N994AJ

Part: FIRE WARNING — FALSE ACTIVATION (CARGO BAY) · airframe 74,273 hrs · 42,834 cycles

FIRE WARNING LOWER CARGO ACTIVATED AFTER TAKEOFF. DID AIR RETURN TO MKJP. INSPECTED LOWER CARGO COMPARTMENTS FOR EVIDENCE OF FIRE. NO EVIDENCE OF FIRE FOUND. PERFORMED OPERATIONAL TEST OF THE LOWER SMOKE DETECTION SYSTEM. CHECK NORMAL PER THE AM.

Part: ACTUATOR — BROKEN (LT MLG) · airframe 74,260 hrs · 42,826 cycles

ON GEAR RETRACTION LEFT MAIN GEAR RED GEAR LIGHT AND DOORS LIGHT REMAINED ILLUMINATED. MAINTENANCE FOUND THE LEFT MAIN GEAR LOCK ACTUATOR ROD END BROKEN. THE LOCK ACTUATOR WAS REPLACED, A RETRACTION TEST WAS PERFORMED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: HOSE — DAMAGED (THRUST REVERSER)

NR 1 ENGINE STRUT OVERHEAT LIGHT CAME ON IN CLIMBOUT 6000 FT. LIGHT WENT OUT ON REDUCING POWER TO 1.4 EPR. THE AIRCRAFT RETURNED TO MIA. THE THRUST REVERSER FLEXIBLE HOSE WAS FOUND DAMAGED. THE HOSE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: UPLOCK — CRACKED (RT MLG)

FLIGHT 8714 WHILE ON TAXI FROM THE GATE AT SAP THE CREW REPORTED THAT THE RIGHT MAIN LANDING GEAR UNSAFE RED LIGHT ILLUMINATED AND WARNING HORN SOUNDED. THE AIRCRAFT RETURNED TO THE GATE WITHOUT ANY FURTHER INCIDENT. MAINTENANCE TROUBLESHOOT THE INDICATION PROBLEM AND FOUND THE RIGHT HAND MAIN LANDING GEAR SEGMENT ASSY UPLOCK CRACKED. THE CRACKED RIGHT HAND MAIN LANDING GEAR SEGMENT ASSY UPLOCK IS IN THE PROCESS OF BEING REPLACED. THE UPLOCK WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ENGINE — FAILED (ZONE 400)

FLIGHT 843 DEPARTED MIA AND DURING THE CLIMB THE CREW REPORTED NR 1 ENGINE LOW OIL PRESSURE LIGHT CAME ON DURING FLIGHT FOLLOWED BY F/E'S OIL PRESSURE GAUGE DROPPED TO 5 TO 10 PSI, SHUT DOWN NR 1 ENGINE PER AMJ CHECKLIST. DUMPED FUEL AND RETURNED TO MIA. THE NR 1 ENGINE WIND MILLED FOR 15 MINS AFTER SHUT DOWN, MAINTENANCE TROUBLESHOT THE NR 1 ENGINE LOW OIL PRESSURE, THE NR 1 ENGINE OIL PUMP IS SUSPECTED TO HAVE FAILED. REPLACED THE NR 1 ENGINE GEARBOX ASSY. INCLUDED IN THE GEARBOX ASSY IS THE ENGINE OIL PUMP, REMOVED AND REPLACED GEARBOX, SEE WORK ORDER OA5321 BY REPAIR STATION ENVR123K. LEAK CHECK AND OPERATIONAL CHECK TEST "B" IAW MM CH 71-00-00, ALL PERAMETERS NORMAL PER MM CH 71-00-00 NO LEAKS NOTED. THE

Part: PUMP — FAILED (NR 1 GEARBOX)

FLIGHT 843 DEPARTED MIA AND DURING THE CLIMB THE CREW REPORTED NR 1 ENGINE LOW OIL PRESSURE LIGHT CAME ON DURING FLIGHT FOLLOWED BY F/E'S OIL PRESSURE GAUGE DROPPED TO 5 TO 10 PSI, SHUT DOWN NR 1 ENGINE PER AMJ CHECKLIST, DUMPED FUEL AND RETURNED TO MIA. THE NR 1 ENGINE WINDMILLED FOR 15 MIN. AFTER SHUT DOWN, AMERIJET MAINTENANCE TROUBLESHOT THE NR 1 ENGINE LOW OIL PRESSURE, THE NR 1 ENGINE OIL PUMP IS SUSPECTED TO HAVE FAILED. REPLACED THE NR 1 ENGINE GEARBOX ASSY INCLUDED IN THE GEARBOX ASSY IS THE ENGINE OIL PUMP. REMOVED AND REPLACED GEARBOX. LEAK CHECK AND OPERATIONAL CHECK TEST -B- IAW MM CH 71-00-00, ALL PARAMETERS NORMAL PER MM CH 71-00-00 NO LEAKS NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LINE — LEAKING (HYD SYSTEM)

