N906R

Part: SEAL — OPEN (PAX DOOR) · airframe 78,531 hrs · 26,083 cycles

UNABLE TO CONTROL PRESSURIZATION DURING CLIMB. PERFORMED AIR TURNBACK - OVERWEIGHT LANDING INTO KMIA WITHOUT ANY FURTHER INCIDENTS. PRESSURIZED AIRCRAFT AND FOUND CABIN ENTRANCE DOOR ANGLE-SEAL UPPER AND LOWER RETAINER PARTIALLY OPEN, LUBE CABIN SEAL IN ACCORDANCE WITH M/M 12-83-1; OPERATIONAL CHECK NORMAL IN ACCORDANCE WITH M/M 21-30-0; PRESSURALIZATION NORMAL.

Part: CONTROL CABLE — BROKEN (HYD SHUTOFF) · airframe 78,530 hrs · 26,082 cycles

ON PRE-FLIGHT RUDDER CONTROL LIGHT OFF WITH AUXILIARY HYDRAULIC PUMP ON AND RUDDER POWER LEVER OFF POSITION. FOUND RUDDER HYDRAULIC SHUT-OFF CABLE BROKEN. REMOVED AND REPLACED CONTROL CABLE IN ACCORDANCE WITH M/M 20-17-0 AND 91-10-0; OPERATIONAL CHECK NORMAL IN ACCORDANCE WITH M/M 27-20-0.

Part: CONTROL PANEL — FAILED (BUSS PROTECTION) · airframe 78,249 hrs · 25,942 cycles

ON TAXI OUT, NR 4 GENERATOR TRIPPED OFF. REMOVED AND REPLACED GCU IN ACCORDANCE WITH M/M 24-20-5. REMOVED AND REPLACE BUSS PROTECTION PROTECTION PANEL IN ACCORDANCE WITH 24-20-7. REMOVED AND REPLACED FREQUENCY LOAD CONTROLLER IN ACCORDANCE WITH M/M 24-10-16. OPERATIONAL CHECK GOOD; ALL SYSTEMS NORMAL ON ENGINE RUN IN ACCORDANCE WITH M/M 71-00.

Part: GENERATOR — TRIPPED (NR 4)

ON TAXI OUT, NR 4 GENERATOR TRIPPED OFF.

Part: RESISTOR — FAILED (CLIMATE CONTROL) · airframe 78,165 hrs · 25,895 cycles

ON TOP OF CLIMB, A BURNING ODOR & SMOKE APPEARED IN COCKPIT, REPEATEDLY PERFORMED APPROPRIATE CHECKLIST; PERFORMED FUEL DUMPING PER ABNORMAL CHECKLIST; PULLED CUR. C/B PER EMERGENCY CHECKLIST. SMOKE SOURCE IDENTIFIED AT LOW BLOW FAN RESISTOR "COCKPIT CLIMATE CONTROL"; REMOVED & WIRING STOWED HI-BLOW; OPS NORMAL IAW TECH AIR MM ON STC NR ST145CH, SEE 4-M LOW BLOW; INSPECTED FUEL DUMP SYSTEM AND DUMP CHUTES AND RETRACTED AND SAFETY IAW MM 28-38-00; RESET C/B SYS, OPS NORMAL IAW MM 23-70-0; ENTERED ON DMI NR 19078 AS PER MEL 21-61-C CAT C . R & R CLIMATE CONTROL LOW SENSOR; SYS GROUND TEST NORMAL IAW MM STC ST14SCH. THIS CLEAR DMI 19078.

Part: WIRE — DAMAGED (TE FLAPS) · airframe 78,154 hrs · 25,888 cycles

WING SLOT LIGHT DID NOT COME ON. REPAIR WIRES 2F MAIN CONNECTOR P1-10 IN ACCORDANCE WITH M/M 20-50-1. PERFORMED OPERATIONAL CHECK IN ACCORDANCE WITH M/M 27-52-3.

Part: LINE — LEAKING (HYD SYSTEM) · airframe 78,097 hrs · 25,855 cycles

AFTER LANDING LOST HYDRAULIC PRESSURE; QUANTITY DOWN TO AUX LEVEL. REMOVED AND REPLACED BOGIE TRIM CYLINDER (BTC) HYDRAULIC LINE AS PER MM 32-33-1. LEAK CHECK OK, NO LEAKS NOTED.

