N867BX

Part: CONNECTOR — CONTAMINATED (T/E FLAP) · airframe 82,158 hrs · 26,441 cycles

AFTER TAKEOFF FROM PDX, THE TAKEOFF WARNING HORN SOUNDED WHEN THE LANDING GEAR AND FLAPS WERE RETRACTED AND COULD NOT BE SILENCED. THE FLIGHT RETURNED TO PDX FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE FLAP LIMIT SWITCH CONNECTOR CONTAMINATED. MAINTENANCE CLEANED THE CONNECTOR AND PERFORMED A SUCCESSFUL OPERATIONAL CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: STRIKER — WORN (GEAR DOOR) · airframe 82,158 hrs · 26,440 cycles

ENROUTE FROM BFI TO PDX, THE LANDING GEAR NOT LATCH LIGHT ILLUMINATED DURING THE GEAR UPLATCH CHECK. THE FLIGHT CREW CYCLED THE LANDING GEAR BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CONTINUED TO PDX FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE RIGHT MAIN GEAR DOOR SWITCH STRICER WORN. MAINTENANCE REPLACED THE STRIKER AND PERFORMED A SUCCESSFUL OPERATIONAL CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WARNING LIGHT — ILLUMINATED (LANDING GEAR) · airframe 82,149 hrs · 26,437 cycles

ENROUTE FROM TOL TO LAX, AFTER THE LANDING GEAR WAS RETRACTED THE DOOR UNSAFE LIGHT REMAINED ILLUMINATED. THE FLIGHT CREW CYCLED THE LANDING GEAR, PERFORMED A SUCCESSFUL GEAR UP LATCH CHECK, BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CONTINUED TO LAX FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR DOOR WARNING ELECTRICAL SYSTEM WITH NO DISCREPANCIES NOTED IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONTROL VALVE — DEFECTIVE (WHEEL WELL) · airframe 81,479 hrs · 26,237 cycles

ENROUTE FROM TOL TO DFW, THE GEAR DOOR NOT LATCH LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. THE FLIGHT CREW CYCLED THE GEAR, BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CONTINUED TO DFW FOR AN UNEVENTFUL LANDING. MAINTENANCE PERFORMED AN OPERATIONAL CHECK WHICH REVEALED A DEFECTIVE LEFT MAIN GEAR DOOR ACTUATOR AND DOOR CONTROL VALVE. MAINTENANCE REPLACED THE DEFECTIVE COMPONENTS AND PERFORMED A SUCCEFUL OPERATION CHECK IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: HARNESS — MISRIGGED (MLG) · airframe 81,351 hrs · 26,176 cycles

ENROUTE FROM DFW TO TOL, THE GEAR DOOR NOT LATCH WARNING LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. THE GEAR WAS CYCLED BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT RETURNED TO DFW FOR AN UNEVENTFUL LANDING. MAINTENANCE PERFORMED A GEAR SWING WITH NO DISCREPANCIES NOTED. MAINTENANCE REPLACED BOTH MAIN GEAR DOOR LATCH ASSEMBLIES AS PRECAUTIONARY MEASURE. THE AIRCRAFT WAS RELEASED FOR A CHECK FLIGHT, WHICH FAILED. THE DISCREPANCY COULD NOT BE DULPICATED ON GROUND CHECK. THE AIRCRAFT WAS REMOVED FROM SERVICE, AND WAS FERRIED TO A HEAVY MAINTENANCE FACILITY FOR ADDITIONAL REPAIRS. THE MAIN LANDING GEAR DOOR FOLLOW UP SYSTEM WAS FOUND OUT OF RIG. THE SYSTEM WAS RIGGED PER THE AIRCRAFT MAINTENANCE.