DURING CLIMB, CREW REPORTED "A" SYSTEM HYD QTY IND DROPPED, CREW SUSPECTED AN "A" SYSTEM HYD FLUID LEAK. A/C RETURNED BACK TO MIA AND LANDED W/O ANY FURTHER INCIDENT. MX TROUBLESHOT "A" SYSTEM HYD LEAK, A LEAKING HYD LINE FOUND AT "B" NUT CONNECTION TO "A" SYSTEM HYD MODULE, HYD SUPPLY LINE R/R`D IAW B-727 MM CH-20-10-05. HYD SYSTEM WAS SERVICED IAW B-727 MM CH 12-12-0, AN OPS & LEAK CHECK PERFORMED IAW B-727 MM CH 29-11-61. ALL CHECKED OUT NORMAL. AN INSPECTION AND REPLACEMENT OF "A" SYSTEM PRESSURE AND CASE DRAIN FILTERS ACCOMP FOR CONTAMINATION, NO DISCREPANCIES NOTED, WORK ACCOMP IAW B-727 MM CH 29-11-0 AND LEAK CHECK GOOD IAW B-727 MM CH 29-11-41. A WATCH ITEM WAS INITIATED TO REINSPECT "A" SYSTEM CASE

Part: CONTROL PANEL — UNSECURE (COCKPIT)

CLIMBED TO CRUISE, CREW REPORTED NR 3 GEN BREAKER LIGHT CAME ON & WOULD NOT HOLD POWER, NR 2 GEN BREAKER & FIELD LIGHTS CAME ON, NO FAULT NOTED, RESET NR 2 GEN & 20 MIN LATER FAULT RETURNED NO LIGHTS. DID NOT RESET NR 2 BREAKER. DIVERTED ACFT, & LANDED WITHOUT INCIDENT. MX INSP & T/SHOT ACFT GEN SYS, MX FOUND NR 3 GEN CONTROL PANEL NOT SECURED, MX SECURED NR 3 GCU IAW MM & PERFORMED AN OPS CHK IAW MM, OPS CHK ON GROUND FOUND NORMAL. OPS CHK OF NR 2 GEN AC POWER PERFORMED IAW 24-22-00, OPS NORMAL. BUSS PROTECTION PANEL R & R IAW MM; GCU NR 2 SWAPPED TO APU GCU FOR T/SHOOTING. NR 2 AC POWER GEN SYS & APU GEN SYS OPS TESTED & CHKD NORMAL IAW MM. FERRY FLT BACK TO MIA FOR FURTHER INSP. ACFT RETURNED W/OUT INCIDENT.

Part: FLOW VALVE — DEFECTIVE (CABIN PRESSURE)

ON CLIMBOUT, CREW REPORTED PRESSURIZATION SYSTEM WILL NOT MAINTAIN CABIN ALTITUDE. AIRCRAFT RETURNED BACK TO DEPARTURE AND LANDED WITHOUT ANY FURTHER INCIDENT. MAINTENANCE TROUBLESHOT PRESSURIZATION SYSTEM AND FOUND FLOW CONTROL AND MODULATING VALVE AT FAULT, THE FLOW CONTROL AND MODULATING VALVE WAS REMOVED AND REPLACED IAW MM CH-36-12-61, PRESSURIZATION SYSTEM WAS OPERATIONALLY CHECKED AND FOUND NORMAL IAW W/C 7-29 AND MM CH-5-51-101. AIRCRAFT WAS RETURNED TO SERVICE.