Part: PRESSURE SWITCH — FAILED (NR 1 ENGINE OIL) · airframe 78,080 hrs · 25,847 cycles

ON CLIMBOUT FROM MIAMI, NR 1 ENGINE OIL LIGHT ILLUMINATED, PERFORMED ABNORMAL OIL PRESSURE LIGHT ILLUMINATED CHECKLIST. LIGHT REMAINED ON. SHUTDOWN ENGINE NR 1. ALL OTHER INDICATIONS WERE NORMAL. RETURNED TO KMIA WITHOUT INCIDENT. REMOVED AND REPLACED NR 1 ENGINE OIL LOW PRESSURE SWITCH IN ACCORDANCE WITH MM 79-32-2 AND SYSTEM OPERATIONAL CHECK NORMAL ON ENGINE RUN-UP IN ACCORDANCE WITH MM 71-00.

Part: FUEL CONTROL — FAILED (NR 4 ENGINE) · airframe 78,059 hrs · 25,834 cycles

ON TAKEOFF, LOSS ENGINE OIL PRESSURE PRIOR TO V-1 ABORTED TAKEOFF; ALSO NOTICED COMPRESSOR STALLED. TROUBLESHOOTING FOUND NR 4 ENGINE FUEL CONTROL UNIT (FCU) LEAKING. REMOVED AND REPLACED FUEL CONTROL UNIT IN ACCORDANCE WITH MM 73-20-1. OPERATIONAL CHECK FOUND NORMAL IN ACCORDANCE WITH MM 71-00.

Part: SKIN — CRACKED (RT WING) · airframe 77,793 hrs · 25,713 cycles

DURING A "C" CHECK INSPECTION, THE FOLLOWING WAS FOUND, RT WING INBOARD L/E LOWER SECTION STA XCW 69 OUTER PLATING AND INNER DOUBLER WITH 3 INCH CRACK.

Part: SKIN — CORRODED (FUSELAGE) · airframe 77,793 hrs · 25,713 cycles

DURING C-CHECK INSPECTION, THE FOLLOWING WAS FOUND; DISCREPANCY: FORWARD LOWER CARGO COMPARTMENT STA 230 BETWEEN LONG. 36 AND LONG 35R, SKIN WITH CORROSION.

Part: BUSS CABLE — BROKEN (AILERON) · airframe 77,772 hrs · 25,702 cycles

UPON INSPECTION, FOUND LT (LT) AILERON BUS CABLE BROKEN. ALSO FOUND LT AILERON BUS CABLE CRANK PULLEYS WORN. REMOVED DAMAGE CABLE AS REQUIRE IAW MM 27-10-0. FABRICATED NEW CABLE IAW SAMPLE IAW MM 91-10-12. INSTALLED NEW CABLE, ADJUSTMENT AND TEST FOUND NORMAL IAW MM 27-10-0. REMOVED AND REPLACED PULLEYS IAW MM 20-10-0. NO DEFECT NOTED AT THIS TIME.

Part: INDICATOR — ERRATIC (EPR) · airframe 77,377 hrs · 25,504 cycles

LOG PAGE NR 107344, AFTER ALL ENGINES SPOOLED AND TAKEOFF STARTED NR 1 EPR (ENGINE PRESSURE RATIO) ERRATIC; DISCONTINUED TAKEOFF AND TAXIED BACK TO RAMP. TRANSFERRED TO DMI NR 18568 IAW MM. AIRCRAFT RELEASED IAW MEL NR 77-1-2 CAT (A). REMOVED AND REPLACED NR 1 EPR INDICATOR; CHECKED SYSTEM ON GROUND, OK IAW MM 77-11-0 AND 71-00. CLEARED DMI NR 18568.

