N872SJ

Part: LINE — CRACKED (HYDRAULIC SYS) · airframe 84,408 hrs · 32,587 cycles

DURING DESCENT HYD QUANITY AND PRESSURE LOST. UTILIZED EMERGENCY/ABNORMAL HYD CHECKLIST FOR APPROACH AND LANDING. FOUND LEAK AT NLG PIPE ASSY-CROSS TO GLAND STA 244 TO 240. REPLACED PIPE ASSY. ACFT RETURNED TO SERVICE.

Part: LINE — CRACKED (HYDRAULIC SYS) · airframe 84,408 hrs · 32,587 cycles

IN DESCENT HYDRAULIC QUANITY AND PRESSURE LOST. UTILIZED EMERGENCY/ABNORMAL HYDRAULIC CHECKLIST FOR APPROACH AND LANDING AT LBBG. FOUND LEAK AT NLG PIPE ASSY-CROSS TO GLAND STA 244 TO 240. REPLACED PIPE ASSY. AIRCRAFT RETURNED TO SERVICE.

Part: CABLE — OUT OF RIG (NR 1 ENGINE) · airframe 83,464 hrs · 32,329 cycles

NR 1 ENGINE FLAMED OUT AT IDLE AT 30,000 FT. BEGAN PERFORMING ENGINE FLAMEOUT ABNORMAL CK LIST. ENGINE RELITE AND PERFORMED NORMALLY AFTER IGNITION TURNED ON. FINISHED ABNORMAL CK LIST. WEATHER VMC. PERFORMED PULL, TRAVEL AND RIGGING CHECKS OF VBV AND VSV FEEDBACK CABLES IAW MM 73-20-1, PULL AND TRAVEL CHECKS OF VBV AND VSV CABLES NO DEFECTS. RIGGED VBV AND VSV CABLES IAW MM 73-20-1.

Part: STRAP — CRACKED (RT WING) · airframe 83,402 hrs · 32,308 cycles

DURING C-CHECK, FOUND RT WING XFS 6.225 CENTER LEADING EDGE INTERIOR LOWER STRAP HAS 5 INCH CRACK.

Part: STRAP — CRACKED (RWS 341)

DURING C-CHECK FOUND RT WING XFS 341.500 CENTER LEADING EDGE INTERIOR LOWER SURFACE STRAP HAS 12 INCHES CRACK. (K)

Part: FITTING — CORRODED (THRUST REVERSER)

DURING C-CHECK FOUND NR 1, 2, 3, 4 ENGINE THRUST REVERSER TRANSLATING COWL RAIL FITTINGS CORRODED. (K)

Part: STRAP — CRACKED (RWS 430)

DURING C-CHECK, FOUND RT WING XFS 430.000 CTR LEADING EDGE INTERIOR LOWER SURFACE STRAP HAS 18 INCH CRACK. (K)

Part: STRINGER — CRACKED (RT WING)

DURING C-CHECK INSP, FOUND RT WING X RS NR 4 MAIN FUEL TANK STRINGER 58 HAS 2 INCH TRANSVERSAL CRACK BY ACCESSORY PANEL NR 5050. (K)

Part: SKIN — CORRODED (FS 8 L21R)

DURING C-CHECK INSP, FOUND FUSELAGE EXTERIOR FS 8.000, L-21R SKIN WITH BULGING AND CHERRY MAX RIVETS. (K)

Part: STRINGER — CRACKED (RT WING)

DURING C-CHECK INSP, FOUND RT WING X RS 202 NR 4 MAIN FUEL TANK STRINGER 67 HAS 2 INCH CRACK BY ACCESSORY PANEL NR 5050. (K)

Part: SKIN — DENTED (RT ELEVATOR)

DURING C-CHECK INSP, FOUND RT ELEVATOR XE117-594 LOWER SURFACE DENTED. (K)

Part: BRACKET — CRACKED (BOOST PUMP)

DURING C-CHECK INSP, FOUND LT WING NR 1 ALTERNATE FUEL TANK INTERIOR BOOST PUMP BRACKET FITTING (2) CRACKS. (K)