Part: PROXIMITY SWITCH — FAULTY (NR 5 SLAT)

FLIGHT 713 DURING TAKEOFF ROLL OUT OF MIA CREW REPORTED NUMBER (5) LEADING EDGE SLAT AMBER LIGHT ILLUMINATED ON FLIGHT ENGINEERS PANEL. THE CREW ABORTED THE TAKEOFF & RETURNED TO THE BLOCK WITHOUT ANY FURTHER INCIDENT. MAINTENANCE FOUND NUMBER (5) LEADING EDGE SLAT POSITION INDICATING SWITCH DEFECTIVE, NUMBER (5) L/E SLAT POSITION SWITCH WAS REMOVED AND REPLACED. FUNCTIONALLY CHECKED GOOD IAW BOEING 727 MM CH 27-82-11. A HIGH ENERGY STOP INSPECTION WAS ALSO ACCOMPLISHED IAW BOEING 727 MM CH 5-51-121, NO DEFECTS NOTED. AIRCRAFT WAS RETURNED BACK TO SERVICE.

Part: PCU — MALFUNCTIONED (ZONE 300) · airframe 69,056 hrs · 39,780 cycles

ON TAXI OUT, ACFT ELEVATOR NOSE DOWN STIFF, NOSE UP NORMAL. TAXIED ACFT BACK TO RAMP. VISUAL INSP & TEST OF LT & RT ELEVATOR CABLE SYS & PERFORMED CK OF ELEVATOR CONTROL SYS. OP’S & LEAK CHECK OF ELEVATOR FEEL CONTROL UNIT ACCOMPLISHED, NO DEFECTS NOTED. INSP OF LT & RT ELEVATOR LINKAGES & PUSHRODS IN HORIZONTAL STAB, NO DEFECTS NOTED. INSP REVEALED A FROZEN PULLEY AT FS 280, FROZEN PULLEY LUBED & FREED, OP’S CKD NORMAL. INSP REVEALED LT ELEVATOR PCU HAD A BUMPY FEEL. LT ELEVATOR PCU R & R, OPS & LEAKED CKD NORMAL. INSP OF LT & RT ELEVATOR HINGES ACCOMPLISHED, NO DEFECTS NOTED. LUBED LT & RT ELEVATOR HINGES. ELEVATOR SYS FRICTION TEST. FINAL OPS CK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN, BODY STA 1110, UPPER CAP CORRODED IN SEVERAL PLACES, WL 208.1.

Part: SKIN — CORRODED (CENTER WING SEC)

WING CENTER SECTION FROM STA 740 TO STA 745 BETWEEN LBL 67.000 INCHES AND LBL 61.000 INCHES, UPPER SKIN PANEL WITH CORROSION ON OUTER SURFACE.

Part: PLATE — CORRODED (WING CENTER SEC)

LT WING, FRONT SPAR LOWER CHORD PLATE FROM FSS 731 TO FSS 759, WITH CORROSION.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 720A FLOORBEAM UPPER CHORD CORRODED.

Part: FLOORBEAM — DAMAGED (FUSELAGE)

MAIN CARGO CABIN, BS 1070, FLOORBEAM DAMAGED. REPAIRED.

Part: FLOORBEAM — CORRODED (FUSLEAGE)

MAIN CARGO CABIN AT B STA 480 FROM RBL 62 INCHES TO LBL 65 INCHES FLOORBEAM UPPER CHORD WITH CORROSION IN SEVERAL PLACES.

Part: BEAM — DAMAGED (HORIZONTAL STAB)

LT HORIZONTAL STABILIZER, T/E UPPER BEAM REPAIR.

Part: SKIN — CORRODED (FUSELAGE)

AFT CARGO COMPARTMENT, NR 3 CARGO DOOR CUTOUT SKIN CORRODED AT THE INTERNAL SURFACE.

Part: SKIN — CORRODED (CENTER WING)

WING CENTER SECTION LOWER SKIN AFT SECTION BETWEEN LBL 30 AND RBL 30 SKIN OUTER FACE CORRODED.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN, AT B STA 1050 FROM LBL 63 INCHES TO RBL 56 INCHES FLOORBEAM UPPER CHORD WITH HEAVY CORROSION IN SEVERAL PLACES.

Part: FLOORBEAM — CORRODED (MAIN CABIN)

MAIN CARGO CABIN, BS 1130 FLOORBEAM UPPER AND LOWER CHORD, CORRODED.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN, BS 950F, WL 208 FLOORBEAM UPPER CHORD CORRODED.

Part: KEELBEAM — CORRODED (FUSELAGE)

AFT CARGO COMPARTMENT, STR 29L KEELBEAM, OB FLANGE CORRODED.