Part: AMPLIFIER — MALFUNCTIONED (NR 2 FIRE LOOP) · airframe 77,323 hrs · 25,477 cycles

DURING TAXI, NR 2 ENGINE FIRE WARNING INTERMITENTLY ILLUMINATED FIRE WARNING TEST INOPERATIVE, SHUT DOWN ENGINE; RETURNED TO RAMP. NO FIRE NOTED. CHECK FIRE WARNING SYSTEM AT RUNUP CONDITION. CHECK WIRING FOR CONDITION, ELEMENTS FOR CONDITION AT NR 2 ENGINE FIRE WARNING SYSTEM IAW MM 26-10-1. REMOVED AND REPLACED NR 2 FIRE DETECTOR AMPLIFIER IAW MM 26-10-2; FOUND SYSTEM NORMAL. CHECKED NR 2 ENGINE AT BLAST FENCE FOR FIRE WARNING SYSTEM IAW MM 71-0 AND MM 26-10-0, FOUND NORMAL.

Part: STRUCTURE — CORRODED (SUBFLOOR) · corrosion level 2 · airframe 77,276 hrs · 25,451 cycles

DURING AN A-CHECK INSPECTION THE FOLLOWING WAS FOUND; COCKPIT STA -12.000 SUBFLOOR WITH CORROSION, RBL 50. CLEANED UP CORROSION, TREATED AND PRIMED AREA IN ACCORDANCE WITH DC8 SRM 51-1-8. REPAIR COCKPIT BETWEEN STA 12 & RBL 49 SUBFLOOR WAS ACCOMPLISHED IAW AS ELEVEN INC DRAWING AS11566, SHEETS 1 THRU 4, DATED 0526/04 AND APPROVED BY FAA FORM 8110-3, DATED 05/26/04.

Part: PRESSURE PANEL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 77,276 hrs · 25,451 cycles

DURING AN A-CHECK INSPECTION THE FOLLOWING WAS FOUND; COCKPIT STATION 12.000 AND STA 8.000 SUBFLOOR WAS FOUND WITH CORROSION, RBL 60. REPAIRED FUSELAGE NOSE FLOOR PRESSURE PANEL BETWEEN -12 TO FS 8 AND L22L IAW ELEVEN INC DRAWING AS11566 SHEET 1 THRU 4, DATED 05/26/04. ISSUED FAA FORM 8110-3, DATED 05/26/04, APPROVING THIS REPAIR.

Part: BLADE — DAMAGED (NR 2 ENGINE) · airframe 77,276 hrs · 25,451 cycles

NR 2 ENGINE EGT (EXHAUST GAS TEMPERATURE) IS 40 DEGREES HIGHER THAN OTHER ENGINES IN CRUISE. ALL OTHER PARAMETERS NORMAL. ON POST-FLIGHT INSPECTION, NR 2 ENGINE APPEARS TO HAVE T4 BLADES DAMAGED. UPON INSPECTION, NR 2 ENGINE TURBINE 1ST STAGE (T-1) VANE BLADE BROKEN (50 PERCENT) AND L/E WITH NICKS. REMOVED AND REPLACED NR 2 ENGINE IAW ARROW AIR J/C DC8MM 007 & DC8MM 71-00. ACCOMPLISHED ENGINE RUN-UP IAW ARROW AIR J/C DC8MM 003 & DC8MM 71-00, FOUND NORMAL.

Part: BLEED VALVE — SURGES (NR 3 ENGINE) · airframe 77,112 hrs · 25,374 cycles

ON TAKEOFF ROLL NR 3 ENGINE EPR INDICATOR SUDDENLY INCREASED TO 2.02 UNITS AFTER ALL ENGINES HAD BEEN SPOOLED AND STABLE AND ALL POWER LEVERS ALIGNED. EGT ALSO INCREASED TO MAX TAKEOFF LIMITS. ABORTED TAKEOFF AT 80 KIAS AND REJECTED TAKEOFF CHECKLIST WAS ACCOMPLISHED. CHECKED NR 3 ENGINE AT BLAST FENCE; PERFORMED RUN UP AND TROUBLE-SHOOTING INDICATES EPR SYSTEM ERRONEUS; ALL OTHER PARAMETERS FOUND NORMAL IAW MM. ENTERED NR 3 EPR SYSTEM ON DMI 18494 AS PER MEL 77-1-2 CATEGORY A. CLEARED DMI 18494 ON 4/17/04; DURING RUN-UP FOUND COMPRESSOR BLEED VALVE OUT OF SCHEDULE (STICKING) REMOVED & REPLACED NR 3 SURGE BLEED VALVE IAW MM 75-30-3. OPERATIONAL CHECK NORMAL, ALL PARAMETERS OK.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 76,845 hrs · 25,280 cycles

