N120DL

Part: FMC — FAILED (COCKIT) · airframe 69,508 hrs · 31,825 cycles

DURING CRUISE EICAS STATUS MESSAGE R FMC FAIL APPEARED WITH CORRESPONDING LOSS OF FIRST OFFICERS, FMC DISPLAY ALONG WITH THE FIRST OFFICERS LOSS OF MAP AND NAVIGATION DATA. REMOVED AND REPLACED THE FIRST OFFICERS FMC IAW AMM 34-61-01, OPS CHECK GOOD NO DEFECTS NOTED.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 69,506 hrs · 31,824 cycles

ON 12/05/2009, ON AIRCRAFT 120DL, INSPECTION OF THE CABIN REVEALED THE EMERGENCY LIGHTS AT SEAT ROWS 17-28 WILL NOT STAY ILLUMINATED FOR VERY LONG DURING THE REQUIRED EMERGENCY LIGHT TEST. REMOVED AND REPLACED THE M732 EMERGENCY LIGHT BATTERY PACK PER AMM 31-51-07. RE-TESTED EMERGENCY LIGHT SYSTEM, OPS CHECK GOOD. AIRCRAFT OK FOR SERVICE.

Part: SELECTOR VALVE — LEAKING (BRAKE SYS) · airframe 68,598 hrs · 31,594 cycles

DURING CRUISE HYDRAULIC FLUID APPEARED TO BE MIGRATING FROM THE RT SYSTEM TO THE CENTER DIVERTED TO SUITABLE AIRPORT READINGS UPON LANDING INDICATED .45 CENTER AND 1.38 IN RT SYSTEM. REMOVED AND REPLACED THE ALTERNATE BRAKE SELECTOR VALVE IAW AMM 32-41-04 LEAK/OPS GOOD AT THIS TIME. COULD NOT DUPLICATE PROBLEM ON GROUND AT THIS TIME. PERFORMED FIM 29-11-00 PAGE 155, NO DEFECTS NOTED AT THIS TIME.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 68,508 hrs · 31,575 cycles

WHILE PERFORMING MAINTENANCE ON AIRCRAFT 120DL DURING THE INSPECTION PROCESS A DENT AND CRACK ON THE C2 CARGO DOOR OPENING FRAME WEB AT FS 1270 WL 162.5. THE CRACKS MEASURE APPROXIMATELY 1 INCH UP/DOWN BY 1.4 IB/OB. REPAIRED WEB AND OUTER CORD, C-2 DOOR OPENING FRAME AT FS 1270 WL 162.5 IAW ERA 476056-14 AND NON-ROUTINE CARD NUMBER 230.

Part: STRUCTURE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 68,508 hrs · 31,575 cycles

WHILE PERFORMING MAINTENANCE ON AIRCRAFT 120DL DURING THE INSPECTION PROCESS CORROSION DAMAGE WAS DISCOVERED BETWEEN FS 632 TO FS 654 ALONG STRINGERS 35L TO 36L. THE DAMAGE IS LOCATED AT THE MID-GALLEY DRAIN MAST ATTACH POINT. REMOVED A 3 INCH SECTION STRINGER, HOWEVER SECTION IS REPAIRABLE PER THE SRM 53-00-03 REPAIR NR 2 AND ERA 476086-14 DUE TO RIVET SPACING REQUIREMENTS.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHTS) · airframe 68,508 hrs · 31,575 cycles

DURING ACCOMPLISHMENT OF TASK-CARD 767-33-033-01 EMERGENCY LIGHT POWER SUPPLIES ON C-CHECK 1C/2C/S1C/S2C ALL BATTERY PACKS FAILED THE CAPACITY CHECK AND RT EXTERIOR LIGHTS ABOVE THE R-4 DOOR AND BOTH AFT WING SLIDE LIGHT FAILED TO ILLUMINATE. REMOVED AND REPLACED ALL BATTERY PACKS PER AMM 33-51-07, RE-TESTED SYSTEM, OPS CHECK GOOD.

Part: CABLE ASSY — OUT OF RIG (EVAC SLIDE) · airframe 68,508 hrs · 31,575 cycles

DURING INSPECTION OF EMERGENCY ESCAPE SYSTEM ON C-CHECK 1C/2C/S1C/S2C BOTH THE LT AND RT OFF-WING SLIDE BOTTLE INFLATION CABLES WERE FOUND OUT OF RIG. INSTALLED CABLES IN CORRECT POSITIONS PER CMM 25-61-24, OPS CHECK GOOD.