Part: STRAP — CRACKED (DOOR FRAME)

DURING C-CHECK INSPECTION, FOUND AFT SERVICE DOOR (R2) AFT UPPER JAMB CORNER WITH CRACK OF 0.800 LENGTH ON BEAR STRAP (AFTER ACCOMPLISHED X-RAY INSPECTION). (K)

Part: FRAME — CORRODED (FUSELAGE)

DURING C-CHECK INSP, FOUND FWD CARGO COMPARTMENT F3 8.00 BTW L-24R FRAME WITH CORROSION. (K)

Part: SUPPORT ANGLE — CRACKED (LT WING)

DURING C-CHECK INSP, FOUND LT WING X RS 71, 5-52 NR 2 MAIN FUEL TANK INTERIOR LOWER SUPPORT ANGLE CRACKED. (K)

Part: STRUCTURE — CRACKED (BS 560)

DURING C-CHECK INSP, FOUND LWR CARGO COMPARTMENT, STA 560.000 RT CUSP EXTRUSION WITH 2 INCH CRACK. (K)

Part: ENGINE — FLAMED OUT (NR 1) · airframe 83,161 hrs · 32,227 cycles

NR 1 ENGINE FLAMED OUT TOP OF DESCENT AT IDLE. RELIGHT PERFORMED IAW INFLIGHT ENGINE START PROCEDURES, OBSERVED NORMAL START AND INDICATION.

Part: SKIN — CORRODED (FUSELAGE) · airframe 83,154 hrs · 32,222 cycles

DURING INSPECTION, FOUND CORROSION AT AFT CARGO COMPARTMENT AREA STATION 1440 LONGERON 36 RT EXTERNAL LOWER SKIN.

Part: SKIN — CRACKED (BS 1380 S36R) · airframe 82,387 hrs · 31,894 cycles

DURING INSPECTION FOUND CRACK AT AFT CARGO COMPARTMENT STATION 1380 STRINGER 36 RT ON EXTERNAL LOWER SKIN. COMPLETED FUSELAGE SKIN TEMPORARY EXTERNAL REPAIR AT FUSELAGE STATION 1380/LONG 36R PER FLIGHT VEHICLES CONSULTING, INC DRAWING NR 53-07027-1 AND FAA FORM 8110-3 NR 07027 DATED JANUARY 22, 2007.

Part: SKIN — CORRODED (BS 1418 S36R) · airframe 82,387 hrs · 31,894 cycles

DURING INSPECTION FOUND CORROSION AT AFT CARGO COMPARTMENT AREA STATION 1418 STRINGER 36 RT ON EXTERNAL LOWER SKIN. FOUND 1" CRACK FWD OF FLIGHT STATION 1418 STRINGER 36 RT EXTERNAL SKIN. COMPLETED FUSELAGE SKIN TEMPORARY EXTERNAL REPAIR AT FS 1418/LONG 36 RT PER FLIGHT VEHICLES CONSULTING, INC DRAWING NUMBER 53-07027-1 AND FAA FORM 8110-3 NR 07027 DATED JANUARY 22, 2007.

Part: FITTING — CORRODED (FUSLEAGE) · airframe 81,332 hrs · 31,461 cycles

LONGERON END FITTING LOCATED AT FRAME 80 AFT, L27R FOUND CORRODED BEYOND LIMITS. CLASSIFIED AS LEVEL 2 CORROSION.