Part: CLAMP — LOOSE (NR 3 ENGINE)

FLT CREW REPORTED, AFTER ROTATION, RT DUCT PRESSURE EXCEEDED 100 PSI, ALSO WITH NR 3 ENG BLEED CLOSED FOR APPROX 2 MIN NR 3 ENG STRUT OHEAT LIGHT ILLUMINATED, CREW RETARDED THROTTLE & LIGHT STAYED ILLUMINATED. CREW RETURNED & MADE AN UNEVENTFUL OWEIGHT LANDING. MX PERFORMED AN OWEIGHT LANDING INSP PER MM, NO DEFECTS NOTED. MX TROUBLESHOT & INSP REVEALED PNEUMATIC LEAKS. FOUND NR 3 ENG BLEED VALVE & 13TH STAGE DUCT CLAMPS LOOSE. MX TIGHTENED LOOSE CLAMPS IAW SRM. MX R & R HIGH PRESSURE REGULATOR & 13TH STAGE MODULATING VALVES PER MM. MX RAN ENGINES AT PART POWER & TAKEOFF FOR FIVE MINUTES IAW MM. REPLACED VALVES & TIGHTEN CLAMPS OPS & LEAK CKD NORMAL. A/C RETURNED TO SERVICE. (M)

Part: CONNECTOR — INOPERATIVE (LE FLAP)

FLT 835 - KMIA-MTPP - CREW REPORTED, AFTER TAKEOFF ALL LEADING EDGES DEVICES REMAINED EXTENDED, FORWARD AND AFT GREEN LIGHT REMAINED ILLUMINATED. AIRCRAFT RETURNED KMIA WITHOUT FURTHER INCIDENT. MAINTENANCE REPAIRED L/E FLAP BYPASS VALVE CONNECTOR IAW STANDARD PRACTICES MANUAL 20-11-02, OPERATIONS CHECK GOOD IAW MM 57-81-0. AIRCRAFT WAS RELEASED AND RETURNED TO SERVICE. (M)

Part: CLAMP — LOOSE (NR 3 ENGINE)

FLT 829 - TTPP-SYCJ, FLIGHT CREW REPORTED, OVERHEAT ENGINE STRUT 3 ILLUMINATED AFTER TAKEOFF, JETTISONED FUEL, 9000 LBS. FLIGHT CREW DIVERTED AIRCRAFT BACK TO TTPP AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE TROUBLESHOOTING AND INSPECTION REVEALED AN PNEUMATIC LEAK. THE PNEUMATIC LEAK WAS A RESULT OF A LOOSE CLAMP AT THE NR 3 ENGINE 13TH STAGE DUCT. MAINTENACE REPOSTIONED AND TIGHTENED THE 13TH STAGE DUCT CLAMP. MAINTENANCE RAN ENGINE FOR FIVE MINUTES AT 1.4 SETTING. OPS CHECKED NORMAL, NO LEAKS NOTED AND LIGHT REMAINED OFF AT GROUND POWER RUN IAW 70-00-0. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BLEED VALVE — INOPERATIVE (NR 1 ENGINE)

CREW REPORTED, NR 1 ENGINE BLEED AIR VALVE TRIP LIGHT ON DURING FLIGHT AND VALVE STATED CLOSED AFTER ACCOMPLISHING THE ALTERNATE PROCEDURE FROM AOM. AIRCRAFT RETURNED TO KMIA WITHOUT FURTHER INCIDENT. MAINTENACNE REMOVED AND REPLACED THE NR 1 ENGINE BLEED SHUTOFF VALVE IAW MM 36-10-01. OPS CHECKED ACCOMPLISHED IAW AMERIJET FORM B-41. AIRCRAFT WAS RELEASED AND RETURNED TO SERVICE. (M)

Part: LINE — LOOSE (NR 2 ENGINE)

CREW REPORTED NR 2 ENGINE PRECAUTIONARY SHUTDOWN DUE TO LOSS OF OIL QUANTITY AND OIL PRESSURE FLUCTUATING IN FLIGHT. AIRCRAFT LANDED AT THE INTENDED DESTINATION WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND NR 2 ENGINE OIL PRESSURE LINE LOOSE. THE LINE WAS TIGHTENED, SERVICED ENGINE OIL, RAN ENGINE, NO LEAKS NOTED AND ALL PARAMETERS CHECK OK. IWA MM.

Part: BEAM — CORRODED (HORIZ STAB)

LEFT HORIZONTAL STAB, TRAILING EDGE BEAM UPPER CHORD AT STAB STA 198 INCHES WITH CORROSION.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN - BS 1070 FLOORBEAM UPPER CHORD, CORRODED.

