N8974U

Part: SKIN — CRACKED (MLG DOOR CUTOUT) · airframe 53,818 hrs · 16,200 cycles

NR 34M. DURING "A" CHECK NON-ROUTINE INSPECTION, THE FOLLOWING WAS FOUND- NLG WW LT SIDE, STA. 208 L-33L CORNER WITH .2500 INCH CRACK. TRIMMED OUT CRACK ON EDGE OF NOSE SKIN AT NOSE LANDING GEAR DOOR LEFT AFT CORNER AND FABRICATED FILLER FROM 707STG.O50 AND DOUBLER FROM 707STG-063 IAW AVITAS ENGINEERING REPAIR ORDER AROW-033RO-1, INITIAL RELEASE, DATED 07/08/03, PAGE 1 TO 2, AND REPAIR SKETCH AIPSAC-N8974U-01/03, SHEET 1 TO 4, DATED 07/02/03. PRIMED PARTS IAW DC8 SRM 51-1-8 AND INSTALLED PARTS IAW AVITAS ENGINEERING REPAIR ORDER AROW-033RO-1, AND REPAIR SKETCH AIPSAC-N8974U-01/03. ISSUED FAA FORM 8110-3 DATED 07/08/03.

Part: LINE — LEAKING (NR 3 HYD SYS)

IN FLIGHT ABOUT ONE HOUR OUT OF VTBU AFTER TAKE-OFF AIRCRAFT WAS LOSING HYDRAULIC FLUID. DID IN-FLIGHT TURNBACK, DUMPED FUEL AND LANDED BACK AT VTBU. RAN ALL APPROPIATE CHECK LISTS. FOUND NR 3 ENGINE HYDRAULIC PUMP SUPPLY LINE LEAKING. REMOVED AND REPLACED LINE AND LEAK CHECKED NORMAL IAW MM 20-12-0 AND MM 29-00 & 71-00.

Part: O-RING — LEAKING (HYD SYSTEM) · airframe 53,074 hrs · 16,018 cycles

ON FINAL APPROACH LOSS OF HYDRAULIC FLUID TO THE STAND PIPE. FOUND EMPENNAGE FILTER BOWL LEAKING AT MAGNETIC PLUG. REMOVED AND REPLACED O-RING LEAK CHECK NORMAL IAW MM.

Part: SEAL — LEAKING (TURBO COMPRESSOR) · airframe 52,032 hrs · 15,703 cycles

EN ROUTE FROM QPG TO OKO, WHEN THE FLIGHT CREW TURNED ON THE NUMBER ONE TURBO COMPRESSOR A SQUEAL WAS HEARD AND AN ODOR WAS SENSED IN THE COCKPIT. THE FLIGHT CREW SECURED THE TURBO COMPRESSOR, THE ODOR SUBSIDED. THE FLIGHT CONTINUED TO OKO FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE TURBO COMPRESSOR LOCATING A DEFECTION OIL SEAL ON THE OIL TANK. MAINTENANCE REPLACED THE SEAL, PERFORMED A SUCCESSFUL OPERATIONAL TEST IN ACCORDANCE WITH THE MAINTENANCE MANUAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LINE — DEFECTIVE (ENGINE) · airframe 51,820 hrs · 15,657 cycles

EN ROUTE FROM KWI TO HIK, THE FLIGHT CREW NOTICED THE MAIN HYDRAULIC SYSTEM FLUID QUANTITY DECLINING. THE FLIGHT CREW FOLLOWED COMPANY EMERGENCY PROCEDURES, DECLAIRED AN EMERGENCY, AND CONTINUED TO HIK FOR AN UNEVENFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT LOCATING A RUPTURED HYDRAULIC PRESSURE LINE ON THE NUMBER TWO ENGINE DRIVEN HYDRAULIC PUMP. MAINTENANCE REPLACED THE LINE. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UPLOCK — MALFUNCTIONED (MLG)