Part: UPLOCK TARGET — LOOSE (LT MLG DOOR) · airframe 81,350 hrs · 26,175 cycles

EN ROUTE FROM TOL TO DFW, AFTER GEAR RETRACTION THE GEAR DOOR WARNING LIGHT REMAINED ILLUMINATED. THE FLIGHT CREW CYCLED THE LANDING GEAR, THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CONTINUED TO DFW FOLLOWING COMPANY PROCEDURES FOR AN UNEVENFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR WARNING INDICATION SYSTEM LOCATING A LOOSE TARGET STRICKER ON THE LEFT MAIN GEAR DOOR. MAINTENANCE SECURED THE TARGET AND PERFORMED A SUCCESSFUL GEAR SWING. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ROD — OUT OF ADJ (LT MLG) · airframe 81,345 hrs · 26,173 cycles

EN ROUTE FROM TOL TO DFW, THE LANDING GEAR DOOR NOT LATCH LIGHT ILLUMINATED AFTER THE LANDING GEAR WAS RETRACTED. THE FLIGHT CREW CYCLED THE LANDING GEAR AND PERFORMED AN UNSUCCESSFUL UPLATCH CHECK. THE LANDING GEAR HANDLE WAS PLACED IN THE UP POSITION AND THE FLIGHT CONTINUED TO DFW FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR WHICH REVEAL THE LEFT MAIN GEAR BOOGIE TRIM CYLINDER ROD END MIS ADJUSTED. MAINTENANCE ADJUSTED THE ROD END IN ACCORDANCE WITH THE MAINTENANCE MANUAL AND PERFORM A SUCCUSSFUL GEAR SWING. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (NOSE GEAR) · airframe 81,183 hrs · 26,087 cycles

DURING DESCENT INTO TOL, WHEN THE LANDING GEAR WAS EXTENDED FOR LANDING THE NOSE LANDING GEAR DOWN AND LOCKED INDICATION LIGHT FAILED TO ILLUMINATE. THE FLIGHT CREW CYCLED THE GEAR. THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CREW FOLLOWED COMPANY PROCEDURES AND THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE NOSE LANDING GEAR INDICATION SYSTEM LOCATING A BROKEN WIRE AT THE DOWN AND LOCK SWITCH. MAINTENANCE REPAIRED THE WIRE. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: INDICATION — MALFUNCTIONED (MLG)

EN ROUTE FROM IAH TO TOL, THE MAIN LANDING GEAR NOT LATCHED LIGHT ILLUMINATED DURING THE UPLATCH CHECK, THE MAIN GEAR DOOR NOT LATCHED LIGHT REMAINED EXTINGUISHED. THE FLIGHT CREW CYCLED THE LANDING GEAR WITH THE WARNING INDICATION REMAINING THE SAME. THE FLIGHT CONTINUED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WITH NO DISCREPANCIES NOTED. MAINTENANCE PLACE THE GEAR UPLATCH SYSTEM CHECK ON DEFERRAL IN ACCORDANCE WITH COMPANY PROCEDURES. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: RETRACT MECH — OUT OF ADJUST (NLG DOOR)

AFTER TAKEOFF WHEN THE LANDING GEAR WAS RETRACTED, THE FLIGHT CREW NOTICED A NOISE AND VIBRATION COMING FROM THE NOSE WHEEL WELL AREA. THE CREW CYCLED THE GEAR BUT THE VIBRATION CONDITION WAS STILL PRESENT. THE AIRCRAFT RETURNED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE RIGHT AFT NOSE GEAR DOOR OUT OF RIG. MAINTENANCE RIGGED THE NOSE GEAR DOOR IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL AND PERFORMED A SUCCESSFUL NOSE GEAR SWING.

Part: MECHANISM — MISRIGGED (LANDING GEAR)

AFTER TAKEOFF, WHEN THE FLIGHT CREW RETRACTED THE LANDING GEAR, THE CONTROL HANDLE WOULD NOT POSITION TO THE UP POSITION. THE CREW RETURNED THE GEAR HANDLE TO THE DOWN POSITION, RECEIVING THREE DOWN AND LOCK INDICATIONS. A SECOND ATTEMPT TO RETRACT THE GEAR WAS UNSUCCESSFUL AND THE AIRCRAFT RETURNED TO DFW. MAINTENANCE INSPECTED THE AIRCRAFT, FINDING THE LANDING GEAR ANTI-RETRACT LATCH MECHANISM MISRIGGED. MAINTENANCE RIGGED THE SYSTEM IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: PLANK — CRACKED (NR 4 PYLON)

PYLON PLANK CRACK LOCATED AT YN226. SUSPECT CAUSE OF THE CRACK IS VIBRATION.