Part: BELLCRANK — DISCONNECTED (RT ELEVATOR) · airframe 81,332 hrs · 31,461 cycles

DURING INSPECTION, RT ELEVATOR GEARED TAB OUTBOARD CRANK P/N 4710542-3 FOUND DISCONNECTED FROM LINK P/N 271442-501. NOTE: AIRCRAFT IS CURRENTLY CLASSIFIED PART 91.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

LT W/W UPPER LT SIDE FWD AND AFT OF SIXTH FLOOR SUPPORT HAS CORROSION. GBAMC NR 4178 CLEANED, CHECKED FOUND TO BE OUT OF LIMITS IAW DC-8 SRM 53-2-0. REMOVED LT W/W, L/H SIDE AFT FLOOR SUPPORT AT STA 960.00 AND REPLACED FLOOR SUPPORT FITTING AT STA 960.00 IAW DC-8 SRM 53-2-0.-CLOSED-

Part: GUSSET — CRACKED (FUSELAGE) · airframe 81,330 hrs · 31,460 cycles

RT UPPER GUSSET CRACKED AT STA XW5.000 GBAMC NR#04187. STOP DRILLED, FAB`D DOUBLER IAW DC-8 SRM. INSTALLED TOP AND BOTTOM DOUBLER IAW DC-8 SRM 51-1-21 AT STA XW5.000

Part: FINGER DOUBLER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

LT OB TOP SIDE OF WHEEL WELL PRESSURE DOGHOUSE BETWEEN STA 960 AND 980, FINGER DOUBLER HAS CORROSION ON FWD UNDERSIDE. GBAMC NR304186 -OPEN-

Part: DOOR — CORRODED (CARGO BAY) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

D-PIT, AFT BULKHEAD DOOR 645 CORRODED GBAMC NR#04172 CUT OUT DAMAGED MATERIAL ON D PIT DOOR AFT BULKHEAD DOOR 645 IAW DC-8 SRM 52-2-0 FIG 4 SHEET 2. FABRICATED DOUBLER PATCH OUT OF 7075T6 .032 AND INSTALLED DOUBLER PATCH ON D-PIT BULKHEAD DOOR IAW DC-8 SRM 52-2-0 FIG 4 SHEET 2.

Part: FINGER DOUBLER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

CARGO AREA RT SIDE STA 960 HAS CORROSION UNDER FINGER DOUBLER UNDER FLOORBOARD. GBAMC NR04182 -OPEN-

Part: STRUCTURE — CORRODED (LT MLG WW) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

LT WW UPPER LT SIDE FWD AND AFT OF NR 6 FLOOR SUPPORT HAS CORROSION. GBAMC NR04178 -OPEN-

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

LT W/W LT SIDE UPPER, SECOND FLOOR SUPPORT HAS CORROSION ON LOWER SIDE. GBAMC NR04176 -OPEN-

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

A/C COMP AREA INTERIOR A/C OUTFLOW DUCT HAS CORROSION GBAMC NR 04160 CLEANED CORRISON ON INTERIOR A/C OUTFLOW DUCT PANEL IAW DC-8 SRM 51-1-8,CORRISON FOUND TO BE OUT OF LIMITS IAW DC-8 SRM 53-2-0. MATERIAL THICKNESS.130,MATERIAL LOSS .104 FABED DOUBLER IAW COTNEY AEROSPACE INC. DWG W93-R02 REV IR AND INSTALLED DOUBLER AT STA 35 TO 55 AND L28R TO TO L30R IAW DC-8 SRM 51-1-21 SUPPORTED BY 8110-3. -CLOSED-

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 81,330 hrs · 31,460 cycles

LAV ACCESS SERVICE PANEL HAS CORROSION UNDER PAINT GBAMC NR 04161 AND NR 04185 UPON INVESTIGSTION FOUND SKIN TO BE OUT OF LIMITS BELOW LIP ON ACCESS DOOR, REMOVED DAMAGED SKIN AREA OF 1.75X9.00 FABED FILLER,FABED FINGER DOUBLER FOR BACK, FAB DOUBLER FOR EXTERNAL, INSTALLED SPLICE, INSIDE DOUBLER& OUTSIDE DOUBLER IAW COTNEY AEROSPACE DWG W93-RO3 REV.IR-CLOSED-

Part: ALTIMETER — ERRATIC (COCKPIT)

ON CLIMB OUT MIA AT 17,000 CAPT. ALTIMETER BECAME ERRACTIC AND STICKING AND GIVING ERRONEOUS READINGS, LOG BOOK, PAGE 201510. REMOVED AND REPLACED CAPT. ALTIMETER, ACCOMPLISHED PITOT STATIC SYSTEM LEAK CHECK AND OPS CHECK- FOUND NORMAL IAW MM. PITOT STATIC TESTER 10100164, BARFIELD CAL DATE 10-10-00, DUE RECALIBRATION, DATE 01-10-2001.