DURING AN A-CHECK INSPECTION, AFT LOWER CARGO COMPARTMENT AFT DOOR JAMB TOP FORWARD CORNER WITH CRACK STA 1440.000. TRIMMED OUT CRACK & FABRICATED FILLER, DOUBLER AND TRIPLER IAW DC8SRM 53-2-0, TR 53-188 AND SRM 51-1-21, 51-1-20D & 51-1-11.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 76,845 hrs · 25,280 cycles

DURING A-CHECK INSPECTION, THE FOLLOWING WAS FOUND, FUSELAGE EXTERIOR STA 1690 BETWEEN L-35R AND L-36 SKIN BROKEN, NEAR BUTT JOINT. PERFORMED REPAIR OF THE SKIN NEAR BUTT JOINT AT STA 1690, BTW LONGERON 35R & 36R IAW DC8SRM 53-2-1, FIG8, SHEET 1,2, PAGES 123/124 AND 125/126, AND TR 53-173. THE DETAIL OF THE REPAIRS FOLLOWED INSTRUCTIONS OF SERVICE REWORK DWG SR08530010, INCLUDED IN THE ABOVE SRM REFERENCE. SKIN REPLACED BTW LONGERON 31L AND 31R.

Part: CONNECTOR — DAMAGED (NR 2 ENGINE) · airframe 76,743 hrs · 25,200 cycles

MASTER FIRE WARNING ILLUMINATED NR 2 FIRE SHUTOFF LEVER LIGHT ON, DISCHARGED BOTH FIRE BOTTLES. THREE ENGINE APPROACH AND LANDING WAS COMPLETED. DURING TROUBLESHOOTING FOUND NR 2 ENGINE FIRE WARNING CONNECTION P1-136 DAMAGE. REMOVED AND REPAIR CONNECTION IAW MM 20-50-1. OPS CHECK IAW MM 26-10-0, FOUND NORMAL. CHECKED ON ENGINE RUN-UP, CHECKED SATISFACTORY. REMOVED AND REPLACED NR 1 POS AND NR 2 POS FIRE EXTINGUISHING AGENT, TESTING AND FUNCTIONAL CHECKED SATISFACTORY. ALL SYSTEMS TESTED, AND AIRCRAFT RETURNED TO NORMAL.

Part: PRESSURE SWITCH — FAILED (NR 1 ENGINE) · airframe 75,699 hrs · 24,807 cycles

NR 1 ENGINE LOST OIL QTUANTITY. ENGINE WAS SHUT DOWN. AIRCRAFT LANDED IN KMIA WITHOUT INCIDENTS. FOUND NR 1 ENGINE OIL PRESS DIFFERENTIAL SWITCH LEAKING. REMOVED AND REPLACED SWITCH IAW DC8 MM 79-31-06. PERFORMED ENGINE RUN UP AND OPS CK IAW DC8 MM 71-00 FOUND NORMAL.

Part: ACCUMULATOR · airframe 74,669 hrs · 24,433 cycles

LOG PAGE # 502922. DISCREPANCY: ON CLIMB OUT OF MIA AT 8.0, OBSERVED QUANTITY DROPPED TO STAND PIPE WITH RESERVE LOW AND AILERON AND RUDDER REVERSION LITES ON; EMERGENCY CHECK LIST ACCOMPLISHED, FUEL DUMPED TO MAX LANDING WEIGHT PER ABN CHECK LIST. CORRECTIVE ACTION: FOUND HORIZONTAL STABILIZER AND RUDDER HYDRAULIC PRESSURE ACCUMULATOR LEAKING. REMOVED AND REPLACED HYDRAULIC PRESSURE ACCUMULATOR IAW MM 27-41-11. OPS NORMAL, NO LEAKAGE NOTED. ALSO BLEEDED BOTH ENGINE DRIVEN HYDRAULIC PUMPS IAW MM 29-10-12. OPS CHECK NORMAL IAW MM 12-30-1.