Part: PLANK — CRACKED (NR 2 PYLON)

PYLON PLANK HAS CRACK LOCATED AT 19.5 INCHES AFT FROM YN190. SUSPECT CAUSE OF THE CRACK WAS VIBRATION.

Part: SPAR CAP — CRACKED (LT WING XRS22)

FOUND LT WING INBD LOWER AUXILIARY SPAR CAP CRACKED ON VERTICAL FLANGE AT XRS22. SUSPECT CAUSE OF THE CRACK WAS VIBRATION.

Part: BULKHEAD FITTING — CRACKED (BS 1744)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED ON AFT PRESSURE BULKHEAD LOWER SUPPORT FITTING AT FUSELAGE STATION 1744, LONGERON 36. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING, FABRICATION AND INSTALLATION A NEW FITTING IN ACCORDANCE WITH DOUGLAS STRUCTUAL MAINTENANCE MANUAL 53-1-0, 51-1-20 AND 51-3-0.

Part: PLATING — CORRODED (BS 1752-1766)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON LOWER FUSELAGE EXTERNAL PLATING FROM FUSELAGE STATIONS 1752 AND 1766, BETWEEN LONGERONS 35 LEFT AND 35 RIGHT. REPAIR ACCOMPLISHED CORROSION REMOVAL IN ACCORDANCE WITH DOUGLAS FAX ACTION NUMBER 372660, FILE NLC00042, FAA DER APPROVED DRAWING COO-SJO-98-0406DAC AND ENGINEERING ORDER 53-DC8-911.

Part: ANGLE — CORRODED (BS 380)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED BETWEEN FUSELAGE STATION 380 AND 400, LONGERON 27 LEFT. REPAIR ACCOMPLISHED REMOVAL OF CORRODED ANGLE, FABRICATION AND INSTALLATION A NEW LONGERON ANGLE IN ACCORDANCE WITH FAA DER APPROVED DRAWING COO-8-53-346-98, DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-0 AND ENGINEERING ORDER 53-DC8-888.

Part: FRAME — CORRODED (BS 70)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON THE FUSELAGE FRAME AT FUSELAGE STATION 70, BETWEEN LONGERON 32 AND 34 RIGHT. REPAIR ACCOMPLISHED CORROSION REMOVAL, FABRICATION AND INSTALLATION AN INTERNAL REPAIR ANGLE IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL 51-1-8, 51-10-2 AND ENGINEERING ORDER 53-DC8-871.

Part: DOUBLER — CORRODED (CENTER WING)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON CENTER WING UPPER JOINT DOUBLER AT FUSELAGE STATION 816, STRINGER 6. REPAIR ACCOMPLISHED BLENDED OUT CORROSION IN ACCORDANCE WITH FAA DER APPROVED DRAWINGS, COO-SJO-98-0393DDAC, COO-SJO-98-0394DAC, DOUGLAS FAX ACTION NUMBER 371688 AND ENGINEERING ORDER 57-DC8-900.

Part: FITTING — CORRODED (BS 70-80)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON A FUSELAGE FITTING BETWEEN FUSELAGE STATION 70 AND 80, LONGERON 33 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING. FABRICATION AND INSTALLATION A NEW FITTING IN ACCORDANCE WITH DOUGLAS DRAWING 4718340, STRUCTUAL REPAIR MANUAL 53-1-0 AND ENGINEERING ORDER 53-DC8-870.

