N87

Part: WARNING LIGHT — ACTIVATED (STALL WARNING) · airframe 12,969 hrs · 5,452 cycles

STALL PROTECTION SYSTEM FAIL LIGHTS FLASHING IN FLIGHT.

Part: WIRE HARNESS — DAMAGED (ANTI SKID SYS) · airframe 12,896 hrs · 5,421 cycles

R/ OUTBOARD ANTI-SKID FAIL ILLUMINATED AFTER TEST. (AIRBORNE)...TEMP REPAIR #2 MLG HARNESS FOR SFP TO REPAIR STATION. WILL MONITOR

Part: CHARGER — FAILED (MASTER BATTERY) · airframe 12,782 hrs · 5,392 cycles

BATTERY CHARGER CIRCUIT BREAKER TRIPPED IN FLIGHT. CORRECTION: REMOVED AND REPLACED AIRCRAFT BATTERY CHARGER.

Part: MOTOR — FAILED (TE FLAP) · airframe 12,782 hrs · 5,392 cycles

FLAP MOTOR 2 CIRCUIT BREAKER POPPED IN FLIGHT. REPLACING FLAP MOTOR CORRECTED THE DISCREPANCY.

Part: SKIN — CRACKED (RT WING) · airframe 12,760 hrs · 5,381 cycles

CRACKS THE WING SKIN

Part: CONTROL HEAD — BURNED (CVR) · airframe 12,626 hrs · 5,331 cycles

DESCENDING THROUGH 5000'MSL CREW NOTICED ACRID SMELL. DONNED OXYGEN MASK AND TURNED AFIS OFF. SMELL SLOWLY DISSIPATED. NO SMOKE WAS VISIBLE. CAUSE WAS FOUND TO BE CVR CONTROL HEAD BURNED INTERNALLY.

Part: CRANK ASSY — CRACKED (PAX DOOR) · airframe 12,263 hrs · 5,203 cycles

PASSENGER DOOR LATCH MECHANISM CRANK CRACKED PART 600-31890-21.

Part: DISPLAY — INOPERATIVE (COCKPIT) · airframe 12,106 hrs · 5,106 cycles

AFIS FAILED IN FLIGHT. DISPLAY WENT DEAD, AND ELECTRICAL FUMES WERE PRESENT. MILTOPE(EIFW IN-FLT WKSTATION)

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 12,028 hrs · 5,082 cycles

PILOT SIDE FRONT WINDOW OUTER GLASS HAD A MAJOR CRACK. REMOVED AND REPLACED PILOT'S WINDSHIELD.

Part: CONNECTOR — DIRTY (ANTI ICE SYS) · airframe 11,514 hrs · 4,887 cycles

RIGHT ENGINE COWL ANTI-ICE FAIL LIGHT ILLUMINATED DURING FLIGHT, PROBLEM WAS CORRECTED AFTER CLEANING OF ELECTRICAL CONNECTORS.

Part: ANTI-ICE SYSTEM — DEFECTIVE (WINDSHIELD) · airframe 10,549 hrs · 4,487 cycles

PILOT LT SIDE WINDSHIELD HEAT FAIL. REPEAT FAILURE.

Part: FMS — MALFUNCTIONED · airframe 10,422 hrs · 4,445 cycles

WAAS 1 & WAAS 2 FAILED IN CRUISE FLIGHT. MULTIPLE NAV SYS FAILURES, FD, CDU, FMS 1 & 2 FLAGS ON MFD BOTH SIDE NAV INDICATIONS FAILED. RE-SEATING & RE-LOADING THE FMS DATABASES CORRECTED THE ISSUE.

Part: HYDRAULIC LINE — LOOSE (ZONE 200) · airframe 9,543 hrs · 4,166 cycles

SUPPLEMENTAL INFORMATION: CORRECT ATA CODE(C) TO 2910, CORRECT HOW DISCOVERED (E) TO V-VISUAL. CORRECTIVE ACTION: FOUND LOOSE B NUT ON HYDRAULIC TUBE ASSY P/N: 601-75238-43 AFT CONNECTION. INSPECTED B-NUT, RE-TORQUED B NUT FITTING. LEAK CHECK SATISFACTORY. CREATED MAINTENANCE ALERT DIRECTIVE MAD14-01 TO INSPECT ALL FAA FLIGHT INSPECTION CHALLENGER (CL601, CL604, AND CL605) AIRCRAFT. NO DEFECTS NOTED WITH OTHER AIRCRAFT. MAD DOCUMENTED IN AIRCRAFT LOGBOOK AND CLOSED.

Part: WINDOW — CRACKED (COCKPIT) · airframe 8,887 hrs · 3,955 cycles

DURING FLIGHT, CREW HEARD LOUD POP. INITIAL INSPECTION DISCOVERED LEFT PILOT SIDE WINDOW WITH LARGE CRACK AND SIGNIFICANT GAP IN OUTER PANE WITH ASSOCIATED "FAIL" LIGHT ON WINDSHIELD HEAT.