Part: FUSE — MELTED (BRAKE ASSY) · airframe 74,560 hrs · 24,397 cycles

DURING POST FLIGHT INSPECTION THE FOLLOWING WAS FOUND: NR 3, 4 & 8 MWA THERMAL FUSE MELTED; NR 7 MWA DUE CHANGE FROM STRESS BEYOND LIMITS. FOUND CRACK AT NR 3 & 4 BRAKE ASSY. DURING MWA; FOUND NR 8 BRAKE ASSY. SEVERLY OVERHEATED AT MWA. FOUND NR 7 & 6 BRAKE NOT OPERATING. REMOVED AND REPLACED NR 3, 4 AND 8 MWA IAW DC8 MM 32-40-1. REMOVED AND REPLACED NR 7 MWA IAW DC8 MM 32-40-1. REMOVED AND REPLACED NR 3, 4 AND 8 BRAKE ASSY. IAW DC8 MM 32-42-1. REMOVED AND REPLACED RH OUTBD ANTISKID VALUE IAW MM 32-43-3 LEAK CHECK OK OPS CHECK OK IAW DC8 MM 32-43-0. REMOVED AND REPLACED ANTISKID CONTROL BOX IAW MM 32-43-0. ACCOMPLISHED COMPLETE ANTISKID TEST OK IAW 32-43-0

Part: INDICATOR — STICKING · airframe 74,439 hrs · 24,340 cycles

ON TAKEOFF ROLL OUT OF MIAMI, FIRST OFFICERS AIRSPEED INDICATOR STUCK AT 70 KNOTS. CAPTAINS INDICATOR 95 KNOTS. ABORTED TAKEOFF, RETURNED TO RAMP FOR CORRECTIVE ACTION. REMOVED & REPLACE WITH NEW PART, FIRST OFFICERS AIRSPEED INDICATOR. ALL WORK ACCOMPLISHED IAW MFG. RECOMMENDED MAINTENANCE PROCEDURES 34-12-0. PITOT STATIC CHECK OF SYSTEM AND SYSTEM TEST CHECKED SATISFACTORY. AIRCRAFT RETURNED TO SERVICE.

Part: PIN — SHEARED (GEAR) · airframe 74,066 hrs · 24,141 cycles

DURING POST FLIGHT INSPECTION IN OMA, THE FLIGHT ENGINEER FOUND THAT THE RIGHT MAIN LANDING GEAR RETRACT PIN SHEARED. THE AIRCRAFT WAS FERRIED FOR REPAIRS IN ACCORDANCE WITH COMPANY PROCEDURES. MAINTENANCE REPLACED THE RETRACT PIN IN ACCORDANCE WITH MAINTENANCE MANUAL AND SERVICE BULLETIN. MAINTENANCE PERFORMED A SUCCESSFUL OPERATIONAL CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FAN — DEFECTIVE (A/C BAY) · airframe 73,474 hrs · 23,958 cycles

EN ROUTE FROM DWI TO NSY, WHEN THE FLIGHT CREW OPERATED THE CENTER RECIRCULATION FAN, AN ODOR WAS SENSED IN THE COCKPIT. THE FLIGHT CREW SECURED THE FAN AND THE ODOR SUBSIDED. THE FLIGHT CONTINUED TO NSY FOR AN UNEVENTFUL LANDING. A COMPANY REPERSENTATIVE INSPECTED THE FAN WHICH WAS FOUND DEFECTIVE. THE FAN WAS PLACED ON DEFERRAL. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ACTUATOR — MALFUNCTIONED (LT MLG)

RMS - FLT DQ1 - EN ROUTE FROM CAI TO RMS, THE GEAR DOOR WARNING LIGHT ILLUMINATED DURING THE LANDING GEAR UPLATCH CHECK.. THE FLIGHT CREW CYCLED THE LANDING GEAR BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CONTINUES TO RMS FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR DOORS WHICH REVEALED THE LEFT MAIN GEAR DOOR ACTUATOR DEFECTIVE. MAINTENANCE REPLACED THE GEAR DOOR ACTUATOR AND PERFORMED A SUCCESSFUL OPERATIONAL TEST. THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SWITCH — CORRODED (LT MLG)

