · 25,732 cycles

LOST ALL HYDRAULIC PRESSURE DURING TAXI. REPAIR WIRE ON HYDRAULIC PRESSURE TRANSMITTER IAW MM 20-51-00; OPERATIONAL CHECK NORMAL IAW MM 20-00-00.

Part: COMPRESSOR — STALLED (NR 4 ENGINE) · airframe 80,373 hrs · 25,698 cycles

LOG PAGE NR 124562. ABORTED TAKEOFF AT 105 KTS FOLLOWING NR 4 ENGINE COMPRESSOR STALL. INSPECTED NR 4 ENGINE COMPRESSOR SURGE BLEED VALVE AND TIGHTEN ALL SENCE LINES IAW MM 75-30-01/201; OPERATIONAL CHECK NORMAL ON ENGINE RUN IAW M/M 71-00/501.

Part: O-RING — LEAKING (HYD SYSTEM) · airframe 80,033 hrs · 25,530 cycles

PRIOR TO DESCENT, OBSERVED A LOSS OF HYDRAULIC QUANTITY TO THE STAND PIPE LEVEL FOLLOWED BY A LOSS OF PRESSURE. REMOVED AND REPLACED DAMAGE O-RING ON NR 2 ENGINE HYDRAULIC PUMP PRESSURE LINE FITTING IN ACCORDANCE WITH M/M 20-12-0 PAGE 211. OPERATIONAL CHECK NORMAL IN ACCORDANCE WITH M/M 72-00 PAGE 517. ENGINE STARTING.

Part: STRIKER — UNKNOWN (MLG DOOR PROX) · airframe 79,816 hrs · 25,428 cycles

AFTER NORMAL GEAR RETRACTION, RED DOORS NOT LATCHED, LIGHT ILLUMINATED ON UP-LATCH CHECK; PERFORMED ABNORMAL CHECKLIST, LIGHT REMAINED ON. REMOVED AND REPLACED LT MAIN GEAR INBOUND DOOR LATCH STRIKER IN ACCORDANCE WITH M/M 32-31-4; ALSO REPLACED BOTH TARGET ASSEMBLY PROXIMITY SWITCH IN ACCORDANCE WITH M/M 32-31-4; OPERATIONAL CHECK IN ACCORDANCE WITH M/M 32-30-0 FOUND NORMAL ON GEAR SWING.

Part: ENGINE — LEAKING (NR 2) · airframe 79,772 hrs · 25,402 cycles

DURING CRUISE, NR 2 ENGINE LOSS OF ALL OIL QUANTITY AND PRESSURE; PRECAUTIONARY ENGINE SHUTDOWN AS PER CHECKLIST (TIME 0655). REMOVED AND REPLACED NR 2 ENGINE IN ACCORDANCE WITH ARROW AIR TASK CARD NR DC8-N-003. LEAK CHECKED, NO LEAKS NOTED; OPERATIONAL CHECK NORMAL; FUNCTIONAL CHECK NORMAL.

Part: PROXIMITY SWITCH — MALFUNCTIONED (MLG) · airframe 76,759 hrs · 25,394 cycles

"GEAR NOT LATCHED" LIGHT ILLUMINATED AFTER GEAR UPLATCH CHECK; CONTINUED OPERATION AS PER ABNORMAL CHECKLIST. PERFORMED PROXIMITY SWITCHES TEST IN ACCORDANCE WITH M/M 32-60-0. REMOVED AND REPLACED CONTROL BOX PROXIMITY SWITCHES SYSTEM OPERATIONAL CHECK NORMAL IN ACCORDANCE WITH M/M 32-60-0.

Part: ENGINE — VIBRATION (NR 3) · airframe 79,688 hrs · 25,349 cycles

SHUT-DOWN NR 3 ENGINE IN FLIGHT DUE TO VIBRATION. COMPLIED WITH ALL CHECKLIST. C/W RED BORDER NR 019421 NR 3 ENGINE P-679000 REPLACEMENT. COMPLY WITH RED BORDER NR 019421; REMOVED AND REPLACED NR 3 ENGINE IN ACCORDANCE WITH MAINTENANCE MANUAL 71-00-00. OPERATIONAL CHECK NORMAL.

Part: SKIN — DAMAGED (LT AILERON) · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, LT O/B AILERON BETWEEN XA 678 AND XA 685 LOWER SKIN RIVETS SHEARED. REMOVED LT O/B AILERON PLATING BETWEEN XA 662 & XA 724 AND REPLACED WITH SOLID SKIN IN ACCORDANCE WITH DRAWING NR AIPSAC-N784AL-09/05, ISSUED FAA FORM 8110-3 APPROVING THIS REPLACEMENT.