Part: THRUST REVERSER — MALFUNCTIONED (RT ENGINE)

AT FL150, GOT RIGHT T/R UNLOCK LIGHT. CREW PRESSED T/R EMERGENCY STOW AND COMPLIED WITH CHECKLISTS. DECLARED EMERGENCY AND DIVERTED TO NEAREST AIRPORT WITH ADEQUATE RUNWAY LENGTH.

Part: BULKHEAD — BUCKLED (FUSELAGE) · airframe 7,682 hrs · 3,541 cycles

BULKHEAD AND AIRCRAFT SKIN AT FORWARD FUSELAGE STATION 235 IS CRACKED AND BUCKLED.

Part: PROXIMITY SWITCH — FAULTY (NLG) · airframe 7,247 hrs · 3,248 cycles

AFTER TAKEOFF THE LANDING GEAR HANDLE WAS MOVED TO THE UP POSITION. BOTH MAIN GEAR RETRACTED BUT THE NOSE GEAR DID NOT RETRACT. THE ONLY INDICATION IN THE COCKPIT WAS ONE GREEN NOSE GEAR DOWN LIGHT. HOLDING WAS COORDINATED WITH ATC. EMERGENCY AND NORMAL CHECKLISTS WERE ACCOMPLISHED. NORMAL GEAR DOWN INDICATIONS WERE OBSERVED IN THE COCKPIT. A TOWER FLY-BY WAS ACCOMPLISHED TO CONFIRM THAT ALL LANDING GEAR APPEARED TO BE EXTENDED. AN EMERGENCY WAS NOT DECLARED AND TRAFFIC PRIORITY WAS NOT REQUESTED. AIRCRAFT WAS STOPPED STRAIGHT AHEAD ON RUNWAY AFTER LANDING AND MAINTENANCE PINNED GEAR BEFORE RESUMING TAXI TO RAMP. TROUBLESHOOTING FOUND LEFT NOSE GEAR DOOR PROX SWITCH INOP (CLOSED). ALSO FOUND NOSE GEAR UPLOCK PROX SWITCH INOP (CLOSED). REMOVED AND REPLACED BOTH PROX SWITCHES.

Part: UNKNOWN — MALFUNCTIONED (AUTOPILOT SYS) · airframe 6,662 hrs · 3,081 cycles

TWO UNCOMMANDED ABRUPT RIGHT RUDDER INPUTS. AUTOPILOT ON. YAW DAMP ON. AIRCRAFT CLIMBING THROUGH 8000 FEET AT 250 KNOTS. SECOND EVENT 11000 FEET AT 250 KNOTS. NO SERVO MONITOR LIGHT ILLUMINATED. NO INDICATION OF JAM RUDDER. ALL THREE HYDRAULIC SYSTEM PRESSURES NORMAL. INITIATED PHONE PATCH WITH FICO, FICO MX AND CHIEF PILOT. DISCUSSED VARIOUS OPTIONS AND DETERMINED SAFEST PLAN WAS TO RECOVER INTO PLANNED DESTINATION (FLIGHT TIME LESS THAN 20 MINUTES). KEPT BELOW FL210, 250 KNOTS. LANDED UNEVENTFULLY. MAINTENANCE PERFORMED FUNCTIONAL TEST OF RUDDER/YAW SYSTEM. CHECKED RUDDER CONTROL CABLES FOR BINDING OR OBSTRUCTIONS. ALL CHECKED GOOD.

Part: WINDSHIELD — SPLIT (COCKPIT) · airframe 6,308 hrs · 2,891 cycles

AFTER APPROXIMATELY 1.0 HOUR OF FLYING IN THE CLIMBOUT TO NEXT WORK, NOTICED WINDSHIELD SPLITTING FROM A SMALL SCRATCH. LEVELED OFF TO 17,000 FEET, RAN CHECKLIST AND GOT CLEARANCE TO RETURN.

Part: HYDRAULIC LINE — CHAFED (PYLON) · airframe 5,350 hrs · 2,422 cycles

NUMBER 2 HYDRAULIC SYSTEM LOST PRESSURE ON APPROACH. FOUND PRESSURE HOSE ASSY IN PYLON CHAFED BY HOSE CLAMP WHERE RUBBER LINER WAS ERODED AND THE CLAMP AND HOSE WERE METAL TO METAL. REPLACED HOSE, CLAMP, AND ENGINE DRIVEN HYDRAULIC PUMP. INSPECTED FILTERS, LEAK AND OPS CHECK SATISFACTORY.

Part: WINDSHIELD — CRACKED (COCKPIT)

FLYING AT FL340 1.5 HOURS INTO FLIGHT THE CO-PILOTS WINDSHIELD OUTER PLY CRACKED. COMING INTO THE TERMINAL AREA WITH -3 DEGREE C AND MOISTURE IN THE AIR, RAIN STARTED TO GET INSIDE THE CRACK. ON A 14 MILE ILS FINAL TO RWY 28 AT ABOUT 3000' HEARD A LOUD POP AND A 1/4 OF THE CO-PILOT'S WINDSHIELD OUTER PLY BROKE OFF. AFTER LANDING, RIGHT SIDE OF AIRCRAFT TO INCLUDE THE NR 2 ENGINE WAS INSPECTED WITH NO VISIBLE DAMAGE NOTICED.

