N12135

Part: BATTERY PACK — INOPERATIVE (ZONE 200) · airframe 49,291 hrs · 31,312 cycles

INT EXIT ROW EMERGENCY LIGHTS INOPERATIVE. REMOVED AND REPLACED BPS 3. OPS CHECK GOOD.

Part: DUCT — SEPARATED (ZONE 400) · airframe 49,258 hrs · 31,282 cycles

BLEED 1 LEAK, BLEED 1 OVERTEMP, AND ICING CONDITIONS A/ICE INOPERATIVE EICAS MESSAGE IN CRUISE. LOST PRESSURIZATION AFTER BLEED 1 LEAK MESSAGE POPULATED. FOUND SYSTEM NR 1 BLEED LINE COUPLING NR 17 DISCONNECTED. REMOVED AND REPLACED BLEED DUCT AT NR 17. OPS CHECK AND LEAK CHECK GOOD. PERFORMED PRESSURIZATION CHECK. OPS CHECK SAT.

Part: MOUNT — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

CORROSION FOUND ON RAT 2 ANTENNAE MOUNT, BETWEEN FRAMES 65 AND 66. REPAIRED CORROSION FOUND UNDER RAT 2 ANTENNA MOUNT ON REAR FUSELAGE LOWER SKIN BETWEEN FR 65 AND 66.

Part: SCUFF PLATE — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

AFTER REMOVAL OF SCUFF PLATE, FOUND AFT CARGO LOWER THRESHOLD TO HAVE CORROSION IN NUMEROUS SCREW HOLES. REMOVED AND REPLACED AFT CARGO LOWER THRESHOLD BEAM.

Part: FLOOR SUPPORT — MECHANIC ERROR (ZONE 200) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

RH OMEGA BEAM REPAIR BETWEEN FR 59 AND 61 MISDRILLED . CORROSION FOUND ON BOTH OMEGA BEAMS FR 59 AND FR61 UNDER GUSSETS. REMOVED CORROSION AND REPAIRED CENTER AND RH OMEGA BEAMS BETWEEN FR59 AND FR61 UNDER GUSSETS.

Part: ANTENNA — CORRODED (VHF 2) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

CORROSION FOUND UNDER VHF 2 ANTENNA AT FRAMES 21-22. BLENDED AREA. APPLIED ALODINE TO THE AIRCRAFT SKIN AT VHF 2 ANTENNA MOUNT POINT AT FRAMES 21-22

Part: FLOOR SUPPORT — CORRODED (ZONE 200) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

CORROSION FOUND UNDERNEATH FLOOR BOARDS 262CF AND 262DF. REMOVED AND REPLACED RH AND CENTER GUSSETS UNDER FLOORBOARDS 262CF AND 262DF.

Part: RETAINER — CORRODED (WINDOW FRAME) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

DURING INSPECTION FOR OK TO INSTALL, FOUND CORROSION ON R/H DV WINDOW RETAINER RING FRAME. REMOVED CORROSION FROM RH DV WINDOW RETAINER RING FRAME. REPLACED DV WINDOW

Part: FLOOR SUPPORT — DAMAGED (ZONE 200) · airframe 49,133 hrs · 31,159 cycles

CENTER OMEGA BEAM DAMAGED ON RH SIDE UNDER CENTER GUSSET BETWEEN FRAME 16 AND 17. REPAIRED CENTER OMEGA BEAM BETWEEN 16 AND 17 INSTALLED A U CHANNEL DOUBLER AND FILLER.

Part: WINDOW — CRACKED (ZONE 200) · airframe 49,133 hrs · 31,159 cycles

RH DV WINDOW CRACKED AT FIRST FASTENER FWD OF LATCH HANDLE. REMOVED AND REPLACED RH DV WINDOW.

Part: BRACE — CRACKED (ZONE 800) · airframe 49,133 hrs · 31,159 cycles

CARGO COMPARTMENT DOOR CUTOUT BRACES CRACKED. INSTALLED NEW CARGO THRESHOLD BRACE AND ANGLE.