DURING APPROACH INTO TOL, AFTER THE LANDING GEAR WAS EXTENDED THE LEFT MAIN GEAR DOWN AND LOCK INDICATION LIGHT FAILED TO ILLUMINATE. THE FLIGHT CREW CYCLED THE LANDING GEAR SEVERAL TIMES BEFORE THE DOWN AND LOCK LIGHT ILLUMINATED. MAINTENANCE INSPECTED THE LANDING GEAR POSITIONING INDICATION SYSTEM WHICH REVEALED THE LEFT MAIN GEAR SWITCH ELECTRICAL CONNECTOR CORRODED. MAINTENANCE CLEANED THE ELECTRICAL CONNECTOR AND PERFORMED A SUCCESSFUL OPERATIONAL CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: STRIKER — LOOSE (RT MLG DOOR)

EN ROUTE FROM TOL TO CLT, AFTER GEAR RETRACTION, THE GEAR NOT LATCH LIGHT ILLUMINATED ACCOMPANIED BY AN ALTERNATE RIGHT MAIN GEAR DOOR WARNING LIGHT. THE FLIGHT CREW CYCLED THE GEAR, THE GEAR NOT LATCH LIGHT REMAINED ILLUMINATED AND THE ALTERNATE GEAR DOOR WARNING LIGHT EXTINGUISHED. THE FLIGHT CONTINUED TO CLT FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE LANDING GEAR WARNING SYSTEM WHICH REVEALED THE RIGHT MAIN GEAR DOOR SWITCH STRIKER NOT SECURED. MAINTENANCE SECURED THE RIGHT MAIN GEAR DOOR STRIKER AND PERFORMED A SUCCESSFUL OPERATIONAL TEST.

Part: WIRE — CHAFED (NLG)

EN ROUTE MGUM TO KFLL, THE GEAR UPLATCH CHECK FAILED WITH THE GEAR NOT LATCHED WARNING LIGHT ILLUMINATED. THE CREW CYCLED THE GEAR BUT THE WARNING INDICATION REMAINED THE SAME. THE FLIGHT CONTINUED TO KFLL FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT AND LOCATED CHAFFED WIRES AT THE NOSE GEAR UPLATCH SWITCH. MAINTENANCE REPAIRED THE WIRES, CLEANED AND LUBRICATED THE RIGHT MAIN GEAR UPLATCH MECHANISM. MAINTENANCE PERFORMED A SUCCESSFUL GEAR SWING IN ACCORDANCE WITH THE DOUGLAS MAINTENANCE MANUAL RETURNING THE AIRCRAFT TO SERVICE.

Part: PLATING — CRACKED (WS 376)

DURING ROUTINE C-CHECK INSPECTION, A TWO INCH CRACK WAS FOUND ON THE RIGHT WING LEADING EDGE PLATING AT STATION XFS376.000. REPAIR ACCOMPLISHED STOP DRILLING ENDS OF THE CRACK, FABRICATION AND INSTALLATION OF A REPAIR DOUBLER IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 57-22-1, FIGURE 2, 51-1-21 AND ENGINEERING ORDER 57-DC8-710.

Part: BRACKET — CRACKED (RT WING)

DURING ROUTING C-CHECK INSPECTION, FOUND THE RIGHT WING INBOARD CANOE FITTING HANGER BRACKET CRACKED. REPAIR ACCOMPLISHED REMOVAL OF BRACKET, FABRICATION AND INSTALLATION OF NEW BRACKET IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 51-1-21, 51-1-0 AND 51-1-8.

Part: BULKHEAD BRACKET — CRACKED (BS 1766)

DURING ROUTINE C-CHECK INSPECTION, FOUND THE AFT PRESSURE BULKHEAD RIGHT SUPPORT BRACKET CRACKED ABOVE THE THIRD STIFFENER. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED BRACKET, FABRICATION AND INSTALLATION OF NEW BRACKET IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY SRM 51-1-21, 51-1-0 AND 51-1-8.

