N87554

Part: TRUSS — CRACKED (ENGINE) · airframe 31,365 hrs · 37,090 cycles

DURING MAGNETIC PARTICLE INSPECTION DISCOVERED ENGINE TRUSS MOUNT WELD AREA CRACKS AND TRUSS TUBE CHAFE. PERFORMED WELD REPAIR TO ENGINE MOUNT ATTACH POINTS WELD AREAS AND ENGINE TRUSS TUBE IN ACCORDANCE WITH FAA APPROVED DATA.

Part: WARNING HORN — INOPERATIVE (COCKPIT) · airframe 31,322 hrs · 37,014 cycles

FLIGHT: 3577 LWT/BIL GEAR WARNING HORN INOPERATIVE DURING DESCENT INTO BIL. GEAR HYDRAULIC PUMP ACTIVATING FREQUENTLY IN FLIGHT. REPLACED AURAL TONE, OPERATIONAL CHECK GOOD.

Part: TERMINAL — LOOSE (GEAR WARNING) · airframe 30,555 hrs · 35,456 cycles

FLIGHT: 3565 SDY/BIL PILOT REPORTED LANDING GEAR WARNING HORN SILENCE BUTTON INOPERATIVE. TIGHTENED TERMINAL END ON THE BACK OF GEAR HORN OPERATIONAL CHECKED GOOD.

Part: SKIN — CHAFED (RT WING) · airframe 29,833 hrs · 34,622 cycles

DURING SCHEDULED ROUTINE MAINTENANCE DISCOVERED RIGHT UPPER WING SKIN IS CHAFED UNDER RIGHT OUTBOARD SIDE OF TURTLE BACK. INSTALLED REPAIR PATCH TO UPPER WING SKIN CHAFE AREA.

Part: HANDLE — LACK OF LUBE (EMERGENCY EXIT) · airframe 29,646 hrs · 34,322 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED RT EMERGENCY EXIT WILL NOT OPEN FROM INSIDE. LUBRICATED INTERCONNECT SHAFTS BETWEEN OUTSIDE HANDLE AND INSIDE HANDLE, OPS CHECK GOOD.

Part: CABLE — BROKEN (PAX DOOR) · airframe 29,193 hrs · 33,761 cycles

DURING SCHEDULED ROUTINE MX, DISCOVERED AIRSTAIR DOOR FWD CABLES BROKEN, FWD CAMS WILL NOT ROTATE. REPLACED AIRSTAIR DOOR CABLE ASSY.

Part: STRINGER — CORRODED (RT WING) · airframe 29,193 hrs · 33,761 cycles

DURING SCHEDULED ROUTINE INSP, DISCOVERED CORROSION ON THE RT WING LOWER SKIN BONDED STRINGER AT WS 114.25 TO WS 124.25 CUT OUT 4.5 INCH SECTION ON CORRODED STRINGER. FABRICATED AND INSTALLED FROWARD REPAIR ANGLE AND AFT REPAIR ANGLE ON RIGHT WING LOWER BONDED STRINGER.

Part: SKIN — CHAFED (BS 258) · airframe 29,189 hrs · 33,760 cycles

DURING SCHEDULED ROUTINE INSP DISCOVERED SKIN CHAFE LT PRESSURE PLATE AREA APPROX FS 258 AT WS 305. REPAIRED SKIN CHAFE INSTALLED DOUBLER 2.5 X 10.5 INCHES ON LT PRESSURE PLATE AREA AT FS 258, WS 305.

Part: DOOR FRAME — CRACKED (BS 460 S3L) · airframe 29,189 hrs · 33,760 cycles

DURING SCHEDULED ROUTINE INSPECTION DISCOVERED CARGO DOOR FRAME UPPER FWD AREA CRACKED APPOX 2.5 INCHES AT FS 460 AT STRINGER 3L. STOP DRILLED ENDS OF CRACK AND INSTALLED DOUBLER REPAIR.