Part: PANEL — DELAMINATED (LT WING)

LEFT WING, TRAILING EDGE UPPER PANEL WITH DELAMINATION.

Part: FLAP — DELAMINATED (LT WING)

LEFT WING, INBOARD AFT FLAP WITH DELAMINATION.

Part: AILERON — DELAMINATED (RT WING)

RIGHT WING, OUTBOARD AILERON TRAILING EDGE WITH DELAMINATION.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN - BS 1090 FLOORBEAM UPPER CHORD CORRODED.

Part: SKIN — CORRODED (RT WING)

RIGHT WING, LOWER SKIN PANEL, INBOARD BOOST PUMP-CUTOUT, CORRODED.

Part: BEAM — CORRODED (HORIZ STAB)

LEFT HORIZONTAL STAB TRAILING EDGE BEAM LOWER CHORD AT STAB STA 105 INCHES WITH CORROSION.

Part: PANEL — DELAMINATED (LT WING)

LEFT WING, MAIN LANDING GEAR PANEL WITH DELAMINATION.

Part: STIFFENER — CRACKED (LT WING)

LEFT WING - NR 17 UPPER STIFFENER CRACKED AT WS 330.50.

Part: FLOORBEAM — CORRODED (FUSELAGE)

BS 950C FLOOR BEAM UPPER CHORD CORRODED FROM RBL 48 TO RBL 60 AND FROM LBL 46 TO LBL 60.

Part: PANEL — DELAMINATED (LT WING)

LEFT WING, TRAILING EDGE LOWER PANEL WITH DELAMINATION.

Part: PANEL — DELAMINATED (RT WING)

RIGHT WING MAIN LANDING GEAR TRAILING EDGE UPPER PANEL WITH DELAMINATION.

Part: FLAP — DELAMINATED (RT WING)

RIGHT WING INBOARD AFT FLAP WITH DELAMINATION.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN - BS 620 FLOORBEAM UPPER CHORD, CORRODED.

Part: ANGLE — CORRODED (LT WING)

LEFT WING REAR SPAR LOWER CHORD ANGLE, CORRODED.

Part: FLOORBEAM — CORRODED (FUSELAGE)

MAIN CARGO CABIN BS 680 FLOOR BEAM UPPER CHORD CORRODED.

Part: BEAM — CORRODED (LT WING)

LEFT WING, REAR TRUNNION SUPPORT BEAM - WBL 124.2, LOWER SURFACE CORRODED.

Part: FLAP — DELAMINATED (RT WING)

RIGHT WING, INBOARD FORE FLAP WITH DELAMINATION.

Part: RELIEF VALVE — DEFECTIVE (ENGINE OIL)

CREW REPORTED NR 1 ENGINE OIL PRESSURE AT IDLE READS 37 PSI. AIRCRAFT RETURNED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACE NR 1 OIL PRESSURE RELIEF VALVE MM. OPS CHECK NORMAL IAW MM. AIRCRAFT RETURNED TO SERVICE.

Part: RELIEF VALVE — DEFECTIVE (ENGINE OIL)

CREW REPORTED ENGINE NR 1 HAD 80 PSI ON CLIMB 1.85 EPR. AIRCRAFT RETURNED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED NR OIL PRESSURE RELIEF VALVE. OPS CHECK NORMAL IAW MM. AIRCRAFT RETURNED TO SERVICE.

Part: SEAL — TORN (CARGO DOOR)

CREW REPORTED UNABLE TO PRESSURIZE AIRPLANE IN FLIGHT. FLIGHT CREW RETURNED AND MADE AN UNEVENTFUL OVERWEIGHT LANDING. AS A RESULT OF THE FLIGHT CREW DISCREPANCY, MAINTENANCE TROUBLESHOOTING AND INSPECTION REVEALED LEAKAGE AT THE FUSELAGE C-1 DOOR CUTOUT SEAL. MAINTENANCE PROCEEDED TO REMOVE AND REPLACE THE DAMAGED SEAL AS REQUIRED PER MM AND PERFORMED A PRESSURIZATION AND AIRCRAFT PRESSURIZED ON GROUND TO 6.0 PSI. AC PRESSURIZATION SYSTEM ALL LEAK AND OPERATIONALLY CHECKED NORMAL IAW MM. AIRCRAFT WAS RETURNED TO SERVICE.