Part: ACCESS PANEL — CORRODED (ZONE 600) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

R/H WING FUEL ACCESS PANELS AND CLAMP RINGS:641BB, 631CB, 156CZ, 651AB, 641CB, 641EB, 641DB, 631DB, 631BB, 631AB, AND 641AB HAVE CORROSION AND FRETTING DAMAGE (PITTING). PERFORMED CORROSION REMOVAL PROCESS ON RH FUEL ACCESS DOOR PANEL 641CB, 641EB, 641DB, 631DB, 631AB, 631BB, 641AB, 631CB, AND 156CZ CLAMP RING IAW ETD2025-145-924469. CLAMP RING 651AB CLAMP RING 641BB FOUND TO BE BAD AND WILL BE INSTALLED NEW FROM STOCK

Part: ACCESS PANEL — CORRODED (ZONE 500) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

LH WING FUEL ACCESS PANELS AND CLAMP RINGS: 541EB, 541AB, 531BB, 531DB, 531AB, 541CB, 541DB, 551AB, 541BB, 531CB, 155BZ, AND 155CZ HAVE CORROSION AND FRETTING DAMAGE (PITTING). BLENDED OUT CORROSION AND PITTING FOUND ON FUEL ACCESS PANEL FLANGES. PANELS 541EB, 541AB, 531BB, 531DB, 531AB, 541CB, 541DB, 551AB, 541BB, 531CB, AND 155CZ FOUND WITHIN MAX ALLOWABLE LIMITS OF .11875". PANEL 155BZ FOUND OUT OF LIMITS.

Part: SHEAR TIE — CRACKED (ZONE 200) · airframe 49,133 hrs · 31,159 cycles

ZONE 231 FOUND CRACK AT FRAME #20 (STRINGER 3L - SHEAR CLIP). REMOVED AND REPLACED STRINGER 3L - SHEAR CLIP FITTING AT FRAME 20.

Part: DOOR FRAME — CORRODED (ZONE 200) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

ZONE 132, 232, AND 234 FOUND CORROSION AT THE RH SILL SERVICE DOOR AT FRAMES 20 AND 22. REMOVED AND REPLACED RH SILL SERVICE DOOR LOWER FRAME BETWEEN FRAME 20 AND 22.

Part: DOOR SILL — CORRODED (ZONE 200) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

ZONE 132, 232, AND 234 FOUND CORROSION AT THE RH SILL SERVICE DOOR AT FRAMES #20 AND #22 (LOWER BEAM AND SCREW HOLES UNDER FLOOR BOARD). REMOVED AND REPLACED RH SILL SERVICE DOOR LOWER FRAME BETWEEN FR20 AND 22.

Part: FRAME — CRACKED (ZONE 200) · airframe 49,133 hrs · 31,159 cycles

ZONE 231 FOUND CRACK AT FRAME 20. REMOVED AND REPLACED STRINGER 3L-SHEAR CLIP FITTING AT FRAME 20.

Part: ATTACH BRACKET — CRACKED (ZONE 100) · airframe 49,133 hrs · 31,159 cycles

RH WING TO FUSELAGE FAIRING ATTACH BRACKET SECOND FROM FDW SIDE OF WING CRACKED. INSTALLED NEW RH WING FAIRING ATTACH BRACKET AND DOUBLER.

Part: WEB — CRACKED (ZONE 100) · airframe 49,133 hrs · 31,159 cycles

RH MLG BAY AFT WEB CRACKED AT SPAR III LOWER OB CORNER. REMOVED AND REPLACED RH MLG BAY AFT WEB AT SPAR III LOWER OB CORNER

Part: COWLING — DAMAGED (ZONE 100) · airframe 49,133 hrs · 31,159 cycles

APU COWLING LWR SKIN HAS A DENT NEAR THE APU EXHAUST DRAIN. RECONTOURED APU COWLING LWR APU SKIN TO REMOVE DENT NEAR THE APU EXHAUST DRAIN. PERFORMED HFEC ON APU COWLING LWR SKIN DENT NEAR THE APU EXHAUST DRAIN

Part: BRACKET — CRACKED (ZONE 100) · airframe 49,133 hrs · 31,159 cycles

BRACKET CRACKED RH SIDE OF CENTER GUSSET BETWEEN FRAMES 16&17 (STRINGER 21L & 21R). REMOVED CRACKED BRACKET LOCATED ON RH SIDE OF CENTER GUSSET BETWEEN FR16 AND FR17 (STRINGER 21L-21R)

Part: BRACKET — CRACKED (ZONE 100) · airframe 49,133 hrs · 31,159 cycles

BRACKET CRACKED LH SIDE OF CENTER GUSSET BETWEEN FRAME 16 & 17 (STRINGER 21L-21R). REMOVED AND REPLACED BRACKET LH SIDE OF CENTER GUSSET BETWEEN FRAME 16&17 (STRINGER 21L & 21R)

Part: GUSSET — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

CORROSION IN CENTER GUSSET AT SCREW HOLES UNDER BETWEEN FRAMES 16 & 17 (STRINGER 21L & 21R). REMOVED CORROSION AND REPAIRED CENTER GUSSET AT SCREW HOLES BETWEEN FRAMES 16 & 17.