Part: SKIN — CORRODED (BS 1690-1734) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, FUSELAGE EXTERIOR BETWEEN STA 1690 & STA 1734 AND L-26L THRU L-28L SKIN WITH CORROSION. REPAIRED FUSELAGE TAIL SECTION PLATING BETWEEN FS 1696 TO FS 1766 AND L-24L TO L-28L IN ACCORDANCE WITH DRAWING NR AIPSAC-N784AL-03/05, SHEETS 1 THRU 5, DATED 08/21/05. ISSUED FAA FORM 8110-3, DATED 01/06/06, APPROVING THIS REPAIR.

Part: SKIN — CORRODED (BS 1690-1720) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; LOWER FUSELAGE STA 1690 THRU STA 1720, L-31L THRU L-31R SKIN PANEL WITH CORROSION AT SEVERAL PLACES. REPAIRED FUSELAGE TAIL SECTION PLATING BETWEEN FS 1690 TO FS 1720 AND L-28R TO L-34 IN ACCORDANCE WITH DRAWING NR AIPSAC-N784AL-01/05, SHEETS 1 THRU 4, DATED 08/24/05. ISSUED FORM 8110-3, DATED 01/06/06, APPROVING THIS REPAIR.

Part: SKIN — DELAMINATED (RT ELEVATOR) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, RT ELEVATOR XE 28.843 LOWER SURFACE WITH DELAMINATION. REMOVED RT ELEVATOR SKIN UPPER SURFACE BETWEEN XAE 0 TO SE 103 AND XE 273 TO XE 285 AND REPLACED WITH SOLID SKIN IN ACCORDANCE WITH DRAWING AIPSAC-N784AL-05/05. ISSUED FAA FORM 8110-3 APPROVING THIN REPLACEMENT.

Part: SKIN — CORRODED (BS 1620) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION THE FOLLOWING WAS FOUND; AFT ACCESSORY COMPT INTERIOR STA 1620 BETWEEN L-30L AND L-31L SKIN WITH CORROSION. REPAIRED INNER DOUBLER BETWEEN FS 1620 AND FS 1680 AND L-26L AND L31L IN ACCORDANCE WITH DRAWING NR AIPSAC-N784AL-06/05, ISSUED FAA FORM 8110-3.

Part: FINGER DOUBLER — CORRODED (BS 920-960) · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, MAIN CARGO COMPARTMENT STA.920, STA.940, STA.960, XCW 0 - XCW 23 CENTER WING SECCTION RT FINGER DOUBLER WITH CORROSION. REPAIRED FUSELAGE CENTER SECTION PRESSURE PANEL BETWEEN STA 920 AND FS 940 IN ACCORDANCE WITH DRAWING AIPSAC-N784AL-02/05.

Part: STRUCTURE — CRACKED (NR 3 PYLON) · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION THE FOLLOWING WAS FOUND; NR 3 PYLON FOOT STOOL I/B SIDE WITH 1 - 3/4" CRACK. REMOVED AND REPLACED NR 3 PYLON FOOT STOOL FITTING IN ACCORDANCE WITH DC8 S/B AS7-99 REVISION 1 DATED 09/03/93 AND DC8 S/B AS7-87, REVISION NR 2, DATED 01/14/91 AND MCDONNELL DOUGLAS DRAWING NR TUI SF5753054-501/-502, SHEET 1 THRU 10 (USED DOUGLAS HOLE/SURFACE DUPLICATION TOOL P/N 5753054-502 SF1).

Part: SKIN — CORRODED (BS 1490-1690) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; LOWER FUSELAGE STATION 1490 THROUGH STATION 1690L, L-31L THRU L31R SKIN PANEL WITH CORROSION AT SEVERAL PLACES. REMOVED AND REPLACED SKIN FROM FUSELAGE STA 1490 TO FS STA 1690 IN ACCORDANCE WITH AIPSAR EA NR 1702, DC8 SRM 51-1-200, 53-4-1 FIG 17A, 51-1-21, 51-1-11 AND DPS 3-67-27.

Part: SKIN — CORRODED (BS 1620-1640) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; AFT ACCESSORY COMPARTMENT INTERIOR STA 1620-STA 1640 BETWEEN L-32L & L-33L SKIN WITH CORROSION; N/R 1022- AFT ACCESSORY COMPARTMENT INTERIOR STA 1620 BETWEEN L-30L & L-31L SKIN WITH CORROSION. REPAIR INNER DOUBLER BETWEEN FUSELAGE 1620 AND FS 1680 AND L-26L AND L-31L IAW DRAWING NR AIPSAC-N784AL-06/05, ISSUED FAA FORM 8110-3.