Part: ANGLE — CRACKED (BS 150 S9L) · airframe 29,189 hrs · 33,760 cycles

DURING SCHEDULED ROUTINE INSP DISCOVERED AIRSTAIR DOOR FWD ANGLE CRACKED AT LOWER SNUBBER ATTACH POINTS APPROX FS 150 AT STR 9L. REMOVED 28 INCH SECTION OF -3 ANGLE AND INSTALLED -3 FILLER ANGLE AND 8.5 INCH UPPER SPLICE AND 6.5 INCH LOWER -11 SPLICE ANGLE.

Part: ANGLE — CRACKED (BS 288) · airframe 29,189 hrs · 33,760 cycles

DURING SCHEDULED ROUTINE INSP DISCOVERED RT HEAVY ANGLE CRACKED AT APPROX FS 288.0 IN RADIUS. STOP DRILLED END OF CRACK AND INSTALLED REPAIR ANGLE CLIP AND FASTNERS AS REQUIRED.

Part: ANGLE — CRACKED (BS 288) · airframe 29,189 hrs · 33,760 cycles

DURING SCHEDULED ROUTINE INSP, DISCOVERED LT HEAVY ANGLE CRACKED AT APPROX FS 288.0 IN RADIUS. STOP DRILLED END OF CRACK AND INSTALLED REPAIR ANGLE CLIP AND FASTNERS AS REQUIRED.

Part: SWITCH — MALFUNCTIONED (MLG) · airframe 28,866 hrs · 33,392 cycles

FLIGHT 9202, ON LANDING GEAR RETRACTION RED UNSAFE LIGHT REMAINS ILLUMINATED AND GEAR HORN IS HEARD.RETURNED TO GHB LANDED WITHOUT INCIDENT. REPLACED RT POWER LEVER GEAR HORN SWITCH OPS CHECK NORMAL. TEST FLIGHT SATISFACTORY.

Part: SPAR — DAMAGED (WING) · airframe 28,051 hrs · 32,516 cycles

COMPLIED WITH COLD EXPANSION OF FASTENER HOLES IN THE WING REAR SPAR LOWER CAP IAW FAA APPROVED DATA CONTAINED IN THE ACFT COMPANY KIT 118-4014-0003. NOTE: ACFT DOWN FOR KIT WING REAR SPAR INSTALLATION.

Part: SWITCH — BROKEN (MLG) · airframe 27,817 hrs · 32,250 cycles

PILOT REPORTED LANDING GEAR WARNING HORN SILENCE BUTTON INTERMITTENT NEED TO WIGGLE AROUND TO SILENCE. REPLACED LANDING GEAR WARNING HORN SILENCE SWITCH S14. OPS CK NORMAL.

Part: WIRE — CHAFED (UPLOCK SWITCH) · airframe 27,784 hrs · 32,217 cycles

DURING APPROACH, LANDING GEAR WARNING HORN AND GEAR HANDLE ILLUMINATED WITH GEAR HANDLE IN THE DOWN POSITION 3 GREEN WAS ILLUMINATED BEFORE GEAR HANDLE ILLUMINATED AND HORN SOUNDED. REPAIRED CHAFED WIRES TO LT GEAR UPLOCK SWITCH, OPS CHECK NORMAL.

Part: UPLOCK SWITCH — OUT OF ADJUST (MLG) · airframe 27,725 hrs · 32,157 cycles

DURING CLIMB OUT UP TO 3000 FT LANDING GEAR INTRANSIENT LIGHT , GEAR WARNING HORN ILLUMINATED AND SOUNDED INTERMITTENTLY. REPLACED RT MAIN LANDING GEAR UP LOCK SWITCH LANDING GEAR OPS CHECK NORMAL.

Part: WARNING HORN — MALFUNCTIONED (LANDING GEAR) · airframe 27,724 hrs · 32,155 cycles

AFTER TAKEOFF LANDING GEAR HORN GOES OFF AFTER GEAR IS UP. LANDING GEAR OPS CHECK GOOD COULD NOT DUPLICATE.

Part: CIRCUIT BOARD — MALFUNCTIONED (MLG) · airframe 27,399 hrs · 31,813 cycles

DURING FLIGHT, LANDING GEAR HANDLE LIGHT WITH HORN REMAINED ILLUMINATED FOR THE ENTIRE DURATION OF THE FLIGHT. REPLACED PC BOARD A406. LANDING GEAR OPERATIONAL CHECK GOOD.