Part: CROSSBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

FOUND CORROSION ON CROSS MEMBER AT FRAME 20. REMOVED AND REPLACED 1EA CROSS MEMBER IN PAX CABIN FR20

Part: EXHAUST CONE — DENTED (APU) · airframe 49,133 hrs · 31,159 cycles

APU EXHAUST CONE DENTED IN MULTIPLE LOCATIONS. APU TAIL CONE FOUND TO HAVE NUMEROUS DENTS. INSTALLED NEW TAIL CONE ASSEMBLY.

Part: BRACKET — CORRODED (ZONE 100) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

L-CLIP IN BOTTOM LEADING EDGE OF AFT CARGO DOOR CUT-OUT IS CORRODED. REMOVED CRACKED L-BRACKET AND INSTALLED NEW FROM STOCK AT FR65 STR 17L

Part: COWLING — DAMAGED (APU) · airframe 49,133 hrs · 31,159 cycles

APU COWLING LWR SKIN HAS MULTIPLE PROTRUDING DENTS NEAR THE APU DRAIN. RECONTOURED APU COWLING LWR SKIN NEAR THE APU DRAIN TO REMOVE MULTIPLE PROTRUDING DENTS. PERFORMED HFEC.

Part: SHEAR TIE — CRACKED (ZONE 100) · airframe 49,133 hrs · 31,159 cycles

CRACKED SHEAR CLIP AT FRAME 22A STRINGER 16R. REMOVED AND REPLACED CRACKED SHEAR CLIP AT FRAME 22A STRINGER 16R

Part: FRAME — DENTED (ZONE 100) · airframe 49,133 hrs · 31,159 cycles

FRAME 71 BETWEEN STRINGER 15R AND 16R IS DENTED. RECONTOURED FRAME 71 BETWEEN STRINGER 15R AND 16R

Part: RETAINER — CRACKED (ZONE 800) · airframe 49,133 hrs · 31,159 cycles

ZONE 100 RACK - 123BL DRAIN DIAPHRAGM RETAINER CRACKED. DOOR 123BL INSTALLED NEW FROM STOCK DRAIN DIAPHRAGM AND RETAINER.

Part: FLOOR SUPPORT — CORRODED (ZONE 200) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

RH FLOOR SILL BETWEEN FR 22 AND 23 CORRODED AROUND FWD NUTPLATE. REMOVED AND REPLACED RH FLOORSILL BETWEEN FR 22 AND 23.

Part: FLOOR SUPPORT — CORRODED (ZONE 200) · corrosion level 2 · airframe 49,133 hrs · 31,159 cycles

LH FLOOR SEAL FROM FRAME 23 TO 35 HAS CORROSION. LH FLOOR SEAL FROM FRAME 23 TO 35 REMOVED AND INSTALLED

Part: CONNECTOR — LEAKING (HYD SYSTEM) · airframe 48,561 hrs · 30,595 cycles

BLEED 1 LEAK ON APPROACH WITH ASSOCIATED A/I FAULTS. FOUND ENGINE GROUND CONNECTION LEAKING. REMOVED AND REPALCED ENGINE GROUND CONNECTION. OPS CHECK, LEAK CHECK SAT AT THIS TIME AND FOUND MULTIPLE LEAKS ON PACK 1, GRATE ASSEMBLY AND DUEL TEMP VALVE UPPER SLEEVES RESECURED ALL THE LEAKS. PERFORMED OPS CHECK USING HIGH STAGE VALVE TEST BOX SIMULATING ICING CONDITIONS AND BLEED AIR HEALTH CHECK. OPS CHECK AND LEAK CHECK SAT AT THIS TIME.

Part: ENGINE — FAULTED (UNKNOWN) · airframe 46,761 hrs · 29,002 cycles

OILY SMELL COMING FROM THE ENGINE BLEED. ENGINE 2 HAS BEEN REPLACED.