Part: SKIN — CORRODED (AILERON) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; I/B AILERON BETWEEN XA 565 AND SA 542 LOWER SKIN WITH CORROSION. REMOVED SKIN AND BONDED DOUBLER AND REPLACED BY SOLID SKIN BETWEEN XA 542 AND XW 563 IN ACCORDANCE WITH DRAWING NR AIPSAC-N784AL-07/05. ISSUED FAA FORM 8110-3 APPROVING THIS REPLACEMENT.

Part: SKIN — CORRODED (RT ELEVATOR) · corrosion level 2 · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, RT ELEVATOR XE 276 THRU XE 280 LOWER SURFACE WITH CORROSION. REMOVED RT ELEVATOR SKIN UPPER SURFACE XAE 0 TO XE 103 AND XE 273 TO XH 285 AND REPLACED WITH SOLID SKIN IN ACCORDANCE WITH DRAWING NR AIPSAC-N784AL-05-05. ISSUED FAA FORM 8110-3, APPROVING THIS REPLACEMENT.

Part: SKIN — CORRODED (RT AILERON) · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; RT INBOUND AILERON BETWEEN XA 565 AND XA542 LOWER SKIN WITH CORROSION.

Part: SKIN — CORRODED (BS 1690-1734) · airframe 79,669 hrs · 25,338 cycles

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; FUSELAGE EXTERIOR STA 1690 THROUGH STA 1734, L-29L, SKIN WITH CORROSION.

Part: STRUCTURE — CRACKED (NR 3 PYLON) · airframe 79,669 hrs · 25,338 cycles

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; NR 3 PYLON FOOT STOOL INBOUND SIDE WITH 1.750 INCH CRACK.

Part: STRUCTURE — CRACKED (NR 2 PYLON) · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; NR 2 PYLON FOOT STOOL INBOUND SIDE WITH CRACK, APPROXIMATELY 5/8".

Part: SKIN — CORRODED (BS 1620-1640) · airframe 79,669 hrs · 25,338 cycles

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; AFT ACCESSORY COMPT INTERIOR STA 1620 THROUGH STA 1640, BETWEEN L-32L AND L-33L, SKIN WITH CORROSION.

Part: SKIN — CORRODED (BS 1490-1690) · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; LOWER FUSELAGE STA 1490 THROUGH STA 1690, L-31L THROUGH L-31R, SKIN PANEL WITH CORROSION AT SEVERAL PLACES.

Part: SKIN — CORRODED (BS 1690-1720) · airframe 79,669 hrs · 25,338 cycles

DURING "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND; LOWER FUSELAGE STA 1690 THROUGH STA 1720, L-31L THROUGH L-31R, SKIN PANEL WITH CORROSION AT SEVERAL PLACES.

Part: CONNECTOR — DIRTY (FIRE DETECTOR) · airframe 79,586 hrs · 25,301 cycles

DURING MAINTENANCE INSPECTION, NR 2 FIRE WARNING DOES NOT TEST; NO LIGHT; NO BELL. CLEANED NR 2 FIRE CONNECTOR WARNING; OPERATIONAL CHECK TEST NORMAL IN ACCORDANCE WITH M/M 26-10-0.

Part: LANDING GEAR — LACK OF LUBE · airframe 79,166 hrs · 25,107 cycles

GEAR NOT LATCHED LIGHT ILLUMINATED. REMAINED ILLUMINATED AFTER COMPLETING GEAR NOT LATCHED LIGHT ILLUMINATED CHECKLIST. CHECK LANDING GEAR MECHANISM, LUBRICATED SAME, PERFORM GEAR SWING IN ACCORDANCE WITH MM 32-30-0. ALL LIGHTS OPERATED OK IN ACCORDANCE WITH MM 12-80-0 AND DID NOT DUPLICATE FAIL AT THIS TIME.

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 79,153 hrs · 25,101 cycles

NR 1 ENGINE OIL PRESSURE LIGHT ILLUMINATED; OIL PRESS GAUGE INDICATED 25 PSI, FOLLOWED BY A LOSS OF OIL QUANTITY, WENT TO ZERO. PERFORMED OIL PRESSURE LIGHT ILLUMINATED CHECKLIST; THEN, PERFORMED IN-FLIGHT ENGINE SHUTDOWN ABNORMAL CHECKLIST. ENGINE SHUTDOWN AT 18:17Z, AFTER EVALUATION, CONTINUE TO MIA. REMOVED AND REPLACED NR 1 ENGINE IN ACCORDANCE WITH ARROW AIR TASK CARD DC8UN-003; PERFORMED ENGINE RUN-UP FOUND NORMAL IN ACCORDANCE WITH DC8 MM 71-00.