Part: DOOR — STIFF (EMERGENCY EXIT) · airframe 27,335 hrs · 31,747 cycles

DURING SCHEDULED ROUTINE INSP, DISCOVERED SEAT 6A EMERGENCY EXIT DOOR HARD TO OPEN. LUBRICATED SEAT 6A EMERGENCY EXIT DOOR INNER AND OUTER HANDLES, OPS CHECK OK.

Part: DOOR — STIFF (EMERGENCY EXIT) · airframe 27,335 hrs · 31,747 cycles

DURING SCHEDULED ROUTINE INSP DISCOVERED SEAT 4F EMERGENCY DOOR HARD TO OPEN. LUBRICATED SEAT 4F EMERGENCY EXIT DOOR INNER AND OUTER HANDLES, OPS CHECK OK.

Part: DOOR — STIFF (EMERGENCY EXIT) · airframe 27,001 hrs · 31,388 cycles

DURING SCHEDULED ROUTINE INSPECTION DISCOVERED RIGHT AFT EMERGENCY EXIT DOOR HARD TO OPEN. CLEANED AND LUBRICATED RIGHT AFT EMERGENCY DOOR. OPERATIONAL CHECK OK FOR SERVICE.

Part: CABLE — WORN (HANDRAIL) · airframe 26,661 hrs · 31,031 cycles

FLIGHT:5402 MIA/FLL, PILOT REPORTED AIRSTAIR DOOR DIFFICULT TO CLOSE. FOUND LOWER FORWARD HANDRAIL CABLE WORN, REPLACED CABLE.

Part: HINGE BRACKET — CORRODED (LT ELEVATOR) · airframe 26,633 hrs · 31,003 cycles

DURING SCHEDULED ROUTINE INSP, DISCOVERED LT ELEVATOR OTBD HINGE BRACKET SHOW SIGNS OF EXFOLIATION. REPLACED LT ELEVATOR OTBD HINGE BRACKET.

Part: SKIN — CORRODED (RIGHT WING) · airframe 26,340 hrs · 30,684 cycles

DURING SCHEDULED ROUTINE INSP, RT WING OTBD L/E SKIN IS BULGING DUE TO CORROSION AT RWS 276.01. REMOVED CORRODED SKIN AND INSTALLED DOUBLER REPAIR.

Part: SKIN — CORRODED (WING) · airframe 26,340 hrs · 30,684 cycles

DURING SCHEDULED ROUTINE INSP, DISCOVERED RT T/E SKIN FWD OF OTBD FLAP SHOWS SIGNS OF EXFOLIATION WS 138.36 TO WS 196.06. REMOVED DAMAGED, SKIN FABRICATED AND INSTALLED EXTERNAL REPAIR DOUBLER.

Part: DOOR — STUCK (EMERGENCY EXIT) · airframe 26,118 hrs · 30,450 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED RT AFT EMERGENCY EXIT HARD TO OPEN. LUBRICATED RT AFT EMERGENCY EXIT OUTER AND INNER HANDLE, OPERATIONAL CHECK OK.

Part: SKIN — DAMAGED (BS 280-303) · airframe 25,603 hrs · 29,925 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED UPPER FORWARD SKYTRACK ANTENNA CONNECTOR HOLE ELONGATED SKIN DAMAGE BETWEEN FS 280.75 AND 303.25. REPAIRED SKIN DAMAGE BY INSTALLING AN EXTERNAL DOUBLER REPAIR.

Part: SPAR — CORRODED (VERTICAL STAB) · airframe 25,603 hrs · 29,925 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED VERTICAL STABILIZER RT TRAILING EDGE SPAR ANGLE SHOW SIGNS OF EXFOLIATION AT STA 61. BLENDED OUT CORROSION, FABRICATED AND INSTALLED REPAIR STRAP.

Part: HINGE — CORRODED (LT ELEVATOR) · airframe 25,603 hrs · 29,925 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED LT ELEVATOR CENTER HINGE CORRODED AT BONDING JUMPER ATTACH POINT. REPLACED LT ELEVATOR CENTER HINGE.