Part: ENGINE — FAILED (NR 4)

ENGINE NR 4 SHUTDOWN DURING FLT. DUE TO LOSS OF OIL QUANITY AND PRESSURE. AFTER LANDING, MAINT FOUND TRANSFER GEARBOX MOTORING PAD COVER AND SPLINE-SHAFT IN COWLING, ALL CHIP DETECTORS INSPECTED AND FOUND TRANSFER GEARBOX SCAVENGE IN AND SUPPLY OIL FILTER AND SCAVENGE OIL FILTER CONTAMINATED WITH METAL PARTICLES. SPARE ENGINE, TOOLING AND PERSONNEL DISPATCHED TO VCP FOR ENGINE CHANGE.

Part: ACTUATOR — INOPERATIVE (WING FLAP)

WING SLOT LIGHT ON AFTER TO, FLAPS UP, AND BUFFET. UNABLE TO COMPLETE WING SLOT LIGHT ON ABNORMAL PROCEDURE CONDITION NR 1. NOTE: FLAP INDICATOR REMAINS AT 0 FLAP HANDLE IS PLACED TO 0 DEGREE OR 25 DEGREE FLAP POSITION. CHANGED WING FLAP CONTROL VALVE IAW MM AND PERFORMED RIGGING AND ADJUSTMENT OF WING SLOTS AND WING FLAP IAW MM, STEP D, AND TESTED IAW MM, STEP C.

Part: ACTUATOR — INOPERATIVE (WING FLAP)

WING SLOT LIGHT ON AFTER TO, FLAPS UP, AND BUFFET. UNABLE TO COMPLETE WING SLOT LIGHT ON ABNORMAL PROCEDURE CONDITION NR 1. NOTE: FLAP INDICATOR REMAINS AT 0 FLAP, WHEN FLAP HANDLE IS PLACED TO 0 DEGREE OR 25 DEGREE FLAP POSITION. CHANGED WING FLAP CONTROL VALVE IAW MM AND PERFORMED RIGGING AND ADJUSTMENT OF WING SLOTS AND WING FLAP IAW MM AND TESTED IAW MM.

Part: INDICATOR — FAULTY (EGT)

ON CLIMB OUT, NR 3 EGT STARTED TO RISE AND REACHED TEMP LIMIT. WITH POWER LEVER BACK EGT STAYED WITHIN LIMITS. WITH PMC OFF TEMP STARTED TO RISE. DUMPED FUEL IAW AIRCRAFT ABNORMAL PROCEDURES CHECK LIST. BORESCOPE NR 3 ENGINE HPC AND HPT IAW MM. PERFORMED CHECK OF EGT HARNESS AND T495 EGT PROBES IAW CFM MM. NO DESCREPANCIES FOUND. VISUALLY CHECKED INLET AND EXHAUST AREAS AS REQUIRED, CIT SENSOR, VBV AND VSV SYS. NO LEAKS OR DAMAGE NOTED. B/C AND FOUND FAULTY EGT IND. R AND R EGT IND. IAW MM. OPS AND GROUND CK IAW MM.

Part: ACTUATOR — FAILED (LT TE FLAP)

ON ARRIVAL AT BRU FLIGHT NR 081, DURING ENGINE SHUTDOWN, HYDRAULIC QTY INDICATOR DROPPED TO 6 GAL. INSPECTED AIRCRAFT AND FOUND MID WING ACTUATOR ON LT FLAP SHEARED AND LEAKING AT CONNECTOR. REPLACED ACTUATOR, SYSTEM OPS CHECKED GOOD PER MM CH 27-00.