Part: WARNING LIGHT — ILLUMINATED (MLG) · airframe 79,095 hrs · 25,076 cycles

AFTER GEAR RETRACTION, GEAR NOT LATCHED LIGHT REMAINTED ILLUMINATED, PERFORMED ABNORMAL CHECKLIST. CHECKED ALL WIRING FOR GEAR LATCH LIGHT. JACKED A/C PERFORMED GEAR SWING SEVERAL TIMES. CHECK ALL THREE GEARS FOR CONDITION AND FOUND NORMAL. UNABLE TO DUPLICATE. CHECKED CIRCUIT PER WIRING DIAGRAM SERVICE BULLETIN NR 32-156 PAGES 26 AND 27, WIRING FOUND NORMAL, UNABLE TO DUPLICATE ON GROUND.

Part: INDICATOR — INOPERATIVE (WX RADAR SYSTEM) · airframe 78,713 hrs · 24,910 cycles

LOST WEATHER RADAR IN ROUTE TO GEG. REMOVED AND REPLACED RADAR INDICATOR AND RADAR R/T, OPERATIONS TESTED NORMAL IN ACCORDANCE WITH M/M 34-41-1.

Part: LINK ASSY — FAILED (NLG DOOR) · airframe 78,416 hrs · 24,790 cycles

AFTER TAKEOFF, HAD A VIBRATION BELOW COCKPIT AREA RECYCLED LANDING; GEAR NO HELP; RETURNED TO DEPARTURE (KMIA. REMOVED AND REPLACED RT NOSE GEAR DOOR LINK ASSEMBLY IAW MM 32-22-2. OPERATIONAL CHECK NORMAL.

Part: INDICATOR — MALFUNCTIONED (STANDBY ALT) · airframe 77,868 hrs · 24,541 cycles

STANDBY ALTITUDE INDICATOR FAILED IN FLIGHT. REMOVED STANDBY INDICATOR & REPLACED WITH SERVICE STANDBY ATT. INDICATOR. OPERATIONAL CHECK GOOD IN ACCORDANCE WITH DACO DC-8 MM 24-3-3.

Part: WIRE — DAMAGED (NR 1 ENGINE) · airframe 77,868 hrs · 24,541 cycles

NR 1 OIL TEMPERATURE ERRATIC AND UNREALIABLE IN-FLIGHT. REPAIRED WIRE AT PIN U NR 1 ENGINE PYLON MAIN DISCONNECT PLUG IN ACCORDANCE WITH DACO DC-8 MM 20-50-1. RAN ENGINE FOR 20 MINUTES. OPERATIONAL CHECK GOOD IAW DACO DC-8 MM 71-00-00

Part: COMPRESSOR — STALLED (NR 4 ENGINE) · airframe 77,260 hrs · 24,301 cycles

ON FLIGHT 410, THE NR 4 ENGINE COMPRESSOR STALLED, FOLLOWED BY LOSS OF POWER. ACCOMPLISHED IN FLIGHT ENGINE SHUTDOWN AS PER FOM; ENGINE SHUTDOWN AT 14:35, THE WINDMILLING OIL PRESSURE WAS ZERO.

Part: BRAKE ASSY — DAMAGED (MLG) · airframe 77,168 hrs · 24,226 cycles

AIRCRAFT DOES NOT TAXI UNDER IT'S OWN POWER. FOUND NR 6 BRAKE ASSEMBLY DAMAGED. REMOVED AND REPLACED BRAKE ASSEMBLY IAW DC8 MM 32-42-1 AND MAIN WHEEL ASSEMBLY IAW MM 32-40-1. OPERATIONAL CHECK NORMAL.

Part: LINK — BROKEN (TE FLAP) · airframe 77,026 hrs · 24,169 cycles

ON APPROACH, WHEN SELECTING FLAPS 23 DEGREES AIRCRAFT ROLLED TO THE LEFT WITH SPLIT FLAP INDICATION, ON POST FLIGHT FOUND RT INBOARD FLAP BRACKET BROKEN. RECORD FOR 27-268. REMOVED AND REPLACED RT INBOARD FLAP IAW MM 27-51-4. OPERATIONAL CHECK NORMAL IAW 27-50-0.

Part: SPRING — BROKEN (RT MLG DOOR) · airframe 76,614 hrs · 24,021 cycles

LOG PAGE 102010. AFTER TAKEOFF, DOORS NOT LATCHED LIGHT ILLUMINATED. FOUND BROKEN SPRING AT RT MAIN LANDING GEAR DOOR CONTROL VALVE MECHANISM. REPLACED SPRING IAW MM 32-32-7, PERFORMED GEAR SWING IAW MM 32-30-0; FOUND NORMAL SYSTEM.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 76,358 hrs · 23,938 cycles