Part: PLATING — CRACKED (RUDDER)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED ON THE RUDDER RIGHT SIDE EXTERNAL PLATING AND STATION ZR208.625. REPAIR ACCOMPLISHED STOP DRILLING CRACK, FABRICATION AND INSTALLATION AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING COO-8-55-339-98 AND ENGINEERING ORDER 55-DC8-899.

Part: PLANK — CRACKED (NR 4 PYLON)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED ON NUMBER FOUR PYLON INTERMEDIATE OUTBOARD PLANK AT STATION YIP 241. REPAIR ACCOMPLISHED STOP DRILLING CRACK, FABRICATION AND INSTALLATION OF AN INTERNAL AND EXTERNAL REPAIR DOUBLERS IN ACCORDANCE WITH DOUGLAS STRUCTUAL REPAIR MANUAL, FAX ACTION NUMBERS 371190, 373366, 372887 AND ENGINEERING ORDER 54-DC8-866.

Part: PLATING — CRACKED (WS 304)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS FOUND ON THE RIGHT WING LOWER LEADING EDGE AT STATION XFS 304. REPAIR ACCOMPLISHED STOP DRILL CRACK, FABRICATION AND INSTALLATION OF AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING COO-8-57-313-98 AND ENGINEERING ORDER 57-DC8-860.

Part: LONGERON — CORRODED (BS 180-220)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED BETWEEN FUSELAGE STATION 180 AND 220, LONGERON 31 LEFT. REPAIR ACCOMPLISHED CORROSION REMOVAL, FABRICATION AND INSTALLATION A NEW LONGERON SPLICE FITTING IN ACCORDANCE WITH FAA DER APPROVED DRAWINGS COO-SJO-98-0362DAC, COO-SJO-98-0369DAC, DOUGLAS FAX ACTION NUMBERS 373978, 372,760, 370453 AND ENGINGEERING ORDER 53-DC8-863.

Part: PLANK — CRACKED (NR 2 PYLON)

DURING ROUTINE C CHECK INSPECTION, A CRACK WAS DETECTED ON NUMBER TWO PYLON OUTBOARD INTERMEDIATE PLANK PANEL AT STATION YN 190. REPAIR ACCOMPLISHED STOP DRILL CRACK, FABRICATION AND INSTALLATION AN INTERNAL AND EXTERNAL REPAIR DOUBLERS IN ACCORDANCE WITH FAA DER APPROVED DRAWING 98-05-33-004, DOUGLAS FAX ACTION NUMBER 370114 AND ENGINEERING ORDER 54-DC80862.

Part: PLANK — WORN (NR 4 PYLON)

DURING ROUTINE C CHECK INSPECTION, WEAR WAS DETECTED ON THE NUMBER FOUR PYLON UPPER INBOARD PLANK SIX INCHES FORWARD OF STATION YUS 297. REPAIR ACCOMPLISHED BLENDING, POLISH THE AFFECTED AREA IN ACCORDANCE WITH FAA DER APPROVED DRAWING COO-SJO-98-0351, FAX ACTION NUMBER 369661 AND ENGINEERING ORDER 54-DC8-861.

Part: PLATING — CORRODED (BS 1610/1700)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS FOUND ON THE FUSELAGE EXTERNAL PLATING BETWEEN FUSELAGE STATIONS 1610 AND 1700, LONGERONS 31 LEFT AND 31 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA. FABRICATION AND INSTALLATION A NEW SECTION OF PLATING, INTERNAL DOUBLERS AND AN EXTERNAL DOUBLER IN ACCORDANCE WITH FAA DER APROVED DRAWING COO-8-53-316-98 AND 53-DC8-879.

Part: DOUBLER — CORRODED (BS 1352/1586.5)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON LOWER FUSELAGE, EIGHT EACH EXTERNAL FINGER DOUBLERS BETWEEN FUSELAGE STATIONS 1352 AND 1586.5. REPAIR ACCOMPLISHED TRIMMING OFF THE CORRODED FINGERS OF THE AFFECTED DOUBLERS IN ACCORDANCE WITH DOUGLAS FAX ACTION NUMBER 370339, FAA DER APPROVED DRAWING COO-SJO-98-0363DAC AND ENGINEERING ORDER 53-DC8-864.