Part: BULKHEAD FITTING — CRACKED (BS 1766)

DURING ROUTINE C-CHECK INSPECTION, FOUND THE AFT PRESSURE BULKHEAD LEFT SUPPORT FITTING CRACKED ABOVE THE THIRD STIFFENER. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING, FABRICATION AND INSTALLATION OF NEW FITTING IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY SRM 51-1-21, 51-1-0 AND 51-1-8.

Part: BULKHEAD BRACKET — CRACKED (BS 1766)

DURING ROUTINE C-CHECK INSPECTION, THE TOP AFT PRESSURE BULKHEAD SUPPORT BRACKET WAS FOUND CRACKED. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED BRACKET, FABRICATION AND INSTALLATION OF NEW BRACKET IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY SRM 51-1-21, 51-1-0 AND 51-1-8.

Part: CAP CLIP — CRACKED (WS 69.5)

DURING ROUTINE C-CHECK INSPECTION, THE LEFT WING LOWER OUTBOARD FILLET CAP CLIP WAS FOUND CRACKED AT STATION 69.5. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF NEW CAP CLIP IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 51-1-0, 51-3-0 AND ENGINEERING ORDER 57-DC8-711.

Part: FITTING — CRACKED (BS 1180)

DURING ROUTING C-CHECK INSPECTION, FOUND A CRACKED SUPPORT FITTING AT FUSELAGE STATION 1180, LONGERON 27 LEFT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING, FABRICATION AND INSTALLATION OF A NEW FITTING IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 51-1-21, 51-1-8, 51-1-20 AND 51-3-0.

Part: BRACKET — CORRODED (BS 640)

DURING ROUTINE C-CHECK INSPECTION, FOUND MID SHIP ACCESSORY COMPARTMENT KEEL BEAM BRACKET WITH STRESS CORROSION CRACK AT FUSELAGE STATION 640. REPAIR ACCOMPLISHED REMOVAL OF THE BRACKET, FABRICATION AND INSTALLATION OF NEW BRACKET IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 51-1-20D, 53-2-3 AND ENGINEERING ORDER 51-DC8-719.

Part: FITTING — CORRODED (BS 1200)

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS FOUND ON A SUPPORT FITTING AT FUSELAGE STATION 1200, LONGERON 32 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF THE FITTING, FABRICATION AND INSTALLATION OF A NEW FITTING IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 51-1-8, 51-1-21 AND ENGINEERING ORDER 51-DC8-716.

Part: PLATING — CRACKED (BS 1900)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND ON THE FUSELAGE PLATING AT FUSELAGE STATION 1900, LONGERON 9 LEFT. REPAIR ACCOMPLISHED REMOVAL OF THE DAMAGED AREA, FABRICATION AND INSTALLATION OF AN INTERNAL FILLER AND EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 53-2-0, 51-1-8, AND 51-1-15.

Part: FITTING — CRACKED (BS 1260)

DURING ROUTINE C-CHECK INSPECTION, A LONGERON ATTACH FITTING WAS FOUND CRACKED AT FUSELAGE STATION 1260, LONGERON 34 LEFT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING, FABRICATION AND INSTALLATION OF NEW FITTING IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY SRM 51-1-0, 51-1-8.

Part: ANGLE — CRACKED (BS 781)

DURING ROUTINE C-CHECK INSPECTION, FOUND CENTER WING FUEL TANK SUPPORT ANGLE CRACKED AT FUSELAGE STATION 781, LEFT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED ANGLE, FABRICATION AND INSTALLATION OF A NEW ANGLE IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 53-2-0, 51-1-8, 51-1-21 AND ENGINEERING ORDER 53-DC8-714.

Part: WEB — CRACKED (BS 810)

DURING ROUTINE C-CHECK INSPECTION, THE CENTER WING FUEL TANK OUTER SURFACE WEB WAS FOUND CRACKED ON THE LEFT SIDE OF KEEL BEAM AT FUSELAGE STATION 810. REPAIR ACCOMPLISHED FABRICATION AND INSTALLATION OF A REPAIR DOUBLER IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 53-2-0, 51-1-8, 51-1-21 AND ENGINEERING ORDER 53-DC8-715.