Part: HINGE BRACKET — CORRODED (RUDDER) · airframe 25,603 hrs · 29,925 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED VERTICAL STABILIZER LOWER RUDDER HINGE BRACKET SHOW SIGNS OF EXFOLIATION. REPLACED LOWER RUDDER HINGE BRACKET.

Part: SPAR — CORRODED (VERTICAL STAB) · airframe 25,603 hrs · 29,925 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED VERTICAL STABILIZER RT TRAILING EDGE SPAR ANGLE SHOW SIGNS OF EXFOLIATION AT STA 12. BLENDED OUT CORROSION, FABRICATED AND INSTALLED REPAIR STRAP.

Part: CABLE — BROKEN (PAX DOOR)

PILOT REPORTED UNABLE TO OPEN CABIN DOOR, FOUND UPPER FWD DOOR CABLE BROKEN. REPLACED UPPER FWD DOOR CABLE. (K)

Part: CABLE — BROKEN (PAX DOOR)

PILOT REPORTED UNABLE TO OPEN CABIN DOOR, FOUND UPPER FWD DOOR CABLE BROKEN. REPLACED UPPER FWD DOOR CABLE. (K)

Part: STRUT — MALFUNCTIONED (PAX DOOR)

FLIGHT 9137 - ASD-FLL - PILOT REPORTED MAIN CABIN DOOR FALLS RAPIDLY. SERVICED MAIN CABIN DOOR STRUT. (S)

Part: HANDLE — LACK OF LUBE (EMERGENCY EXIT)

DURING SCHEDULED ROUTINE MAINTENANCE DISCOVERED RT AFT EMERGENCY EXIT HANDLE IS JAMMED. LUBRICATED RT AFT EMERGENCY EXIT HANDLE ASSEMBLY. (S)

Part: HINGE BRACKET — CORRODED (RT ELEVATOR)

DURING SCHEDULED ROUTINE MAINTENANCE DISCOVERED RT OUTBOARD ELEVATOR HINGE BRACKET CORRODED. REPLACED RT OUTBOARD ELEVATOR HINGE BRACKET. (S)

Part: UNKNOWN — ODOR

FLIGHT 9286, DURING FLIGHT, BURNING ODOR OBSERVED. RAN ENGINES WITH ALL ELECTRICAL SYSTEMS ON AND ENVIRONMENTAL SYSTEMS ON NO ODOR NOTED. COULD NOT DUPLICATE. (A)

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT) · airframe 24,138 hrs · 28,334 cycles

FLIGHT: 9131 TPA/TLH AFTER TAKEOFF DURING LANDING GEAR RETRACTION THE LANDING GEAR HORN CAME ON WITH GEAR HANDLE LIGHT ILLUMINATED. RECYCLED THE LANDING GEAR EVERTHING EXTINGUISHED LATER GEAR HANDLE LIGHT ILLUMINATED. RETURNED TO TPA. LANDED WITHOUT INCIDENT. INSPECTED LANDING GEAR SYSTEM, NO DEFECTS NOTED. LANDING GEAR, OPERATIONAL CHECKS OK.

Part: LINE — LOOSE (BRAKE) · airframe 23,849 hrs · 28,000 cycles

FLIGHT:9140, DURING TAXI LT BRAKE PEDAL DROPPED TO THE FLOOR. SECURED MAIN LINE ON LT BRAKE ASSY, PERFORMED BRAKE BLEEDING AND SERVICED RESERVOIR.

Part: CAM — OUT OF ADJUST (AIRSTAIR DOOR) · airframe 23,421 hrs · 27,513 cycles

AT SCHEDULED INSPECTION, DISCOVERED AIRSTAIR DOOR WILL NOT LATCH WHEN CLOSED. ADJUSTED CAM ON DOOR.

Part: SKIN — CORRODED (BS 318 S15L) · airframe 23,421 hrs · 27,513 cycles

AT SCHEDULED INSP, DISCOVERED EXFOLIATED SECTION OF SKIN AT FS 318.250 STR 15L. REMOVED EXFOLIATED SECTION OF SKIN FABRICATED AND INSTALLED EXTERNAL REINFORCEMENT DOUBLER IAW SRM 51-70-06.