HIK - FLT JZ43 - EN ROUTE TO KWA, THE LANDING GEAR FAILED THE GEAR UPLATCH CHECK, ACCOMPANIED BY GEAR AND DOOR WARNING LIGHTS ILLUMINATING. THE FLIGHT CREW CYCLED THE GEAR BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT RETURNED TO HIK FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR WITH NO DISCREPANCIES NOTED. MAINTENANCE CLEANED AND LUBRICATED THE MAIN GEAR UPLATCH MECHANISMS AND PERFORMED A SUCCESSFUL OPERATIONAL TEST. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: PUMPS — DEFECTIVE (NR 2/3 ENGINES)

EN ROUTE, THE MAIN HYDRAULIC SYSTEM FAILED AND HYDRAULIC PRESSURE DROPPED TO ZERO. THE FLIGHT CONTROL MANUAL REVERSION LIGHTS ILLUMINATED CONFIRMING THE FAILURE. THE FLIGHT WAS DIVERTED TO DNA FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE NUMBER TWO AND THREE ENGINE DRIVEN HYDRAULIC PUMPS DEFECTIVE. FURTHER INVESTIGATION REVEALED THE MAIN HYDRAULIC QUANTITY TRANSMITTER DEFECTIVE AND A RUPTURED HYDRAULIC LINE ON THE LEFT WING INBOARD SLOT ACTUATOR. MAINTENANCE REPLACED ALL DEFECTIVE COMPONENTS IN ACCORDANCE WITH THE MAINTENANCE MANUAL. A SUCCESSFUL OPERATIONAL TEST IN ACCORDANCE WITH THE MAINTENANCE MANUAL.

Part: ACTUATOR — FAILED (RT MLG)

AFTER TAKEOFF UPON GEAR RETRACTION, THE DOORS LIGHT REMAINED ILLUMININATED AFTER THE UPLATCH CHECK. THE GEAR WAS RECYCLED SEVERAL TIMES WITH NO CHANGE IN WARNING STATUS. THE FLIGHT RETURNED TO HIK. MAINTENANCE REPLACED THE MAIN GEAR CONTROL VALVE, THE HYDRAULIC SYSTEM PRIORTITY VALVE, AND THE RIGHT MAIN LANDING GEAR RETRACT ACTUATOR IN ACCORDANCE WITH THE APPLICABLE SECTIONS OF THE DOUGLAS DC-8 MAINTENANCE MANUAL. A SUCCESSFUL GEAR SWING WAS MADE AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNSAFE LIGHT — ILLUMINATED (LT MLG DOOR)

RIA FLT NR 7700 MIA - DOVER AIRCRAFT RETURNED TO MIA AFTER TAKEOFF WHEN MLG DOOR UNSAFE LIGHT ILLUMINATED. IN MIA, AIRCRAFT JACKED AND RIGGED LEFT DOOR ACTUATOR. OPS CHECK OK, AIRCRAFT RETURNED TO SERVICE. (M)

Part: DOUBLER — CORRODED (BS 1160-1180)

LEVEL 2 CORROSION/AFT CARGO COMPARTMENT, STR 21R BETWEEN STA 1160 AND STA 1180, FLOOR SUPPORT HAS CORROSION. REMOVED DAMAGED AREA, FABRICATED, AND INSTALLED REPAIR PER RICH E.O. NR RCH D85310-6124. (X)

Part: SKIN — CORRODED (FS 1290)

LEVEL 2 CORROSION/2 SMALL SKIN BULGES JUST AFT OF NR 4 PIT DOOR FS 1290, STR 28R. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED REPAIR PER SRM 53-2-1.