Part: PLATING — CORRODED (BS 1620)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED AT AFT ACCESSORY COMPARTMENT INTERNAL DOUBLER AT FUSELAGE STATION 1620, BETWEEN LONGERONS 24 AND 27 LEFT. REPAIR ACCOMPLISHED CORROSION REMOVAL, FABRICATION AND INSTALLATION REPAIR FILLERS, REPAIR DOUBLER AND TRIPLER IN ACCORDANCE WITH FAA DER APPROVED COO-8-53-314-98 AND ENGINEERING ORDER 53-DC8-877.

Part: JAMB — CRACKED (BS 1177)

DURING ROUTINE C CHECK INSPECTION, A CRACKED FITTING WAS DETECTED AT UPPER TORQUE BOX FORWARD DOOR JAMB, AFT CARGO COMPARTMENT AT FUSELAGE STATION 1177 - X 68. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING, FABRICATION AND INSTALLATION A NEW FITTING IN ACCORDANCE WITH DOUGLAS DRAWING 3754918 AND ENGINEERING ORDER 53-DC-8-910.

Part: FLOOR — CORRODED (BS 863-878)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON MAIN CABIN FLOOR PRESSURE PANEL BETWEEN FUSELAGE STATION 863 AND 878, BL +X4 TO -X5.50. REPAIR ACCOMPLISHED CORROSION BLEND OUT, FABRICATION AND INSTALLATION OF A REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING COO-8-53-290-98 AND ENGINEERING ORDER 53-DC8-857.

Part: PLATING — CORRODED (BS 301.5-324)

DURING ROUTINE C CHECK INSPECTION, CORROSION WAS DETECTED ON FUSELAGE EXTERNAL PLATING BETWEEN FUSELAGE STATION 301.5 AND 324, LONGERONS 33 AND 34 LEFT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA. FABRICATION AND INSTALLATION TWO INTERNAL FILLERS AND AN EXTERNAL DOUBLER, TRIPLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING COO-8-53-318-98 AND ENGINEERING ORDER 53-DC8-880.

Part: FIRE WARNING — MALFUNCTIONED (NR 4 ENGINE)

EN ROUTE, THE NUMBER FOUR ENGINE FIRE WARNING INTERMITTENTLY SOUNDED IN LIGHT TURBULENCE. THE FLIGHT CONTINUED TO TOL FOR AND UNEVENTFULL LANDING. MAINTENANCE INSPECTED THE ENGINE AND THE ASSOCIATED WIRING, WITH NO DISCREPANCIES NOTED. MAINTENANCE ACCOMPLISHED A SUCCESSFUL OPERATIONAL TEST IN ACCORDANCE WITH THE MAINTENANCE MANUAL, AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CLAMP — LOOSE (NR 4 ENGINE)

EN ROUTE TOL TO BFI, THE NR 4 ENGINE FIRE WARNING SOUNDED WITH NUMBER 4 HIGH STAGE BLEED VALVE SELECTED TO HIGH. NR 4 BLEED VALVE WAS SELECTED TO LOW AND FIRE WARNING EXTINGUSHED. FLIGHT CONTINUED TO BFI FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE ENGINE BLEED DUCTS AND FOUND A HIGH STAGE BLEED VALVE CLAMP LOOSE. THE CLAMP WAS SECURED. A SUCCESSFUL ENGINE RUN WAS ACCOMPLISHED TO TEST THE SYSTEMS AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — DEFECTIVE (NR 4 PYLON)

DURING APPROACH, THE NUMBER FOUR ENGINE FIRE WARNING SOUNDED. THE CREW SECURED THE ENGINE, FIRE WARNING EXTINGUISHED. MAINTENANCE INSPECTED THE ENGINE, NO EVIDENCE OF A FIRE WAS NOTED. MAINTENANCE PERFORMED AN INTENSIFIED INSPECTION OF THE WARNING SYSTEM WIRING WITH DISCREPANCIES NOTED IN THE PYLON AREA. THE WIRING WAS REPLACED BETWEEN THE AMPLIFIER AND PYLON DISCONNECT. MAINTENANCE TESTED THE SYSTEM IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL WITH NORMAL OPERATION.