Part: SLIDE — UNWANTED DEPLOY (L2 DOOR)

FLIGHT ATTENDANT DEPLOYED L2 PASSENGER ENTRY DOOR SLIDE. ACFT MADE A FERRY FLIGHT KWI TO BAH FOR DOOR SLIDE REPLACEMENT. INSTALLED SERVICEABLE L2 DOOR SLIDE IAW AMM 28-66-08. (A)

Part: BULKHEAD — CRACKED (BS 287 RBL 25) · airframe 60,930 hrs · 29,262 cycles

THE NLG BULKHEAD AFT WEB AND CHORD AT STA. 287, RBL 25 HAS DRILL DAMAGE TO THE WEB AND CHORD AND THE CHORD WAS STOP DRILLED INSTEAD OF CUT OUT AS REQUIRED PER THE SRM. THE EXISTING REPAIR ANGLE WAS REMOVED AND THE CRACKED CHORD WAS CUT OUT. THE DRILL DAMAGED WEB AND ANGLE WAS CUT OUT AND REPAIR DOUBLERS AND ANGLES WERE INSTALLED. REF. AD 2005-02-02.

Part: SPAR — CRACKED (WS 906) · airframe 60,930 hrs · 29,262 cycles

CRACK WAS FOUND IN LOWER OB FASTENER HOLE IN REAR SPAR. THE CRACK WAS REMOVED BY OVERSIZING HOLE AND INSTALLATION OF A FLANGED BUSHING IAW MFG INSTRUCTIONS. REPAIR ERA 455471-14.

Part: WEB — DAMAGED (BS 654) · airframe 60,930 hrs · 29,262 cycles

WEB AT STA 654+121, LBL 40 WAS FOUND DAMAGED, CARGO COMPARTMENT JUST BELOW INNER CHORD. REPAIR WILL INVOLVE CUTTING THE WEB, SPLICING IAW INSTRUCTIONS. REPAIRED IAW ERA 455777-14.

Part: SKIN — CORRODED (FS 789 S38L) · airframe 60,930 hrs · 29,262 cycles

DURING ROUTINE MTC CORROSION AND MINOR CRACKS WERE FOUND IN FUSELAGE SKIN AT 789.5 AND S-38L. SKIN WAS TRIMMED, DOUBLER AND TRIPLER INSTALLED IAW 455466-14 IAW MFG INSTRUCTIONS.

Part: FITTING — CORRODED (MLG DRAG BRACE) · airframe 60,643 hrs · 29,176 cycles

THE RT MLG DRAG BRACE FITTING HAD CORROSION IN THE BORE. THE CORROSION WAS REMOVED BY OVERSIZING THE BORE.

Part: FITTING — CORRODED (MLG DRAG BRACE) · airframe 60,643 hrs · 29,176 cycles

THE LT MLG ATTACH FITTING DRAG BRACE BORE IS CORRODED. THE BORE WAS OVERSIZED TO REMOVE THE CORROSION.

Part: FRAME — CRACKED (BS 903) · airframe 59,763 hrs · 28,894 cycles

CRACKS WERE FOUND IN THE INNER CHORD OF THE BS 903.5 LT AND RT FRAMES. THE CRACK WAS TRIMMED OUT AND A REPAIR ANGLE WAS INSTALLED REF AD 2003-18-10.

Part: SMOKE DETECTOR — INOPERATIVE · airframe 58,742 hrs · 28,495 cycles

MID LEFT SMOKE DETECTOR WOULD NOT SILENCE. REPLACED SMOKE DETECTOR.

Part: BATTERY — INOPERATIVE (FLASHLIGHT) · airframe 58,742 hrs · 28,495 cycles

1L DOOR FLASHLIGHT WON`T TEST. REPLACED BATTERY.

