N826BX

Part: CONNECTOR — DEFECTIVE (ENGINE) · airframe 83,918 hrs · 33,561 cycles

ENROUTE FROM TOL TO BFI, ON DESCENT THE NUMBER FOUR ENGINE FIRE WARNING SHORT CIRCUIT LIGHT ILLUMINATED. THE FLIGHT CREW FOLLOWED COMPANY PROCEDURES AND SECURED THE ENGINE. THE FLIGHT CONTINUED TO BFI FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE ENGINE WITH NO EVIDENCE OF A FIRE. FURTHER INVESTIGATION REVEALED A DEFECTIVE ELECTRICAL CONNECTOR ON THE SENSING ELEMENT AND WAS REPLACED. MAINTENANCE PERFORMED A SUCCESFUL OPERATIONAL TEST IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: HINGE PIN — WORN (MAIN GEAR DOORS) · airframe 83,219 hrs · 33,247 cycles

IN ROUTE FROM RDU TO TOL AFTER GEAR RETRACTION LANDING GEAR DOOR UNSAFE LIGHT ILLUMINATED. FLIGHT CREW CYCLED THE LANDING GEAR, WARNING INDICATION REMAINED THE SAME. FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENACE INSPECTED THE LANDING GEAR WHICH REVEALED MAIN LANDING GEAR DOOR HINGE PINS WORN. MAINTENACE REPLACED THE HINGE PINS AND PERFORM A SUCCESSFUL OPERATIONAL CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DOOR — OUT OF RIG (MLG) · airframe 83,193 hrs · 33,226 cycles

EN ROUTE FROM TOL TO BDL, THE LANDING GEAR DOOR UNSAFE WARNING LIGHT ILLUMINATED AFTER A SUCCESFUL GEAR UP LATCH CHECK WAS PERFORMED. THE FLIGHT RETURNED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE MAIN LANDING GEAR DOOR FOLLOW UP SYSTEM MISRIGGED. MAINTENANCE RIGGED THE FOLLOW UP SYSTEM IN ACCORDANCE WITH THE MAINTENANCE MANUAL AND PERFORMED A SUCCESSFUL OPERATIONAL CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 83,123 hrs · 33,188 cycles

EN ROUTE FROM SJC TO TOL, THE LANDING GEAR DOOR WARNING LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE LANDING GEAR AND THE GEAR DOOR WARNING LIGHT EXTINGUISHED. THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR INDICATION SYSTEM WITH NO DISCREPANCIES NOTED. MAINTENANCE PLACED THE INDICATION SYSTEM ON DEFERRAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UPLOCK SENSOR — DIRTY (MLG WW) · airframe 83,063 hrs · 33,174 cycles

EN ROUTE FROM SJC TO TOL, THE LANDING GEAR UNSAFE AND DOOR WARNING LIGHTS ILLUMINATED AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE LANDING GEAR AND THE WARNING INDICATING LIGHTS EXTINGUISHED. THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT, CLEANED AND LUBRICATING THE GEAR UPLATCH MECHANISMS AND PERFORMED A SUCESSFUL OPERATIONAL CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (COCKPIT) · airframe 82,852 hrs · 33,058 cycles

EN ROUTE FOR JFK TO TOL, THE GEAR DOOR WARNING LIGHT REMAINED ON DIM AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE LANDING GEAR AND THE WARNING LIGHT EXTINGUISHED. THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT LOCATING A BROKEN WIRE LOCATED AT THE INSTRUMENT DIMMING CONTROL BOX. MAINTENANCE REPAIRED THE WIRE A PERFORMED A SUCCESSFUL OPERATION CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WARNING LIGHT — ILLUMINATED (COCKPIT) · airframe 82,830 hrs · 33,039 cycles

EN ROUTE FROM TOL TO JFK, THE LANDING GEAR DOOR WARNING LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE LANDING GEAR BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CONTINUED TO JFK FOR AN UNEVENTFUL LANDING. THE LANDING GEAR DOOR UPLATCH SYSTEM WAS PLACED ON DEFERRAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SWITCH — CONTAMINATED (MLG WW) · airframe 82,740 hrs · 32,988 cycles

EN ROUTE FROM TOL TO JFK, THE LANDING GEAR DOOR WARNING LIGHT ILLUMINATED AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE GEAR WITH THE WARNING INDICATION REMAINING THE SAME. THE FLIGHT CONTINUED TO JFK FOLLOWING COMPANY PROCEDURES. MAINTENANCE INSPECTED THE LANDING GEAR AND DOORS INDICATION SYSTEM WHICH REVEALED THE LEFT MAIN GEAR DOOR SWITCH CONTAMINATED WITH MOISTURE. MAINTENANCE CLEANED THE SWITCH CANNON PLUG AND PERFORMED A SUCCESSFUL OPERATIONAL CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — LOOSE (WHEEL WELL) · airframe 82,733 hrs · 32,982 cycles