DURING C-CHECK INSPECTION THE FOLLOWING WAS FOUND; FUSELAGE EXTERIOR LOWER SURFACE RIVET PLUNGED, STATION 540, BY L-36. FOUND TO BE OUT OF LIMITS IAW DC8 SRM 53-2-0. REMOVED CORROSION IAW DC8 SRM 51-1-8, FOUND TO BE OUT OF LIMITS IAW DC8 SRM 53-2-0, TRIMMED OUT DAMAGED AREA AND FABRICATED PARTS IAW AVITAS ENGINEERING REPAIR ORDER AROW-031RO-4, PAGE 1 & 2, DATED 05/01/03 AND REPAIR SKETCH AIPSAC-N784AL-04/03, REV IR, SHEET A.1 TO A.5, DATED 05/01/03. TREATED AND PRIMED PARTS IAW DC8 SRM 51-1-8 AND INSTALLED PARTS IAW REPAIR ORDER AROW-031RO-4, PAGE 1 TO 2 AND REPAIR SKETCH AIPSAC-N784AL-04/03, REV IR. ISSUED FAA FORM 8110-3.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 76,358 hrs · 23,938 cycles

DURING C-CHECK INSPECTION THE FOLLOWING WAS FOUND; FUSELAGE EXTERIOR SURFACE WITH CORROSION, STATION 510, L-35R. REPAIRED FUSELAGE LOWER SKIN AT FUSELAGE STA 510 AND L-35R IAW AVITAS ENGINEERING REPAIR ORDER AROW-031RO-5, PAGE 1 & 2, DATED 05/01/03 AND REPAIR DRAWING AIPSAC-N784AL-05/03, REV IR, SHEETS A.1 TO A.5, DATED 05/01/03. ISSUED FAA FORM 8110-3 APPROVING THIS REPAIR.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 76,352 hrs · 23,938 cycles

DURING "C" CHECK INSPECTION THE FOLLOWING WAS FOUND; AFT LOWER CARGO COMPARTMENT AFT DOOR SUPPORT ANGLE WITH CRACK; STATION 1420. REMOVED ANGLE IAW DPS 3.67-27, FABRICATED NEW ANGLE IAW DPS 3.69-4, PRIMED NEW ANGLE IAW DC8 SRM 51- 1-8 AND INSTALLED ANGLE AIW DC8 SRM 51-1-21.

Part: FITTING — CRACKED (RT MLG WW) · airframe 76,358 hrs · 23,938 cycles

N/R 421. DURING "C" CHECK INSPECTION THE FOLLOWING WAS FOUND; RT MAIN LANDING GEAR WHEEL WELL STATION 879, L-24R FITTING WITH CORROSION AND 3 INCH CRACK. REMOVED AND REPLACED FITTING OF R/H MAIN LANDING GEAR WHEEL WELL STA 879, L-24R IAW SRM 51-1-20D AND SRM 53-1-0.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 76,358 hrs · 23,938 cycles

DURING C-CHECK INSPECTION THE FOLLOWING WAS FOUND; AFT FUSELAGE INNER SKIN WITH CORROSION BETWEEN STATION 1660 AND STATION 1680, BETWEEN L-24R AND L-25R. REMOVED CORROSION IAW DC8 SRM 51-1-8, FOUND TO BE OUT OF LIMITS IAW DC8 SRM 53-2-0, REMOVED DAMAGED AREA AND FABRICATED PARTS IAW REPAIR ORDER AROW-031RO-7, REV IR, AND DRAWING AIPSAC-N784AL-06/03, REV IR, SHEET A.1 TO A.5, DATED 05/08/03. TREATED AND PRIMED PARTS IAW DC8 SRM 51-1-8 AND INSTALLED PARTS IAW REPAIR ORDER AROW-031RO-7, REV IR AND DRARWING AIPSAC-N784AL-06/03, REV IR, SHEET A.1 TO A.5, DATED 05/08/03. ISSUED FAA FORM 8110-3.

Part: DOUBLER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 76,358 hrs · 23,938 cycles

DURING "C" CHECK INSPECTION THE FOLLOWING WAS FOUND; AFT LOWER CARGO COMPARTMENT STATION 1620, BETWEEN L-26R AND L-31R INNER SKIN WITH SEVERAL SPOTS OF CORROSION. REPAIRED FUSELAGE INNER DOUBLER AT FS 1620, BETWEEN L-25R AND L-31R IAW MFG ENGINEERING REPAIR ORDER AROW-031RO-3, PAGE 1 TO 2, DATED 05/01/03 AND REPAIR DRAWING NUMBER AISAC-N784AL-03/03, SHEETS A-1 TO A-5, DATED 05/01/03, REVISION IR. ISSUED FAA FORM 8110-3 APPROVING THIS REPAIR.

Part: CLIP — CRACKED (FUSELAGE) · airframe 76,358 hrs · 23,938 cycles

NR 194. DURING "C" CHECK INSPECTION THE FOLLOWING WAS FOUND;FORWARD LOWER CARGO COMPARTMENT STATION 300, BETWEEN L-33R & L-34R FITTING WITH CRACK. REMOVED AND REPLACED FITTING ON FOWARD LOWER CARGO COMPARTMENT STA.300 BETWEEN L-33R & L-34R IAW WITH SRM 51-1-20 (D) AND 51-1-21.