Part: WIRE — BROKEN (NR 9 SMOKE DET)

DURING PREFLIGHT, NR 9 AND NR 10 SMOKE DETECTOR, WOULD NOT TEST. INSPECTED AND FOUND WIRE BROKEN DURING LOADING. NR 9 SMOKE DETECTOR REPAIRED, OPS CHECK GOOD IAW DC8 MM CH 26.

Part: FIRE LOOPS — MALFUNCTIONED (NR 1 ENGINE)

ON DESCENT, NR 1 ENGINE SHORT CIRCUIT LIGHT FLICKERED ON. REMOVED AND REPLACED ALL FIRE LOOPS ON NR 1 ENGINE. PERFORMED ENGINE RUN, OPS CHECKED GOOD IAW ATA CH 26.

Part: FIRE CONTROL — INOPERATIVE (NR 1 ENGINE)

DURING FLIGHT, NR 1 ENGINE FIRE LOOP SHORT CIRCUIT LIGHT FLICKERS ON AND OFF. UPON TAXI IN FIRE WARNING ON NR 1 ENGINE CAME ON AND SHORT CIRCUIT LIGHT CAME ON STEADY. REMOVED AND REPLACED NR 1 FIRE WARNING CONTROL, SYSTEM OPS CHECKED GOOD PER MM CH 26-00.

Part: CONNECTOR — DIRTY (NR 1 FIRE LOOP)

DURING FLIGHT, NR 1 ENGINE FIRE WARNING SHORT CIRCUIT LIGHT FLICKERS ON AND OFF. VISUALLY OBSERVED NR 1 ENGINE, NO FIRE CONDITION EXISTS. AIRCRAFT CONTINUED TO DESTINATION WITHOUT INCIDENT. REMOVED AND CLEANED CANNON PLUG ON NR 1 FIRE CONTROL BOX, OPS CHECKED GOOD PER MM CH 26.

Part: FIRE DETECTOR — FAILED (NR 1 ENGINE)

DURING FLIGHT, NR 1 ENGINE FIRE SHORT CIRCUIT LIGHT, MASTER WARNING LIGHT AND FIRE HANDLE LIGHT ILLUMINATED INTERMITTENTLY, ALL OTHER INDICATIONS WERE NORMAL. OBSERVED NR 1 ENGINE AND FOUND NO ABNORMAL CONDITION EXISTS. AIRCRAFT LANDED WITHOUT INCIDENT. FOUND FIRE DETECTOR CONTROL UNIT FAULTY. REPLACED NR 1 FIRE DETECTOR UNIT PER MM CH 26, SYSTEM OPS CHECKED GOOD.

Part: ACTUATOR SEAL — DETERIORATED (TE SLOT CONTROL)

AFTER TAKEOFF FOR FLIGHT 128 OUT OF EKCH, DURING GEAR RETRACTION, AIRCRAFT HYDRAULIC QUANTITY INDICATED A RAPID FLUID LOSS. FOLLOWED EMERGENCY PROCEDURE AND SELECTED HYDRAULIC SYSTEM TO STAND BY RUDDER PUMP, AIRCRAFT LANDED SAFELY USING AUXILARY PUMP, INSPECTED AIRCRAFT AND FOUND SLOT CONTROL ACTUATOR LEAKING HYDRAULIC FLUID, REPLACED O-RING SEAL, REPLENISHED FLUID, SYSTEM OPS CHECKED AND LEAK CHECKED GOOD PER M.M. CH 29-10-20.

Part: FIRE WARN LIGHT — ILLUMINATED (NR 1 ENGINE)

NR 1 ENGINE FIRE WARNING LIGHT CAME ON AFTER ENGINE SHUT-DOWN AT THE BLOCK, WITHIN 15 SECONDS FIRE LIGHT AND BELL WENT OFF, ENGINE SHORT CIRCUIT LIGHT ALSO CAME ON WITH FIRE WARNING WOULD NOT TEST WENT OFF. VISUALLY VERIFIED NR 1 ENGINE HAD NO FIRE, INSPECTED ENGINE AND FOUND NR 1 ENGINE FIRE LOOP SERVICEABLE, PERFORMED ENGINE RUN AND COULD NOT DUPLICATE PROBLEM, ENGINE FIRE WARNING SYSTEM CHECK CARRIED OUT PER M.M. CH 26.