Part: ROD — BROKEN (LT MLG ACTUATOR) · airframe 55,121 hrs · 26,955 cycles

ON TAKEOFF HAD GEAR DISAGREE LIGHT ON EICAS WITH WARNING, GEAR HANDLE UP. LEFT MAIN GEAR INDICATED DOWN WITH DOORS LIGHT ON AND GEAR LIGHT ON. PUT GEAR DOWN AND ALL GEAR INDICATED SAFE. RETURNED TO ATLANTA. FOUND SIDE BRACE ACTUATOR RETRACT ROD BROKEN. REPLACED SIDE BRACE ACTUATOR PER M/M. JACKED A/C AND PERFORMED GEAR SWING FOR PRECAUTION. GEAR SWING CHECKS GOOD.

Part: FILTER — DIRTY (GALLEY CHILLER) · airframe 54,243 hrs · 26,434 cycles

FLIGHT ATT REPORTS THAT FIRST CLASS GALLEY CHILLER HAS OVERHEATED. ALSO REPORTED AN ELECTIRICAL ODOR THAT APPEARED TO ORIGINATE NEAR THE TRASH BIN. INSPECTED FREEZER ASSY, COULD NOT SMELL ANY ELECTRIC ODOR, FOUND FREEZER FILTER EXTREMELY CLOGGED. CLEANED FILTER ASSY. OPERATED FREEZER, ALL GOOD.

Part: FRAME — CRACKED (BULKHEAD) · airframe 51,426 hrs · 24,980 cycles

INSPECTION OF THE FS 1809.5 BULKHEAD OUTER FRAMES PER BAC S/B 767-53-0078 AND AD 2001-09-13 REVEALED A CRACK IN THE FWD FRAME AND THE AFT FRAME ON THE RT SIDE NEAR STRINGER 12. THE FWD FRAME WAS REPLACED PER THE S/B. THE AFT FRAME WAS REMOVED AND REPLACED WITH A NEW FRAME PER ER/A 384407-14AD, REV A.

Part: SKIN — WORN (RT WING) · airframe 47,861 hrs · 23,240 cycles

DURING ACCOMPLISHMENT OF SIP MOD ON THE NR 2 PYLON WEAR DAMAGE FROM A HYDRAULIC LINE CLAMP SCREW WAS FOUND ON THE LOWER WING SKIN. THE DAMAGE IS LOCATED AT APPROX WS 420 AND IS BETWEEN WING STRINGERS L7 AND L8. THE WORN AREA WAS APPROXIMATELY .11 INCH IN DEPTH AND .375 INCH IN DIAMETER. REPAIR ER/A 398071-14.

Part: BULKHEAD — CRACKED (NR 2 PYLON) · airframe 47,861 hrs · 23,240 cycles

DURING ACCOMPLISHMENT OF PYLON SIP MOD, CRACK INDICATIONS WERE FOUND IN THE MID STRUT BULKHEAD LAYER. REPAIR ER/A 398051-14AD.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 47,004 hrs · 22,854 cycles

AT FL 410 TERRAIN SYSTEM STARTED WARNING OF TERRAIN, NOTICED ODOR OF MELTING PLASTIC. CK UNDER O-CARE SHIELD WIRING OR ODOR FOUND FIBERGLASS ON F/O ALT. REPOSITION, OK. DROPPED O/H PNL, ALL NORMAL. DROPPED C/B BOS NORMAL. CK E/E BUNDLES P51 PNL AREA NORMAL. CK APU NORMAL. GROUND PROX WING TEST OK. SET UP TO REPLACE THE ENHANCED GPWS COMPUTER PER M/M 34-4 6-01-4.

Part: SKIN — PUNCTURED (FS 400, S-33R) · airframe 45,272 hrs · 22,010 cycles

FUSELAGE / SKIN / FS 390-412 / STRG. 33R-34R : PUNCTURE REPAIR . THE FUSELAGE SKIN WAS PUNCTURED BY GROUND EQUIPMENT BETWENN FS 390 & 412 AND BETWEEN STRINGERS 33R & 34R. THE DAMAGE WAS REMOVED WITH A 12 INCH X 7 INCH SKIN CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER INSTALLED PER ER/A 379323-14.

Part: FRAME — DENTED (BS 615)

EXISTING REPAIR REMOVED AT C-1 DOORWAY AFT EDGE. REVEALING DAMAGE TO SKIN BEARSTRAP AND FRAME OUTER CHORD. DAMAGE LOCATED BETWEEN STR-31R AND 32R AT STA 615. SKIN AND BEARSTRAP WERE GOUGED, CUTOUT AND THE FRAME WAS DENTED. ER/A 333883-14 REV A.