Part: AMPLIFIER — FAILED (NR 2 FIRE DETECT) · airframe 76,145 hrs · 23,854 cycles

SHORTLY AFTER TAKEOFF FIRE WARNING ON ENGINE NR 2. REMOVED AND REPLACED NR 2 FIRE DETECTOR AMPLIFIER. OPERATIONAL CHECK NORMAL IAW MM 26-10-0 AND ENGINE RUN UP IAW MM 71-00.

Part: SENSOR — MALFUNCTIONED (MLG)

WHEN LANDING GEAR SELECTED DOWN, HAD BOTH RED DOORS NOT LATCHED AND GEAR NOT LATCHED LIGHTS WITH NO GREEN LEFT LANDING GEAR LIGHT. REMOVED AND REPLACED LT SENSOR OF MAIN GEAR ALL POSITION & WARNING LIGHTS WORK NORMAL IAW MM 32-60-0.

Part: GCU — FAILED (NR 2 GEN)

WHEN GENERATORS ARE PARARELLED NR 2 GENERATOR UNPARELLED, NO VOLTS, NO FREQS AND LOAD. REMOVED AND REPLACED GENERATOR CONTROL UNIT (GCU) IAW MM 24-20-6. OPERATIONAL CHECK NORMAL IAW MM 24-20-1.

Part: RELAY — DAMAGED (BUSS TIE) · airframe 76,073 hrs · 23,829 cycles

NR 2 GENERATOR UNPARALLEL AND LOST NR 2 BUS POWER FAIL LIGHT. FOUND FZ-1 FUSE BLOWN ON GENERATOR CONTROL UNIT (GCU) NR 2 FOR BUS TIE CONTROL. REMOVED AND REPLACED GCU NR BUS TIE RELAY IAW MM 24-20-5 AND 24-20-1; WIRING CHECK ACCOMPLISHED AS PER W/D 24-1-2 NO TROUBLE FOUND. GENERATOR 2 OPERATIONAL NORMAL IAW MM 24-20-0.

Part: VALVE — FAILED (ANTI SKID SYS) · airframe 76,052 hrs · 23,819 cycles

PRIOR TO 80 KTS. ANTI-SKID LIGHT CAME ON. NOTE: REJECTED TAKEOFF AT KMIA. CHECKED ELECTRICAL SYSTEM IAW MM 32-3-0 SMT 1 & 2 FOUND SYSTEM WORKED NORMAL. REMOVED AND REPLACED LAMP CONTROL BOX IAW MM 32-43-7; PENDING OPERATIONAL CONTROL CHECK. ALSO REMOVED AND REPLACED R.A.O. ANTISKID SYSTEM DUAL SERVO VALVE IAW MM 32-43-3. LEAK CHECKED, NO LEAK NOTED. PERFORMED OPS CHECK ANTISKID SYSTEM IAW MM 32-43-0. FOUND ALL NORMAL. PERFORM TAXI AT 70 KTS. NO LIGHT ANTISKID OPERATIONAL NORMAL IAW 32-43-0.

Part: CONTROL BOX — FAILED (ANTI SKID SYS) · airframe 76,052 hrs · 23,819 cycles

ANTI-SKID INOPERATIVE. REMOVED AND REPLACED CONTROL BOX IN ACCORDANCE WITH MM 32-43-6. OPERATIONAL CHECKED GOOD IAW MM 33-43-0.

Part: BLEED VALVE — FAILED (NR 2 ENGINE) · airframe 76,004 hrs · 23,802 cycles

ON TAKE-OFF UNABLE TO ATTAIN MAXIMUM POWERN ON NR 2 ENGINE WITH THROTTLE FIRE WALL EPR 1.36 N1 98 N2 95 FIREWALL POWER. AIRCRAFT ABORTED TAKE-OFF AIRCRAFT RETURNED TO BLOCK. REMOVED AND REPLACED SURGE BLEED VALVE IAW MM 75-30-3. PERFORMED OPERATIONS CHECK AND TEST OF NR 2 ENGINE SURGE BLEED VALVE IAW MM 75-30-3 AND MM 71-0. OPS CHECK FOUND NORMAL.