Part: LIGHT — INOPERATIVE (RT EXTERIOR) · airframe 45,527 hrs · 27,903 cycles

RH EXTERIOR OVERWING EMERGENCY LIGHT IS INOPERATIVE. RH EXTERNAL OVERWIN EMERGENCY LIGHT REMOVED AND REPLACED. OPS CHECK GOOD. NO DEFECTS NOTED AT THIS TIME

Part: BULB — INOPERATIVE (EMERGENCY LIGHT) · airframe 45,527 hrs · 27,903 cycles

CEILING EMERGENCY LIGHTS INOPERATIVE AT ROWS 18 AND 22. REMOVED AND INSTALLED LIGHT BULBS AT ROWS 18 AND 22. OPS CHECK GOOD

Part: LIGHT — INOPERATIVE (LT EXTERIOR) · airframe 45,527 hrs · 27,903 cycles

LH EXTERIOR OVERWING EMERGENCY LIGHT IS INOPERATIVE. LH EXT OVERWING EMERGENCY LIGHT REMOVED AND REPLACED. NO DEFECTS NOTED AT THIS TIME.

Part: SIGN — INOPERATIVE (EMERGENCY LIGHTS) · airframe 45,527 hrs · 27,903 cycles

CTR AISLE FWD FACING EMERGENCY SIGN INOPERATIVE AT EMERGENCY EXIT ROW. REMOVED AND REPLACED CTR AISLE FWD FACING EMERGENCY SIGN. OPS CHECK GOOD. NO DEFECTS NOTED AT THIS TIME

Part: NOT REPORTED — NOT REPORTED · airframe 44,219 hrs · 26,704 cycles

CF II, EXTERNAL FUSELAGE, LIGHTING STRIKE 1.000 INCH FWD FRAME 27 BTW STR 8R-9R. CFII, EXTERNAL FUSE SKIN, 1 FWD OF FRAME 27 BTW STR 8R-9R, PAINT STRIPPED FOR INVESTIGATION. DOUBLER REPAIR FABRICATED. CFII EXTERNAL SKIN, LIGHTNING STRIKE 1 IN FWD OF FR 27 BTW STR 8R-9R REPAIRED

Part: NOT REPORTED — NOT REPORTED · corrosion level 2 · airframe 44,219 hrs · 26,704 cycles

CORROSION FOUND UNDER DATA PLATE ON AFT RF2 EXTERNAL SKIN BTW FR 78-79 AND STR 21L-21R. CORROSION BLENDED OUT OF LIMIT. REAR FUSELAGE II LOWER SKIN BTW FR 80-81 AND BTW STR 21L-21R REPAIRED WITH CUT OUT AND DOUBLER.

Part: NOT REPORTED — NOT REPORTED · corrosion level 2 · airframe 44,219 hrs · 26,704 cycles

CORROSION FOUND ON RH OMEGA BEAM AT FR 23 IN CF I FLOOR STRUCTURE AREA. RH OMEGA BEAM AT FR 23 IN CFI FLOOR STRUCTURE BLENDED OUT OF LIMITS FOR CORROSION REMOVAL. PERFORMED CUTOUT AND DOUBLER REPAIR ON RH OMEGA BEAM AT FR23.

Part: NOT REPORTED — NOT REPORTED · airframe 44,219 hrs · 26,704 cycles

SERVICE DOOR EXTERIOR SKIN, 1 LIGHTNING STRIKE ENTRY POINT SUSPECTED 12" FROM AFT SKIN EDGE AND 13.75 FROM TOP. SERVICE DOOR EXTERIOR SKIN 12" FROM AFT EDGE AND 13.75 FROM TOP EDGE. 1 LIGHTNING STRIKE REPAIRED WITH EXTERNAL DOUBLER.

Part: NONE — NONE · airframe 44,219 hrs · 26,704 cycles

LH OMEGA BEAM FOUND CRACKED AT FR 24 . LH OMEGA BEAM REPLACED

Part: CONTROL HANDLE — FAULTED (MLG) · airframe 43,745 hrs · 26,281 cycles

NLG DOORS OPENED IN FLIGHT AT FL 210 AT 265 KTS. REMOVED AND REPLACED NLG DOOR SEQ VALVE (DID NOT FIX). SLAVED IN LGCU (DID NOT FIX). REMOVED AND REPLACED L CONTROL HANDLE PERFORMED GEAR SWINGS. OPS CHECK GOOD. SOLENOID VALVE - PN 2225-0100-003 SN 822 TSN 43745.17 CSN 26281 - LEVER, LANDING GEAR CONTROL PN 7-45550-3 SN 0294 TSN 33809.42 CSN 21003

Part: SKIN — CRACKED (RT WING) · airframe 43,452 hrs · 26,066 cycles

R/H LOWER WING SKIN CRACKED. REPAIRED CRACK BY REMOVING CRACKED SECTION OF SKIN, FABRICATED FILLER AND INTERNAL REPAIR IAW ETD2020-145-000657.