Part: FITTING — CRACKED (BS 360)

DURING ROUTINE C CHECK INSPECTION, A LONGERON ATTACH FITTING WAS FOUND CRACKED AT FUSELAGE STATION 360, LONGERON 33 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING, FABRICATION AND INSTALLATION OF NEW FITTING IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY SRM 51-1-0, 51-1-8 AND 51-1-21.

Part: BULKHEAD ANGLE — CRACKED (BS 1766)

DURING ROUTING C-CHECK INSPECTION, A ONE INCH CRACK WAS FOUND ON THE AFT PRESSURE BULKHEAD CIRCUMFERENTIAL MOUNT ANGLE AT FUSELAGE STATION 1766, STIFFENER 3 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED ANGLE, FABRICATION AND INSTALLATION OF A NEW MOUNT ANGLE IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY DC-8 SRM 53-2-0, 51-1-8, 51-1-21 AND ENGINEERING ORDER 51-DC8-719.

Part: FITTING — CRACKED (BS 180-240)

DURING ROUTINE C-CHECK INSPECTION, THE LEFT FLOORBEAM SUPPORT FITTINGS WERE FOUND CRACKED BETWEEN FUSELAGE STATION 180 AND 240. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTINGS, FABRICATION AND INSTALLATION OF NEW FITTINGS IN ACCORDANCE WITH DOUGLAS AIRCRAFT COMPANY SRM 51-1-0, 51-1-8 AND 51-1-21.

Part: DNLOCK SWITCH — FAILED (RT MLG)

IN PREPARATION FOR LANDING AT DAY, THE LANDING GEAR WAS EXTENDED, BUT NO SAFE INDICATION WAS PRESENT FOR THE RIGHT MLG. THE AIRCRAFT ACCOMPLISHED A FLY-BY OF THE CONTROL TOWER AND OBTAINED VISUAL VERIFICATION THAT THE RIGHT MLG WAS EXTENDED. A NORMAL LANDING WAS ACCOMPLISHED. MAINTENANCE DETERMINED THAT THE RIGHT MLG DOWNLOCK SWITCH HAD FAILED INTERNALLY, CAUSING AND INDICATION PROBLEM. THE RIGHT MLG DOWNLOCK SWITCH WAS REPLACED, AND THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: ACTUATOR — FAILED (PITCH TRIM COMP)

EN ROUTE FROM KLCK TO TJSJ, THE FLIGHT CREW SMELLED THE STRONG ODOR OF ELECTRICAL SMOKE, AND OBSERVED THAT THE PITCH TRIM COMPENSATION LIGHT FLICKERED SEVERAL TIMES. THE PTC WAS TURNED OFF AND ITS CIRCUIT BREAKER PULLED, AT WHICH TIME THE FUMES STOPPED. INSPECTION ON THE GROUND IN TJSJ REVEALED THAT THE PTC ACTUATOR HAD FAILED ELECTRICALLY, PRODUCING THE ELECTRICAL SMELL. THE ACTUATOR WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (M)

Part: CABIN COMPRESSOR — FAILED (NR 2)

BETWEEN IAH AND BRO, THE NR 2 CABIN COMPRESSOR STALLED AND CREATED LOUD NOISE AND OILY FUMES IN THE COCKPIT. MAINTENANCE DETERMINED THAT THE CABIN COMPRESSOR HAD SEIZED. THE NR 2 CABIN COMPRESSOR WAS DEFERRED AND THE AIRCRAFT WAS RELEASED FOR SERVICE. (M)

Part: TURBO COMPRESSOR — FAILED (NR 2 ENG)

BETWEEN IAH AND BRO, THE NR 2 CABIN TURBO COMPRESSOR STALLED AND CREATED A LOUD NOISE AND OILY FUMES IN THE COCKPIT. MAINTENANCE DETERMINED THAT THE CABIN TURBO COMPRESSOR HAD SEIZED. THE NR 2 TC WAS DEFERRED AND SCHEDULED FOR REPLACEMENT. (M)