Part: PACKING — LEAKING (OIL SYS) · airframe 76,001 hrs · 23,801 cycles

INFLIGHT OIL QUANTITY GRADUALLY DROPPED TO ZERO, SUBSEQUENTLY OIL PRESSURE FLUCTUATED BETWEEN 45 36 PSI. OIL PRESSURE LIGHT ON, PERFORMED IN FLIGHT NR 3 ENGINE SHUTDOWN AS PER ABNORMAL WIND MILL OIL PRESSURE 10 PSI. DECLARED EMERGENCY. PERFORMED FUEL DUMP PROCCEDURE IN ORDER TO LAND AT MPTO WITHOUT INCIDENTS. REPLACING O-RING TO OIL FILTER STRAINED ELEMENT AND INSPECTED STRAINER FOR CONTAMINENTS. NONE NOTED. PERFORMED LEAK AND OPERATIONAL CHECKED IAW PW MM 72-00. ENGINE OPERATIONAL NORMAL. NO LEAKS NOTED.

Part: LINE — LEAKING (HYD SYSTEM) · airframe 75,187 hrs · 23,502 cycles

AFTER LANDING, LOSS HYDRAULIC FLUID TO STANDPIPE. REMOVED AND REPLACED HYDRAULIC BRAKE LINE WITH A FLEX LINE (TEMP) IAW MM 32-42-1 AND GMM 6-6-1 OPS AND LEAK OK IAW MM 32-42-1 SERVICED HYDRAULIC SYSTEM IAW MM 12-03-0. CARRIED OVER ITEM NR 05938 WAS CLOSED ON LOG PAGE NR 113307; REINTALLED FLEX LINE IN FAK AS REQUIRED.

Part: INSULATION — LOOSE (CARGO BAY) · airframe 74,414 hrs · 23,144 cycles

EN ROUTE FROM TER TO RMS, THE FLIGHT CREW SENSED A HYDRAULIC LIKE ODOR EMITTING FROM THE MAIN CARGO COMPARTMENT VENTILATION SYSTEM, THEN THE ODOR SUBSIDED. THE FLIGHT CONTINUED TO RMS FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIR CONDITION DISTRIBUTION DUCTING LOCATING A PIECE OF INSULATION LAYING ON A DUCT IN THE LOWER FORWARD CARGO COMPARTMENT. THE INSULATION WAS REMOVED. FURTHER INVESTIGATION REVEAL NO ADDITIONAL DISCREPANIES. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: INSULATION — MISINSTALLED (A/C BAY) · airframe 74,166 hrs · 23,081 cycles

EN ROUTE FROM RMS TO DAN, THE FLIGHT CREW SENSED FUMES IN THE COCKPIT DURING CLIMB. THE FLIGHT RETURNED TO RMS FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT LOCATING A PIECE OF INSULATION LYING ON THE AIR CONDITIONING DISTRIBUTION DUCT. MAINTENANCE REMOVED THE INSULATION, PERFORMED A SUCCESSFUL OPERATIONAL CHECK ON THE AIR CONDITIOINING SYSTEM. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DOOR — INOP (NLG)

DURING CLIMB FROM RIC TOTOL, A MINOR VIBRATION WAS FELT IN THE NOSE GEAR AREA. THE FLIGHT CREW PERFORMED A SUCCESSFUL GEAR UPLATCH CHECK, THEN CYCLED THE THE GEAR WITH NO CHANGE IN VIBRATION. THE FLIGHT RETURNED TO RIC FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECT THE LANDING GEAR WHICH REVEALED THE RIGHT FORWARD NOSE GEAR DOOR OPEN. MAINTENANCE CLEANED AND LUBRICATED THE LINKAGES AND SECURED THE DOOR.

Part: DOOR — NOT FAIRED (LT MLG)

EN ROUTE, THE GEAR UPLATCH CHECK FAILED WITH THE GEAR NOT LATCH WARNING LIGHT ILLUMINATED, DOOR NOT LATCH REMAINED EXTINGUSHED. THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE JACKED THE AIRCRAFT AND PERFORMED GEAR SWING, WHICH REVEALED THE LEFT MAIN CENTER GEAR DOOR NOT FAIRING PROPERLY. MAINTENANCE ADJUSTED THE CENTER GEAR DOOR IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL. A SUCCESSFUL GEAR SWING, RETURNED THE AIRCRAFT TO SERVICE.

Part: ENGINE — FLAMED OUT (NR 1)

ON CLIMB-OUT FROM BNA TO TOL, THE NR 1 ENGINE FLAMED OUT. THE IGNITORS WERE SELECTED FOR 'BOTH' AND A SUCCESSFUL RESTART WAS ACCOMPLISHED. THE AIRCRAFT CONTINUED TO TOL WITH NO ABNORMAL PROBLEMS. INSPECTION OF THE ENGINE AND FUEL SYSTEM REVEALED NO ABNORMALITY. A PERFORMANCE RUN WAS ACCOMPLISHED IAW ATI JRH, AND ENGINE OPERATION WAS NORMAL. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: TIRE — FAILED (MLG)