Part: DOUBLER — CORRODED (BS 1240-1260)

LEVEL 2 CORROSION/AFT CARGO COMPARTMENT, LT SIDE STR 21L, BETWEEN STA 1240 AND STA 1260, FLOOR SUPPORT CORRODED. REMOVED DAMAGED AREA, FABRICATED, AND INSTALLED REPAIR PER RICH DRAWING D85310-6124. (X)

Part: DOUBLER — CORRODED (BS 1240-1260)

LEVEL 2 CORROSION/AFT CARGO COMPARTMENT, LT SIDE STR 21L BETWEEN STA 1240 AND STA 1260, FUSELAGE SKIN HAS CORROSION. REMOVED DAMAGED AREA, FABRICATED, AND INSTALLED REPAIR PER RICH E.O. D85310-6124, REV 1.

Part: SKIN — CORRODED (FS 540)

LEVEL 2 CORROSION/LOWER FUSELAGE IS BULGED WITH CORROSION AT FS 540R BETWEEN LONGERONS 35R AND 34R BELOW FORWARD CARGO DOOR SILL PLATE. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED REPAIR PER SRM 52-2-1.

Part: STRINGER — CORRODED (BS 1160-1180)

LEVEL 2 CORROSION, AFT CARGO COMPARTMENT STRINGER 21R BETWEEN STA 1160 AND 1180 FLOOR SUPPORT HAS CORROSION. REMOVED DAMAGED AREA FABRICATED AND INSTALLED REPAIR PER SMR 53-2-5.

Part: SKIN — CORRODED (BS 1290)

LEVEL 2 CORROSION, TWO SMALL SKIN BULGES JUST AFT OF NR 4 PIT DOOR FS 1290 STRINGER 28R. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED REPAIR PER SRM 53-2-1.

Part: SKIN — CORRODED (BS 1220-1240)

LEVEL 2 CORROSION, AFT CARGO COMPARTMENT LOWER AREA STRINGER 34R BETWEEN STA 1220 AND 1240 FUSELAGE SKIN HAS CORROSION. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED REPAIR PER SRM 51-1-0.

Part: STRINGER — CORRODED (BS 1240-1260)

LEVEL 2 CORROSION, AFT CARGO COMPARTMENT LEFT SIDE STRINGER 21L BETWEEN STA 1240 AND 1260 FUSELAGE SKIN HAS CORROSION. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED REPAIR PER RICH EO D85310-6124 REV 1.

Part: SKIN — CORRODED (BS 540)

LEVEL 2 CORROSION, LOWER FUSELAGE IS BULGED WITH CORROSION AT FS 540R BETWEEN LONGERONS 35R AND 34R BELOW FORWARD CARGO DOOR SILL PLATE. REMOVED DAMAGED AREA FABRICATED AND INSTALLED REPAIR PER SRM 52-2-1.

Part: SKIN — CORRODED (BS 1220-1240)

LEVEL 2 CORROSION/AFT CARGO COMPARTMENT LOWER AREA, STR 34R BETWEEN STA 1220 AND STA 1240, FUSELAGE SKIN HAS CORROSION. REMOVED DAMAGED AREA, FABRICATED, AND INSTALLED REPAIR PER SRM 51-1-0. (X)

Part: DOUBLER — CORRODED (BS 1160-1180)

LEVEL 2 CORROSION/AFT CARGO COMPARTMENT STR 21R BETWEEN STA 1160 AND STA 1180, FLOOR SUPPORT HAS CORROSION. REMOVED DAMAGED AREA, FABRICATED, AND INSTALLED REPAIR PER SRM 53-2-5. (X)

Part: FIRE LOOP — BROKEN (NR 2 ENGINE)

LICZ/ETAR - FLT BEHF800 - FIRE INDICATION DURING FLIGHT AT CRUISE ON NR 2 ENGINE. SHUT DOWN ENGINE, AND FIRED BOTH FIRE BOTTLES. AIRCRAFT LANDED WITHOUT INCIDENT. FOUND FIRE LOOP BROKEN AND SHORTED. REPLACED LOOP AND BOTH FIRE BOTTLES. SYSTEM OPERATED GOOD ON GROUND. NO CAUSE FOR ORIGINAL BREAK WAS FOUND.