Part: DOOR — INOPERATIVE (EMERGENCY EXIT) · airframe 23,079 hrs · 27,116 cycles

DURING SCHEDULED ROUTINE MAINTENANCE DISCOVERED RT AFT EMERGENCY EXIT DOOR WILL NOT OPEN FROM THE OUTSIDE. LUBRICATED DOOR HANDLE MECHANISIM.

Part: UPLOCK SWITCH — INOPERATIVE (MLG) · airframe 22,713 hrs · 26,690 cycles

AFTER TAKEOFF LANDING GEAR UNSAFE LIGHTS ILLUMINATED WITH LANDING GEAR IN THE UP POSITION. REPLACED LANDING GEAR UPLOCK SWITCH. OPERATIONAL CHECK NORMAL.

Part: UNKNOWN — UNKNOWN (MLG HANDLE) · airframe 22,612 hrs · 26,575 cycles

FLIGHT: 9136 FLL/EYW AFTER TAKEOFF, THE LANDING GEAR HANDLE LIGHT REMAINED ILLUMINATED WITH THE LANDING GEAR RETRACTED. RETURNED TO FLL. LANDED WITHOUT INCIDENT. PERFORMED LANDING GEAR EXTENSION AND RETRACTION OPERATIONAL CHECKS NORMAL.

Part: SKIN — CORRODED (FUSELAGE) · airframe 22,521 hrs · 26,471 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED EXFOLIATION AT LOWER FUSELAGE SKIN AT FS 273.25 AND FS 285.25. REMOVED DAMAGE SKIN FABRICATED AND INSTALLED AN EXTERNAL DOUBLER REPAIR.

Part: OIL SYSTEM — LOW PRESSURE (NR 2 ENGINE) · airframe 22,095 hrs · 25,975 cycles

FLIGHT: 9297 EYW/FLL DURING FINAL INTO FLL, THE NR 2 ENGINE LOW OIL PRESSURE ANNUNCIATOR ILLUMINATED. SECURED THE NR 2 ENGINE. CONTINUED TO FLL LANDED WITHOUT INCIDENT. SERVICED NR 2 ENGINE OIL SYSTEM. REMOVED NR 2 ENGINE STARTER GENERATOR INSPECTED AREA FOR LEAKS. NO LEAKS NOTED. REINSTALLED STARTER GENERATOR. RAN ENGINE OPERATIONAL CHECK, NORMAL, NO LEAKS NOTED.

Part: UNKNOWN — ODOR (RT ENGINE) · airframe 24,492 hrs

FLIGHT: 9165, DURING FLIGHT FUEL ODOR COMING THROUGH AIR VENTS. CHECKED INSPECTED AND CLEANED RT ENGINE PURGE TANK NO DEFECTS NOTED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 19,406 hrs · 22,848 cycles

DURING SCHEDULED ROUTINE MX DISCOVERED 2.0 INCH CRACK IN FUSELAGE BELLY SKIN IN SPAR AREA AT BL 30.62. STOP DRILLED CRACK AND INSTALLED REINFORCEMENT DOUBLER REPAIR.

Part: BRACKET — CORRODED (RT ELEVATOR)

AT SCHEDULED ROUTINE MAINTENANCE, RIGHT CENTER ELEVATOR HINGE BRACKET SHOWS SIGNS OF EXFOLIATION. REMOVED AND REPLACED RIGHT CENTER ELEVATOR HINGE BRACKET. (M)

Part: LINE — LEAKING (LT ENGINE)

DURING FLIGHT, STRONG EXHAUST ODOR PRESENT IN AIRCRAFT WITH BLEED OPEN. REMOVED AND REPLACED FUEL LINE AT LT ENGINE COMPRESSOR INLET. OPERATIONAL CHECKS NORMAL. NO SMELL NOTED.

Part: ELBOW — LOOSE (LT ENG FUEL PUMP)

DURING FLIGHT, STRONG EXHAUST ODOR IN COCKPIT AND CABIN SEEMED TO DISSIPATE WHEN LT ENVIRONMENTAL TURNED OFF. SECURED ELBOW AT LOW PRESSURE FUEL PUMP. NO LEAKS NOTED. OPERATIONAL CHECKS NORMAL.