ENROUTE FROM RDU TO TOL, THE GEAR DOOR WARNING LIGHT ILLUMINATED AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE LANDING GEAR AND THE WARNING INDICATION EXTINGUISHED. THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR LOCATION A LOOSE CANNON PLUG ON THE LEFT MAIN GEAR DOOR SWITCH. MAINTENANCE SECURED THE CANNON PLUG AND PERFORMED PERFORMED AN OPERATIONAL CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — LOOSE (WHEEL WELL) · airframe 82,733 hrs · 32,982 cycles

!ENROUTE FROM RDU TO TOL, THE GEAR DOOR WARNING LIGHT ILLUMINATED AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE LANDING GEAR AND THE WARNING INDICATION EXTINGUISHED. THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR LOCATION A LOOSE CANNON PLUG ON THE LEFT MAIN GEAR DOOR SWITCH. MAINTENANCE SECURED THE CANNON PLUG AND PERFORMED PERFORMED AN OPERATIONAL CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UPLOCK — LACK OF LUBE (WHEEL WELL) · airframe 82,658 hrs · 32,946 cycles

ENROUTE FROM PDX TO TOL, AFTER T.O. THE GEAR DOOR WARNING LIGHT ILLUMINATED WITH THE GEAR RETRACTED. THE FLIGHT CREW CYCLED GEAR WITH THE DOOR WARNING INDICATION REMAINING THE SAME. THE FLIGHT RETURNED TO PDX FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR DOORS AND INDICATION SYSTEMS WITH THE DEFECTS NOTED. MAINTENANCE LUBRICATED THE DOOR UPLATCHES AND PERFORMED A SUCCESFUL OPERATIONAL CHEKCK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SWITCH — MISRIGGED (WHEEL WELL)

GEAR FAILED UPLATCH CHECK. CYCLED SEVERAL TIMES FOLLOWED ATI DOOR WARNING CHECKLIST. FOUND INDICATION PROBLEM AND CONTINUED ACCORDING TO ATI CHECKLIST. 30 MIN LATER LIGHT WENT OUT. CREW LANDED UNEVENTLY AT DESTINATION. MAINTENANCE PERFORMED GEAR SWING AND COULD NOT DUPLICATE. CHANGED LT&RT GEAR DOOR SWITCHES FOE PREVENTITIVE MEASURES. PERFORMED GEAR UPLATCH CHECK OPS CHECK GOOD.

Part: FILTER — CONTAMINATED (NR 1 ENGINE) · airframe 82,384 hrs · 32,809 cycles

EN ROUTE FROM TOL TO DFW, THE NUMBER ONE ENGINE EXPERIENCED A ROLL BACK AT THE TOP OF DESCENT. NO THROTTLE RESPONCE WAS MOMENTARILY NOTED THEN ALL ENGINE PARAMETERS RETURNED TO NORMAL. THE FLIGHT CONTINUED TO DFW FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE ENGINE IN ACCORDANCE WITH THE THE CFMI MAINTENANCE MANUAL WHICH REVEALED CONTAMINATION IN THE MAIN FUEL FILTER. MAINTENANCE REPLACED THE FILTER, PERFORMED A MAXIMUM POWER ASSURANCE CHECK IN ACCORDANCE WITH THE COMPANY JRH BOOK WITH NO DISCREPANCIES NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — WET (LT MLG DOOR)

AFTER TAKEOFF, THE LANDING GEAR WAS RETRACTED, THE GEAR DOOR WARNING LIGHT REMAINED ILLUMINATED. THE CREW CYCLED THE GEAR SEVERAL TIMES WITH THE WARNING INDICATION REMAINING THE SAME. THE CREW PERFORMED A SUCCESSFUL GEAR UPLATCH CHECK AND THE WARNING LIGHT EXTINGUSHED. WHEN THE GEAR HANDLE WAS PLACED BACK IN THE UP POSITION, THE WARNING LIGHT ILLUMINATED AGAIN. THE FLIGHT RETURNED TO DEN FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE GEAR DOOR WARNING SYSTEM, LOCATING MOISTURE IN THE LEFT MAIN GEAR DOOR UPLATCH SWITCH ELECTRICAL CONNECTOR. MAINTENANCE CLEANED THE SWITCH AND PERFORMED A SUCCESSFUL OPERATIONAL TEST IN ACCORDANCE WITH THE MAINTENANCE MANUAL.