Part: FIRE WARNING — MALFUNCTIONED (NR 4 ENGINE)

ENROUTE, THE NUMBER FOUR ENGINE FIRE WARNING SOUNDED AND AN ENGINE SHUTDOWN WAS ACCOMPLISHED FOLLOWING COMPANY PROCEDURES. THE FIRE WARNING EXTINGUISHED SHORTLY AFTER THE SHUTDOWN. MAINTENANCE INSPECTED THE ENGINE AND FOUND NO EVIDENCE OF A FIRE. THE ENGINE PNEUMATIC SYSTEM, FIRE LOOPS AND ASSOCIATED WIRING WERE INSPECTED AND TESTED IN ACCORDANCE WITH THE APPLICABLE PORTIONS OF THE DOUGLAS MAINTENANCE MANUAL, WITH NO DISCREPANCIES NOTED.

Part: BALLAST — BURNT (COCKPIT)

AFTER TAKEOFF TOL, SMOKE EMANATED FROM FLIGHT ENGINEER'S PANEL IN THE VICINITY OF THE CABIN PRESSURE CONTROLLER AND THE HYDRAULIC SELECTOR CONSOLE. FLIGHT RETURNED TO TOL FOR AN UNEVENTFUL LANDING. MAINTENANCE FOUND THAT THE F/E'S INSTRUMENT WHITE LIGHTING BALLAST HAD FAILED. THE BALLAST WAS REPLACED, THE AREA INVESTIGATED FOR ANY OTHER FAULTS AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ELECTRICAL SYST — ODOR (COCKPIT)

EN ROUTE, CREW NOTICED HOT ELECTRICAL SMELL IN COCKPIT BELOW THE CIRCUIT BREAKER PANEL. SMELL DISSIPATED AFTER ABOUT 1 MINUTE. FOLLOWING AN UNEVENTFUL LANDING IN TOL, MAINTENANCE INVESTIGATED THE ORIGIN OF THE SMELL. NO CAUSE WAS FOUND AFTER A COMPLETE ENGINE RUN WITH ALL GENERATORS ON LINE.

Part: UPLATCH SWITCH — UNSECURE (RT MLG DOOR)

ON CLIMBOUT, GEAR DOORS NOT LATCHED LIGHT WOULD NOT EXTINGUISH ON GEAR RETRACTION. LANDING GEAR WAS CYCLED AND THE DOORS LIGHT EXTINGUSHED. AFTER LANDING TOL, MAINTENANCE FOUND AND SECURED THE RIGHT HAND MAIN LANDING GEAR DOOR UPLATCH SWITCH. MAINTENANCE ACCOMPLISHED THE CORRECTIVE ACTION AND OPERATIONAL CHECK IN ACCORDANCE WITH THE DOUGLAS M/M 32-10-2 AND 32-60-0. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (LT MLG)

AFTER TAKEOFF, GEAR UNSAFE LIGHT REMAINED ON AFTER RETRACTION. FLIGHT CREW CYCLED GEAR, LIGHT EXTINGUSHED, GEAR UPLATCH CHECK WAS NORMAL. THE FLIGHT CONTINUED TO TOL WITH AN UNEVENTFUL LANDING. MAINTENANCE FOUND AND REPAIRED A BROKEN WIRE AT THE LEFT MAIN LANDING GEAR UPLATCH SWITCH AND OPERATIONALLY CHECKED THE SYSTEM IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL 32-60-0.