Part: CONTROL MODULE — ODOR (CABIN LIGHTS) · airframe 43,416 hrs · 26,041 cycles

CREW REPORTED BURNING SMELL IN GALLEY AREA. INSPECTION DETERMINED SMELL CAME FROM CEILING LIGHTS CONTROL BOX. REMOVED AND REPLACED CEILING LIGHT CONTROL MODULE WITH OPERATIONAL CHECK GOOD. A/C WAS APPROVED FOR RETURN TO SERVICE.

Part: BUTTSTRAP — CORRODED (FRAMES 59-61) · airframe 31,831 hrs · 19,356 cycles

LAVATORY RT OMEGA BEAM BUTT STRAP IS CORRODED BETWEEN FRAMES 59 - 61. INSTALLED A NEW BUTT STRAP.

Part: SKIN — DENTED (FUSELAGE) · airframe 40,301 hrs · 33,712 cycles

DURING A C-CHECK, A DENT WAS FOUND AT THE RIGHT SIDE OF THE POWER RECEPTABLE. MAINTENANCE INSTALLED A REPAIR TO THE SKIN IAW EC2018-145-042199.

Part: SKIN — DENTED (FRAMES 20-21) · airframe 40,301 hrs · 33,712 cycles

DURING C-CHECK, A DENT WAS FOUND ON THE LEFT FUSELAGE SKIN, BETWEEN FRAMES 20 AND 21, STRINGERS 14L AND 15L. MAINTENANCE INSTALLED A REPAIR IAW SRM 53-21-01.

Part: FITTING — GOUGED (HORIZONTAL STAB) · airframe 40,301 hrs · 23,712 cycles

DURING C-CHECK, WHEN THE OTBD HAT BUSHING FOR THE LEFT HINGE OF THE HORIZONTAL STAB WAS DAMAGED FROM THE SPHERICAL BEARING CHAFING. MAINTENANCE REMOVED BOTH BUSHINGS AND FOUND BOTH OUT OF LIMITS. CONTINUED REAMING THE HOUSING AND REPLACED THE BUSHING. INSTALLED A NEW BUSHINGS IAW SRM 55-10-02. ALL WORK ACCOMPLISHED.

Part: BUSHING — CORRODED (HORIZONTAL STAB) · airframe 40,301 hrs · 23,712 cycles

DURING C-CHECK, THE LEFT OTBD PRESSED BUSHING FOR THE HORIZONTAL STAB HINGE HAD PITTING DAMAGE. MAINTENANCE REMOVED THE BUSHING AND WAS FOUND TO BE OUT OF LIMITS. MAINTENANCE REAMED TO THE FIRST OVERSIZED, AND INSTALLED A NEW BUSHING IAW SRM 55-10-02.

Part: CONTROLLER — FAULTY (COCKPIT) · airframe 38,737 hrs · 22,582 cycles

THE CREW REPORTED PRESSURIZATION SLOWLY RAISES UP TO 11,900 AT 28,000FT. EMERGENCY DESCENT FOLLOWED. MX INSPECTED AND REPLACED THE DIGITAL PRESSURIZATION CONTROLLER, MANUAL CONTROLLER AND ELECTROPNEUMATIC OUTFLOW VALVE. OPERATIONAL CHECKS WERE GOOD.

Part: ACM — SEIZED (NR 1) · airframe 38,434 hrs · 22,374 cycles

CREW REPORTED SMOKE IN THE COCKPIT, POSSIBLY FROM THE F/O'S READING LIGHT. THE AIRCRAFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE COCKPIT WIRING TO BE SATISFACTORY AND THAT THE NUMBER ONE ACM HAD SEIZED CAUSING THE SMOKE. MAINTENANCE REMOVED AND REPLACED THE AFFECTED ACM., OPERATIONALLY TESTED WITH NO DEFECTS NOTED AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: DISPLAY — SHORTED (COCKPIT) · airframe 38,160 hrs · 22,188 cycles

PILOT REPORTED PFD2 FAILED WITH BURNING SMELL AND BLOWN BREAKER. MX REMOVED AND REPLACED PFD2 WITH OPS CHECK GOOD. A/C WAS APPROVED FOR RETURN TO SERVICE.