Part: SWITCH — DEFECTIVE (LT MLG)

ON APPROACH, DURING GEAR EXTENSION FOR LANDING,THE LEFT MAIN GEAR INDICATOR LIGHT FAILED TO ILLUMINATE IN THE DOWN POSITION, ACCOMPANIED BY AN ILLUMINATED GEAR UNSAFE WARNING LIGHT. THE CREW CYCLED THE GEAR BUT THE WARNING INDICATION REMAINED THE SAME. WHILE TURNING THE AIRCRAFT, THE LEFT MAIN GEAR DOWN AND LOCK LIGHT ILLUMINATED AND THE AIRCRAFT CONTINUED FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR INDICATION SYSTEM WHICH REVEALED THE LEFT MAIN GEAR DOWNLOCK SWITCH DEFECTIVE. MAINTENANCE REPLACED THE SWITCH, SYSTEM CHECK GOOD IN ACCORDANCE WITH THE MAINTENANCE MANUAL.

Part: WIRE — CHAFED (LT MLG)

EN ROUTE TOL TO DFW, DURING GEAR EXTENTION FOR LANDING THE LEFT MAIN LANDING GEAR INDICATOR LIGHT DID NOT ILLUMINATE IN THE DOWN POSITION. THE CREW CYCLED THE GEAR THREE TIMES PRIOR TO RECEIVING A DOWN AND LOCKED INDICATION. MAINTENANCE INSPECTED THE LEFT GEAR INDICATION SYSTEM AND FOUND A CHAFED WIRE AT THE DOWNLOCK SWITCH. THE WIRING WAS REPAIRED, SYSTEM CHECKED GOOD IN ACCORDANCE WITH MAINTENANCE MANUAL 32-60-06, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: COALESCER — LOOSE (RT PACK)

EN ROUTE FROM BNA-FLL AT FLT LEVEL 350, OIL SMOKE/MIST WAS NOTED IN THE COCKPIT. THE RIGHT PACK SYSTEM WAS SUSPECTED AND SHUT DOWN FOR THE REMAINDER OF THE FLIGHT. MAINTENANCE FOUND AND SECURED A LOOSE CLAMP AT THE WATER SEPARATOR/COALESCER. OPERATIONALLY CHECKED THE SYSTEM IAW THE MM. AIRCRAFT RETURNED TO SERVICE. (M)

Part: DOWNLOCK SW — INTERMITTENT (LT MAIN GEAR)

ON DESCENT INTO SAN, LANDING GEAR UNSAFE LIGHT ILLUMINATED ACCOMPANIED BY THE WARNING HORN WHEN FLAPS SELECTED TO 50 DEGREES. GEAR CYCLED SEVERAL TIMES UNTIL SAFE INDICATION WAS OBTAINED. LANDING WAS UNEVENTFUL. MAINTENANCE REPLACED THE LEFT DOWNLOCK SWITCH AND OPERATIONALLY CHECKED THE SYSTEM IN ACCORDANCE WITH THE AIRCRAFT MAINTENANCE MANUAL AND THE AIRCRAFT RETURNED TO SERVICE. (M)

Part: DOWNLOCK SW — DIRTY (LT MLG)

UPON GEAR EXTENTION INTO TOL, LEFT GEAR INDICATION LIGHT ILLUMINATED IMMEDIATELY. ALL GEAR LIGHTS ILLUMINATED WITH GEAR UNSAFE LIGHT. GEAR WAS CYCLED, EXTENTION WAS NORMAL EXCEPT LEFT GEAR LIGHT CAME ON IMMEDIATELY. MAINTENANCE FOUND LEFT GEAR DOWNLOCK SWITCH DIRTY. THE SWITCH WAS CLEANED. INDICATION SYSTEM OPERATIONALLY CHECKED GOOD IAW MM 32-60-06. (M)

Part: RIB — CRACKED (RT WING)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND AT XRS-6 RIB. THE RIB WAS REPAIRED IAW DRAWING HSE27-57-169, WHICH WAS FAA DER APPROVED, AND EO 57-DC8-151. (W)

Part: PLATING — CRACKED (WS 453)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND IN THE RIGHT WING LEADING EDGE, STUB WING, PLATING AT XRS 453. UPON DOUGLAS EVALUATION AND FAA DER APPROVAL THE CRACK WAS SUBJECTED TO ADDITONAL INSPECTION. INSPECTION RESULTS FOUND NO ADDITIONAL DAMAGE, AND THE AIRCRAFT WAS RETURNED TO SERVICE. PERMANENT REPAIR MUST BE AT THE NEXT C-CHECK. (W)