ON LANDING TSJU, THE NR 3 AND NR 8 TIRES BLEW, LOCAL TOWER CLOSED RUNWAY UNTIL THE A/C COULD BE REMOVED. THE NR 3 TIRE EXIBITED MULTIPLE FLAT SPOTS AND THE NR 8 TIRE HAD ONE FLAP SPOT. SUBSEQUENT DAMAGE OF THE NR 4 BRAKE LINE OCCURRED. MAINTENANCE REPLACED BLOWN TIRES, ADJACENT TIRES, NR 8 ANTI-SKID TRANSDUCER, NR 4 BRAKE LINE, AND BLED ALL BRAKES IAW THE DOUGLAS MM AND RETURNED THE AIRCRAFT TO SERVICE. (M)

Part: CONNECTOR — LOOSE (RT WINDSHIELD)

BETWEEN KNGU AND BIKF, AN ELECTRICAL SMELL AND A SMALL AMOUNT OF SMOKE WERE NOTED COMING FROM THE FIRST OFFICERS WINDSHIELD AREA. IN KNGU, NO SOURCE COULD BE IDENTIFIED FOR THE SMELL. THE WINDSHIELD HEAT WAS PRECAUTIONARILY DEFERRED FOR FURTHER TROUBLESHOOTING. FURTHER TROUBLESHOOTING REVEALED A LOOSE ELECTRICAL CONNECTOR AT THE FIRST OFFICERS WINDOW HEAT SENSOR. THE LOOSE CONNECTION WAS SECURED, AND THE WINDSHIELD HEAT WAS RETURNED TO SERVICE. (M)

Part: INSTRUMENT AMP — ERRATIC (RADIO RACK)

FLL/TOL - AFTER TAKEOFF, CREW NOTED THE NR 2 COMPASS SYSTEM INDICATORS WERE ERRATIC AND THE CAPTAIN'S ATTITUDE INDICATOR FLAG WAS IN VIEW WITH NO PITCH INDICATION. THE CREW RETURNED TO FLL FOR MAINTENANCE. MAINTENANCE REPLACED THE NR 1 INSTRUMENT AMP AND ALL SYSTEM OPS CHECK NORMAL. THE AIRCRAFT WAS RETURNED TO SERVICE. (X)

Part: WINDSHIELD — SMOKE ODOR (COCKPIT)

KNGU/BIKF - BETWEEN KNGU AND BIKE, AN ELECTRICAL SMELL AND A SMALL AMOUNT OF SMOKE WERE NOTED COMING FROM THE FIRST OFFICER'S WINDSHIELD AREA. IN KNGU, NO SOURCE COULD BE DETERMINED FOR THE SMELL. THE WINDSHIELD HEAT WAS DEFERRED AS A PRECAUTION FOR FURTHER TROUBLESHOOTING. (X)

Part: VERTICAL GYRO — FAILED (NR 2)

BQN - ON DEPARTURE, THE FIRST OFFICER'S ADI TUMBLED. THE AIRCRAFT RETURNED TO BQN FOR MAINTENANCE. MAINTENANCE REPLACED THE NR 2 VG, AND RETURNED THE AIRCRAFT TO SERVICE. (X)

Part: SAFETY VALVE — MALFUNCTIONED (AFT FUSELAGE)

THE AIRCRAFT DEPARTED GSO AND EXPERIENCED FLUCTUATING CABIN PRESSURE THAT COULD NOT BE CONTROLLED EITHER BY THE MANUAL OR AUTOMATIC SYSTEMS. THE AIRCRAFT RETURNED TO GSO FOR MAINTENANCE. TROUBLESHOOTING AND GROUND PRESSURIZATION REVEALED THAT ONE OF THE SAFETY RELIEF VALVES WAS CYCLING ABOVE 6 PSID, INSTEAD OF RELIEVING AT ITS CORRECT SETTING. THE SAFETY VALVE WAS REPLACED, AND THE AIRCRAFT RETURNED TO SERVICE AFTER A FINAL PRESSURIZATION CHECK. (W)

Part: CONNECTOR — DIRTY (CABIN PRESS)

DURING CLIMB-OUT OF GSO, THE CABIN PRESSURIZATION WAS UNCONTROLLABLE BY EITHER MANUAL OR AUTOMATIC SYSTEMS. THE CABIN PRESSURE WAS CYCLING BETWEEN CLIMB AND DESCENT. THE AIRCRAFT RETURNED TO GSO FOR MAINTENANCE. TROUBLESHOOTING REVEALED A DIRTY ELECTRICAL CONNECTOR ON THE CABIN PRESSURE RATION CONTROLLER. THE CONNECTOR WAS CLEANED AND RESECURED. THE AIRCRAFT WAS GROUND PRESSURIZED AND PRESSURIZATION CONTROL OPS CHECKED IAW THE DC-8 MM. CONTROL WAS NORMAL, AND THE AIRCRAFT WS RETURNED TO SERVICE. (W)