Part: FRAME — CORRODED (BS 1562)

FS 1562 FRAME FAIL-SAFE CHORD WAS FOUND CORRODED BETWEEN STR 38L AND STR 38R. THE (P/N 146T1223-30) CHORD WAS REPLACED PER DWG 146T1223.

Part: SPLICE — CORRODED (BS 434)

STRINGER 37L SPLICE WAS FOUND CORRODED AT FS 434. THE (P/N 140T0115-16) SPLICE WAS REPLACED PER SRM 51-10-00. NO DAMAGE TO THE STRINGER WAS FOUND.

Part: SPLICE — CORRODED (BS 434)

STRINGER 38L SPLICE WAS FOUND CORRODED AT FS 434. THE (P/N 140T0115-16) SPLICE WAS REPLACED PER SRM 51-10-00. NO DAMAGE TO THE STRINGER WAS FOUND.

Part: SPLICE — CORRODED (BS 434)

STRINGER 37R SPLICE WAS FOUND CORRODED AT FS 434. THE (P/N 140T0115-16) SPLICE WAS REPLACED PER SRM 51-10-00. NO DAMAGE TO THE STRINGER WAS FOUND.

Part: SPLICE — CORRODED (BS 434)

STRINGER 34L SPLICE WAS FOUND CORRODED AT FS 434. THE (P/N 140T0115-16) SPLICE WAS REPLACED PER SRM 51-10-00. NO DAMAGE TO THE STRINGER WAS FOUND.

Part: SHEAR TIE — CORRODED (BS 1562)

THE FUSELAGE TO FRAME SHEAR TIE AT STA 1562 LOCATED ON THE FWD SIDE OF THE FRAME BETWEEN STR 38L AND 38R WAS FOUND CORRODED. THE (P/N 150T2102-656) SHEAR TIE WAS REPLACED PER DWG 146T1223.

Part: SHEAR TIE — CORRODED (BS 1562)

THE FUSELAGE SKIN TO FRAME SHEAR TIE LOCATED ON THE AFT SIDE OF FRAME STA 1562 WAS FOUND CORRODED. THE (P/N 140T2102-23) SHEAR TIE WAS REPLACED PER DWG 146T1223. THE SHEAR TIE IS LOCATED BETWEEN STR 38L AND STR 38R.

Part: SPLICE — CORRODED (BS 434)

STRINGER 39L SPLICE WAS FOUND CORRODED AT FS 434. THE (P/N 140T0115-16) SPLICE WAS REPLACED PER SRM 51-10-00. NO DAMAGE WAS FOUND ON THE STRINGER.

Part: BULB — FAILED (CABIN)

EXTERIOR EMERG LIGHT AFT OF WING INOP, LEFT SIDE. RELAMPED, CK GOOD.

Part: SKIN — CORROSION (BS 950-955)

DURING ACCOMPLISHMENT OF EO 1-60000-3, CORROSION WAS FOUND DIRECTLY UNDER THE DRAIN SCREEN LOCATED AT APPROXIMATELY LBL 70. THE RESULTING BLENDS, WITH A MAXIMUM DEPTH OF .155, ARE SHOWN ON FIGURE 1. TO FACILITATE INSTALLATION OF A REPAIR DOUBLER UNDER THE LBL 74.81 FLOORBEAM LOWER CHORD. THE CHORD WAS CUT AT APPROXIMATE FS 938. A REPLACEMENT SECTION WILL BE FABRICATED PER DAL DWG 53-0900-004, AND WILL INCORPORATE A MILLED STEP IN THE LOWER FLANGE TO ACCOMMODATE THE DOUBLERS. OTHER DAMAGES EXISTS, REF ER/A 330720-14.

Part: FLOORBEAM — CRACKED (BS 786)

THE FUSELAGE SEAT TRACKS LOCATED AT RBL 33, LBL 54, AND RBL 54 WERE FOUND CRACKED IN THE VERTICAL WEB OF THE UPPER CHORD AT APPROXIMATELY FS 786 AS DESCRIBED IN BOEING SB 767-57-0029. THE VERTICAL WEB IS M/F FROM .063 THK 2024-T3 AL MATERIAL. IN ADDITION, TO THE CRACK REPAIR, PREVENTATIVE MODIFICATIONS TO THE LBL/RBL 33 AND LBL/RBL 54 FLOORBEAMS ARE BEING ACCOMPLISHED PER EO 1-61635-3. DURING ACCOMPLISHMENT OF THE PREVENTATIVE MOD, 3 FASTENER HOLES AT LBL 54 WERE OVERSIZED TO .390 DIA THROUGH THE SPAR STIFFENER, VERTICAL WEB, AND UPPER CAP.