Part: SKIN — CORRODED (FUSELAGE)

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS BLENDED BEYOND SRM LIMITS. THE EXTERIOR PLATING AT STATION 530-550 BETWEEN LONGERONS 33 RT AND 36. DAMAGE WAS REMOVED BY CUTOUT, ADDING A FILLER AND EXTERNAL DOUBLER. REPAIR ACCOMPLISHED IAW DRAWING HSE27-53-168, WHICH IS FAA DER APPROVED AND EO 53-DC8-157. (W)

Part: FRAME — CORRODED (BS 1397)

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS NOTED AT THE BELTFRAME AT FUSELAGE STATION 1397, BETWEEN LONGERONS 34 LEFT AND RIGHT. THE LOCALIZED CORROSION WAS REMOVED BY CUT OUT, MANUFACTURE OF A NEW SECTION, ADDING A SPLICE CHANNEL, AND INSTALLING AN ORIGINAL SPLICE PLATE. REPAIR WAS ACCOMPLISHED IAW DRAWING HSE27-53-171, WHICH IS FAA DER APPROVED AND EO 53-DC8-154. (W)

Part: PANEL — CORRODED (FUSELAGE)

DURING C-CHECK ROUTINE INSPECTION, FOUND LOADER DAMAGE AT THE FORWARD BASKET DOOR CUTOUT. THE FUSELAGE PLATING WAS ROUTED OUT AND AN EXTERNAL DOUBLER ADDED. REPAIR WAS ACCOMPLISHED IAW DRAWING HSE27-53-166, WHICH IS FAA DER APPROVED AND EO 53-DC8-158. (W)

Part: FRAME — CORRODED (BS 520)

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS FOUND AT STATION 520, BETWEEN LONGERONS 33 AND 35 RIGHT. THE SECTION OF BELTFRAME WAS REMOVED MANUFACTURED AND REPLACED. REPAIR ACCOMPLISHED IAW DRAWING HSE27-53-163, WHICH IS FAA DER APPROVED AND EO 53-DC8-156. (W)

Part: PANEL — CRACKED (WS 441.5)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND IN THE LEFT WING LOWER PLATING. THE CRACK MEASURED 1.75 INCHES AND WAS LOCATED AT XW 441.5, BETWEEN STRINGERS 63 AND 64. REPAIR WAS ACCOMPLISHED BY REMOVAL OF THE CRACK, ADDING A FILLER, AND INSTALLING BOTH A DOUBLER AND TRIPLER ON THE INTERNAL AND EXTERNAL SIDES OF THE PLATING. REPAIR ACCOMPLISHED IAW DOUG ROD SKETCH 94-07-11-009, WHICH IS FAA DER APPROVED AND EO 57-DC8-153. (W)

Part: FITTING — CRACKED (CARGO DOOR)

DURING ROUTINE C-CHECK INSPECTION, AN AFT LOWER CARGO DOOR STOP FITTING WAS FOUND CRACKED. THE FITTING WAS MANUFACTURED IAW DRAWING HSE27-53-165, WHICH WAS FAA DER APPROVED AND EO 53-DC8-160. FITTING WAS INSTALLED IAW THE AIRCRAFT MM. (W)

Part: PANEL — CORRODED (FS 560-610)

DURING ROUTINE C-CHECK INSPECTION, LEVEL 2 CORROSION WAS FOUND AT FUSELAGE STATION 560-610. THIS AREA HAD A PREVIOUS REPAIR AND THE CORROSION FOUND IS ATTRIBUTED TO NOT REMOVING ALL CORROSION AT THAT TIME. REPAIR OF THE AREA REQUIRED TWO CUTOUTS OF BOTH THE INTERNAL DOUBLER AND PLATING, ADDING FILLERS AND INSTALLING BOTH A REPAIR DOUBLER AND TRIPLER. REPAIR WAS ACCOMPLISHED IAW DRAWING HSE27-53-167, WHICH IS FAA DER APPROVED AND EO 53-DC8-155. (W)

Part: PANEL — CORRODED (LWR CTR FS 610)

DURING ROUTINE C-CHECK, EXTERIOR CORROSION WAS NOTED AT FS 610, BETWEEN LONGERONS 34 LEFT AND RIGHT. THE CORROSION WAS REMOVED BY CUT OUT, ADDING A REPAIR FILLER, AND INSTALLING 2 EXTERNAL REPAIR DOUBLERS. REPAIR WAS ACCOMPLISHED IAW DRAWING HSE27-53-141, WHICH WAS FAA DER APPROVED AND E.O. 53-DC8-139. (X)