Part: SWITCH — ICE BUILD-UP (LT MLG DOWNLOCK)

DURING FLIGHT 577 TO KEF, LEFT MAIN GEAR GREEN DOWN LIGHT NOT ON AND GEAR UNSAFE LIGHT ILLUMINATED, RECYCLED GEAR WITH SAME RESULT. PERFORMED CHECK PER QRH AND DETERMINED GEARS WERE DOWN AND LOCKED, AIRCRAFT LANDED WITHOUT INCIDENT. INSPECTED LT GEAR DOWNLOCK SWITCH, FOUND ICE BUILD-UP ON SWITCH, CLEANED AND OPS CHECKED GOOD PER M.M. CH 32.

Part: FIRE LOOP — OUT OF POSITION (NR 1 ENG)

DURING DESCENT, FIRE BELL RANG ONCE AND NR 1 SHORT CIRCUIT TEST LIGHT FLICKERED ON BRIEFLY THEN STOPPED. AIRCRAFT LANDED WITHOUT INCIDENT. INSPECTED NR 1 ENGINE, FOUND FIRE LOOP OUT OF POSITION, REPOSITIONED FIRE LOOP, PERFORMED FUNCTIONAL CHECK AND ENGINE RUN-UP CHECK. FIRE WARNING OPERATED NORMALLY PER MM CH 26-00-00.

Part: SKIN — PUNCTURED (LT WING)

ON TAKEOFF, AIRCRAFT HAD BIRD STRIKE. AFTER LANDING AT EBBR, INSPECTED AIRCRAFT AND FOUND BIRD STRIKE CAUSED DAMAGE TO LEFT WING L/E BETWEEN NR 2 PYLON AND FUSELAGE. REPLACED LT WING LANDING LIGHT AND REPAIRED L/E IAW SRM 51 CH 57-2-1.

Part: PIN — NOT REMOVED (NLG)

AFTER TAKEOFF, FOUND NOSE LANDING GEAR WOULD NOT RETRACT, DUMPED FUEL AND LOWERED MAIN LANDING GEAR TO ACCOMPLISH AIR TURNBACK. AIRCRAFT LANDED WITHOUT INCIDENT. FOUND NOSE GEAR PIN NOT REMOVED PRIOR TO DEPARTURE. REMOVED PIN AND RETURNED AIRCRAFT TO SERVICE.

Part: WIRE — FAILED (NR 2 PYLON)

DURING FLIGHT 9829 FROM MIA, NR 2 ENGINE FIRE SHUT-OFF VALVE TRIPS CIRCUIT BREAKER AND WILL NOT RESET. ACCOMPLISHED AIR TURN BACK TO MIA, AIRCRAFT LANDED WITHOUT INCIDENT. REPAIRED WIRING AT NR 2 PYLON SECTION, SYSTEM OPS CHECKED GOOD PER MM CHAPTERS 26-3-1 AND 78-3-1.

Part: SWITCH WIRE — DEFECTIVE (LT MLG DOOR)

DOV - FLT AD01 - ON TAKEOFF AFTER GEAR RETRACTED, GEAR DOORS AND GEAR UNSAFE WARNING LIGHTS REMAINED ON, CYCLED GEAR THREE TIMES, PROBLEM REMAINS. DUMPED FUEL AND DIVERTED TO JFK. AIRCRAFT LANDED SAFELY. AIRCRAFT IS CURRENTLY ON JACKS, FOUND WIRING TO LT MAIN GEAR DOOR SWITCH DEFECTIVE. REPAIRED WIRING PER WDM 32-1-0, GEAR SWING PERFORMED PER CHAPTER 32-60-00. OPS CHECKED GOOD. (X)