Part: STRUCTURE — VIBRATION (AIRFRAME)

DURING APPROACH TO CLT, AIRCRAFT EXPERIENCED A SIGNIFICANT VIBRATION WITH FLAP 23 SELECTED. MAINTENANCE INSPECTED THE AIRCRAFT FLIGHT CONTROL SYSTEMS, LANDING GEAR SYSTEMS, WINGS, AND FUSELAGE WITH NO CAUSE FOUND. A SUBSEQUENT TEST FLIGHT WAS ACCOMPLOSHED WITH NO FINDINGS OR PROBLEMS REPORTED. THE AIRCRAFT RETURNED TO SERVICE. (M)

Part: LINKAGE — BROKEN (LT INBD SPOILER)

EN ROUTE BETWEEN ATL AND TOL, CREW NOTED SPOILER UNLOCK INDICATION LIGHT ILLUMINATED WITH STANDBY SPOILER PUMP OFF. FLIGHT CONTINUED WITH AN UNEVENTFUL LANDING AT TOL. MAINTENANCE FOUND AND REPLACED A BROKEN LEFT INBOARD SPOILER CRANK/LINKAGE IAW THE DOUGLAS MM 27-60-1 AND RETURNED THE AIRCRAFT TO SERVICE. (M)

Part: FIRE LOOP — BROKEN (NR 4 ENGINE)

KTOL - FLT 71266 - NR 4 ENGINE FIRE WARNING CAME ON IN-FLIGHT DURING DESCENT. PERFORMED IN-FLIGHT SHUT DOWN AND DISCHARGED FIRE BOTTLE. LANDED WITHOUT INCIDENT. FOUND NR 4 ENGINE BOTTOM FIRE LOOP BROKEN. REPLACED LOWER FIRE LOOP. GROUND OPS CHECK GOOD IAW MM CHAPTER 26. (X)

Part: BALLAST — FAILED (COCKPIT)

KTOL-KPHL - ELECTRICAL SMELL IN FRONT RIGHT SIDE OF COCKPIT. SUBMITTER STATES, SUSPECT RIGHT GLARESHIELD LIGHT, PULLED BREAKER. NO MORE SMELL, DEFERRED PER MEL 33-1 CAT C DMI NR 654. REPLACED LIGHT BALLAST TRANSFORMER ASSEMBLY. OPS CHECKED GOOD IAW DC-8 MM 33-12-0, DMI NR 654 CLEARED. (M)

Part: SKIN — CORRODED (BS 1660)

KYIP - DURING B-CHECK INSPECTION, FOUND FUSELAGE SKIN BULGING FROM CORROSION AT STATION 1660, LONGERON 30L. REPAIRED FUSELAGE SKIN AT STATION 1660, LONGERON 30L IAW EA NR 95-178. (M)

Part: FITTING — CORRODED (BS 1660)

KYIP - DURING B-CHECK INSPECTION, FOUND LONGERON 30L AT FS 1660, CORRODED. REPAIRED PER DC-8 SRM 53-2-2. REPLACED LONGERON END FITTING, STA 1660 LONGERON 30L. (X)

Part: WIRE — BARE (NR 1 ENGINE)

KTOL - ON SHORT FINAL NR 1 ENGINE FIRE WARNING CAME ON MOMENTARILY. REPAIRED BARE WIRE NEAR FIRE LOOP PLUG, CHECKS OK IAW MM CHAPTER 26. (W)

Part: PRESS REGULATOR — LEAKING (NR 1 ENGINE)

KLRD - FLT 63168 - NR 1 ENGINE FIRE WARNING CAME ON IN-FLIGHT MOMENTARILY, WARNING LIGHT EXTINGUISHED WHEN NR 1 POWER LEVER WAS PULLED BACK TO IDLE. FOUND PRESSURE REGULATOR VALVE LEAKING, REMOVED AND REPLACED PRESSURE REGULATOR VALVE IAW DMM 36-12-1. OPS CHECKED NORMAL IAW DMM 36-12-0. FIRE WARNING OPS CHECKED NORMAL IAW DMM 26-10-0. (X)