Part: ACM — INOPERATIVE (CABIN COOLING)

DURING FLIGHT, STRONG EXHAUST ODOR IN COCKPIT AND CABIN WHEN BOTH BLEEDS ARE OPEN. DISSIPATES SOME WITH BLEED IN ENVIRONMENTAL OFF. MAINTENANCE FERRY. REMOVED AND REPLACED AIR CYCLE MACHINE. OPERATIONAL CHECKS NORMAL.

Part: UNKNOWN — FUMES (COCKPIT & CABIN)

DURING FLT, EXHAUST FUMES PRESENT IN CABIN AND COCKPIT. FUMES DISSIPATED WITH LT AND RT ENVIRONMENTAL VALVES SELECTED IN THE OFF POSITION. RAN NR 1 ENGINE WITH ENVIRONMENTAL ON FOR TEN MINUTES. COULD NO DUPLICATE.

Part: ODOR — DETECTED (COCKPIT)

DURING FLIGHT, MILD ODOR OF FUEL IN COCKPIT WITH LT BLEED AIR VALVE ON. RAN AIRCRAFT SYSTEMS. OPERATIONAL CHECKS GOOD. NO FUMES NOTED. COULD NOT DUPLICATE.

Part: TUBE — CRACKED (LT AFT FERRULE)

DURING LANDING ON DECENT AT 4,000 FT, LT ENGINE LOST POWER. CREW SECURED ENGINE. REMOVED AND REPLACED TUBE ASSY P3 BLEED LINE AT LT FUEL CONTROL UNIT. OPERATION CHECK NORMAL.

Part: HINGE BRACKET — CORRODED (LT ELEVATOR)

AT SCHEDULED ROUTINE MAINTENANE, LT OB ELEVATOR HINGE BRACKET SHOWS SIGNS OF CORROSION. REMOVED AND REPLACED LT OB ELEVATOR HINGE BRACKET.

Part: HINGE BRACKET — CORRODED (LT ELEVATOR)

AT SCHEDULED ROUTINE MAINTENANCE, LT CTR ELEVATOR HINGE BRACKET SHOWS SIGNS OF CORROSION. REMOVED AND REPLACED LT CTR ELEVATOR HINGE BRACKET.

Part: HINGE BRACKET — CORRODED (RT ELEVATOR)

AT SCHEDULED ROUTINE MAINTENANCE, RT OB ELEVATOR HINGE BRACKET SHOWS SIGNS OF CORROSION. REMOVED AND REPLACED RT OB ELEVATOR HINGE BRACKET.

Part: FIRE LOOP — BROKEN (LT ENGINE)

FLT 9307 - EYW/TPA - DUIRNG FLIGHT, LEFT FIRE LOOP AND LEFT FIRE ANNUNCIATOR ILLUMINATED. REMOVED AND REPLACED LEFT ENGINE FORWARD FIRE LOOP. OPERATIONAL CHECK NORMAL. (M)

Part: SWITCH — DIRTY (COCKPIT)

CLE FLT 4377 THE CREW REPORTED LANDING GEAR WARNING HORN AND RED GEAR HANDLE LIGHT ON WITH LANDING GEAR IN UP POSITION. MAINTENANCE CLEANED FLAP POSITION SWITCHES. OPERATIONAL CHECKS WERE GOOD AND AIRCRAFT WAS RELEASED FOR SERVICE.

Part: FIRE LOOP — INOPERATIVE (LT ENGINE)

CLE FLIGHT 3133 THE CREW REPORTED LEFT ENGINE FIRE LOOP WOULD NOT TEST. MAINTENANCE REMOVED AND REPLACED LEFT ENGINE FIRE LOOP AND PERFORMED OPERATIONAL TEST. AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — DIRTY (RT ENGINE)

MDT FLIGHT 3133 THE CREW REPORTED RIGHT ENGINE FIRE LOOP TEST FAILED. MAINTENANCE CLEANED AND RESEATED RIGHT ENGINE FIRE LOOP CANNON PLUG. PERFORMED OPERATIONAL TEST AND AIRCRAFT WAS RETURNED TO SERVICE.