Part: WING — SCRATCHED (RT WINGLET)

UPON POST FLT, DISCOVERED STRATCHES ON RT WINGLET. APPARENTLY WHILE POSITIONING OVER GCP AT RKTP, SCRAPED GCP SIGN. NO INDICATION OF CONTACT WHILE AT RTKP. RETURNED TO RKSO WHERE DAMAGE WAS NOTED. PERFORMED TEMP REPAIR REFERENCE REO. (K)

Part: SEAL — DETERIORATED (FUEL CAP)

AFTER TAKEOFF FUEL WAS SEEN STREAMING OUT OF LT OVERWING FUEL CAP DURING CLIMB. REPLACED FUEL CAP.

Part: SENSOR — FAILED (MLG)

ON FINAL APPROACH GEAR EXTENSION AND ANTI-SKID OUTBOARD FAIL MALFUNCTION OCCURRED. GEAR RECYCLED AND SOME TROUBLESHOOTING WAS UNSUCCESSFUL. IN FLIGHT EMERGENCY WAS DECLARED, EQUIPMENT CALLED OUT, ANTI-SKID TURNED OFF AND UNEVENTFUL LANDING CARRIED OUT. NO DAMAGE TO TIRES OR AIRCRAFT. REPLACED TWO WHEEL SPEED SENSORS AND REPAIRED BROKEN WIRE. (M)

Part: LINE — BROKEN (HYDRAULIC SYS)

NR 1 HYDRAULIC SYSTEM FAILED IN FILGHT WITH COMPLETE LOSS OF FLUID WITHIN THAT SYSTEM. FOUND HYDRAULIC LINE SNAPPED OFF. REPLACED HYDRAULIC LINE. ALSO, REPLACED HYDRAULIC PUMP AND FILTERS DUE TO LOSS OF FLUID. (M)

Part: TUBE — CRACKED (HYD SYSTEM)

NR 1 HYDRAULIC SYSETM FAILED IN FLIGHT WITH COMPLETE LOSS OF FLUID WITHING THAT SYSTEM. FOUND HYDRAULIC LINE WITH CRACK AT BEND RADIUS. REPLACED HYDRAULIC LINE. ALSO, REPLACED HYDRAULIC PUMP AND FILTERS DUE OT LOSS OF FLUID. (M)

Part: HOUSING — CRACKED (APU FUEL FILTER)

APU FUEL FILTER HOUSING ATTACHMENT FLANGES CRACKED. THIS IS THE FIFTH FILTER HOUSING THAT HAS CRACKED SINCE 01/30/99, THREE ON N86 AND TWO ON N87. AFTER INVESTIGATION IT WAS CONCLUDED THAT THE FUEL FILTER HOUSING FAILURES ARE THE RESULT OF FUEL CONTROL UNIT OVERPRESSURE CAUSED BY THE MALFUNCTION OF AN INTERNAL ULTIMATE RELIEF VALVE.

Part: WINDSHIELD — CRACKED (COCKPIT)

DURING CRUISE AT FL330, PILOTS WINDSHIELD, OUTER PLY, POPPED AND THEN CRACKED IMMEDIATELY FROM TOP TO BOTTOM ORIGINATING FROM CENTER. (M)

Part: HOUSING — CRACKED (APU FUEL FILTER)

APU FUEL FILTER HOUSING ATTACHMENT FLANGES, CRACKED. THIS IS THE 5TH FILTER HOUSING THAT HAS CRACKED SINCE 01/30/99, 3 ON N86, AND 2 ON N87.

Part: COVER — BROKEN (APU)

APU MODEL NUMBER GTCP 36-150RJ. THE LOW PRESSURE FUEL FILTER COVER MOUNTING EAR WAS COMPLETELY BROKEN OFF THE COVER WHERE THE MOUNTING BOLT ATTACHES THE COVER TO THE FUEL CONTROL. APU CONTINUED TO RUN AFTER EAR BROKE OFF.

Part: FUEL CAP — DIRTY (RT WING)

FUEL OBSERVED STREAMING DOWN THE RIGHT-HAND WING DURING FLIGHT. FUEL WAS LEAKING AT THE RIGHT-HAND OUTBOARD FUEL CAP. AIRCRAFT MADE UNSCHEDULED LANDING. THE LOCKING DEVICE ON THE CAP WAS INSPECTED AND FOUND TO BE FUNCTIONING PROPERLY. FOREIGN MATTER WAS FOUND UNDER THE FUEL CAP SEAL. FOREIGN MATTER REMOVED, CAP RE-INSTALLED AND NO OTHER DISCREPANCIES NOTED. (X)