Part: BULB — SHORTED (CABIN)

DURING CRUISE 37000 FT 1 HR INTO FLT, SMELLED ELECTRICAL SMELL. SHUT OFF UTILITY BUSSES PULLED C/BS U6 U33. F/A REPORTED, WORSE IN LT HAND F/C TURNED OFF LT PACK WHEN PAX IN 14A. REPORTED PUFF OF SMOKE FROM LT FLOOR BOARD GRAY IN COLOR. RECEIVED PRIORITY HANDLING INTO SLC. FOUND BULB BASE SHORTED AT 14B. REBULBED AND REPLACED INOP LIGHT DECODER.

Part: VALVE — INOPERATIVE (NLG)

NOSE GEAR DID NOT RETRACT ON T/O, DURING GEAR RETRACTION A/C SHUDDERED, CENTER HYD SYS EICAS MSG CAME ON, CENTER HYD PUMP LOW PRESS LTS CAME ON. DEMAND PUMP LOW PRESS LTS CAME ON WHEN GEAR HANDLE WAS PLACED IN DOWN POSITION. CENTER HYD SYS RETURNED TO NORMAL. GEAR WENT DOWN AND GREEN. REPLACED ADP PRSOV VALVE, SYSTEM OPS CHECKS GOOD.

Part: ENGINE — MALFUNCTIONED (NR 2)

RT ENG FLAME-OUT JUST AFTER ROTATION. ALL INDICATIONS NORMAL AT LIFTOFF, THEN FLAME-OUT OCCURRED. REPLACED LEAKING FUEL MANIFOLD LINE AND LEAKING FUEL NOZZLE, LEAK CHECK AND ENGINE RUN OK.

Part: TE WEDGE — DELAMINATION (NR 5 LE FLAP)

THE NR 5 LEADING EDGE SLAT TRAILING EDGE WEDGE WAS FOUND TO HAVE UPPER SKIN DELAMINATED. THE DELAMINATED AREA IS APPROX 3 INCH BY 3 INCH AND IS LOCATED AT THE INBOARD AFT END OF THE TRAILING EDGE. ACCOMPLISHED REPAIRS PER DL ERA 273577-14AD.

Part: LINE — CRACKED (WING ROOT)

ON APPROACH TO ATL, HAD SMOKE OR BURNING ODOR IN AFT AND MID CABIN. FOUND SLAT PRESSURE HYD LINE CRACKED AT WING ROOT FUSELAGE FITTING. REPLACED HYD LINE, NO LEAKS NOTED. REPLACED PRECOOLER FILTERS DUE TO SKYDROL CONTAMINATION.

Part: EEL — INOPERATIVE (LEFT WING)

LEFT WING LWR AFT EMERGENCY LIGHT INOP. RELAMPED, CKS OK.

Part: EEL LAMP — FAILED (CABIN)

RIGHT AFT EXTERIOR EMERGENCY LIGHT INOPERATIVE. LOCATED AFT OF R2 ENTRANCE DOOR. RELAMPED, CHECKS GOOD.

Part: PNEUMATIC SYS — CONTAMINATED (NR 2 ENGINE)

ON TAKEOFF AND CLIMB, HAD SMOKE ODOR AND FUMES IN MID GALLEY LAV AREA, RETURNED FLT TO ATL. FOUND COMPRESSOR WASH FLUID CONTAMINATION IN NR 2 ENGINE INLET. RAN ENGINE UNTIL ODOR WAS GONE, RETURNED TO SERVICE.

Part: HOSE — LEAKING (RT MLG)

AFTER TAKEOFF, RT MAIN LANDING GEAR WOULD NOT RETRACT, RETURNED MCO. FOUND RT MLG TRUCK TILT PRESSURE LINE BROKEN. REPLACED LINE OPERATION NORMAL.