Part: ENGINE — LEAKING (NR 2) · airframe 37,796 hrs · 21,943 cycles

CREW REPORTED SMOKE IN THE CABIN. THE AIRCRAFT RETURNED TO DEPARTURE AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE NUMBER 2 ENGINE TO HAVE AN INTERNAL LEAK. THE ENGINE WAS REMOVED AND REPLACED AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: ACM — SEIZED (NR 1) · airframe 36,122 hrs · 20,811 cycles

THE CREW REPORTED A BURNING ODOR FOLLOWED BY SMOKE IN THE FLIGHT DECK WHILE CLIMBING THROUGH 10,000 FT. THE ACFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE R & R THE NR 1 ACM, OPERATIONALLY TESTED WITH NO DEFECTS NOTED, AND THE ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: WARNING MESSAGE — FALSE ACTIVATION (APU FIRE) · airframe 33,125 hrs · 18,732 cycles

THE CREW REPORTED AN APU FIRE INDICATION IN FLIGHT AND APU TEMP PEAKED AT 962. THE ACFT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE ACFT AND FOUND NO EVIDENCE OF FIRE IN THE APU COMPARTMENT.

Part: SIGN — INOPERATIVE (EMERGENCY LIGHTS) · airframe 33,116 hrs · 18,728 cycles

THE CREW REPORTED EMERGENCY EXIT SIGN NOT ILLUMINATING DURING TEST. MAINTENANCE INSPECTED AND REPLACED THE EMERGENCY EXIT SIGN AT ROW 18. OPS CHECKS WERE GOOD.

Part: CONNECTOR — UNSECURE (EMERGENCY LIGHTS) · airframe 32,918 hrs · 18,612 cycles

DURING POST FLIGHT INSPECTION, THE CREW REPORTED AN EMERGENCY LIGHT TO BE INOPERATIVE. MAINTENANCE INSPECTED THE ACFT AND SECURED THE ELECTRICAL CONNECTOR ON THE FWD CEILING EMERGENCY EXIT LIGHT AT THE EXIT ROW, OPERATIONALLY TESTED WITH NO DEFECTS, AND THE ACTF WAS APPROVED FOR RETURN TO SERVICE.

Part: CONNECTOR — DAMAGED (EMERGENCY LIGHT) · airframe 31,640 hrs · 17,758 cycles

CREW REPORTED THE EMERGENCY EXIT SIGN OVER EXIT ROW INOPERATIVE. MX SECURED CONNECTOR CONTACT PINS WITH OPS CHECKED GOOD. ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 29,778 hrs · 16,607 cycles

DURING C-CHECK LT OMEGA BEAM WAS FOUND TO BE CORRODED BETWEEN FRAMES 22-23. MAINTENANCE REMOVED THE CORROSION AND PERFORMED A DOUBLER REPAIR IAW SRM 53-21-10. THE ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SUPPORT — CRACKED (ZONE 100) · airframe 29,778 hrs · 16,607 cycles

DURING C-CHECK, WASTE DRAIN VALVE SUPPORT WAS FOUND TO BE CRACKED. MAINTENANCE R & R THE SUPPORT IAW SRM 51-40-02. ACFT APPROVED FOR RETURN TO SERVICE.

Part: SKIN — CRACKED (ZONE 200) · airframe 29,778 hrs · 16,607 cycles

DURING C-CHECK, LEFT AFT SKIN WAS FOUND TO BE CRACKED AROUND A FASTENER AT FRAME 79 BETWEEN STRINGERS 5-6L. MAINTENANCE REMOVED THE CRACKS AND PERFORMED A BUSHING REPAIR IAW EC5330-02825. THE ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: FRAME — CRACKED (ZONE 200) · airframe 29,778 hrs · 16,607 cycles

DURING C-CHECK, FRAME 10 SEGMENT BETWEEN STRINGERS 9-10R WAS FOUND TO BE CRACKED, MX R & R FRAME SEGMENT IAW SRM 51-40-02. ACFT APPROVED FOR RETURN TO SERVICE.

Part: CONTROL UNIT — FAULTY (FUEL SYSTEM) · airframe 24,078 hrs · 13,050 cycles

EWR FLT 4323 THE CREW REPORTED THE NR 1-2 FUEL QTY DASHED OUT. THE AIRCRAFT DIVERTED INTO CLE AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED AND REPLACED THE FUEL CONTROL UNIT. OPERATIONAL CHECKS WERE GOOD.

Part: SENSOR — FAULTY (BLEED AIR SYS) · airframe 23,521 hrs · 12,717 cycles

IAH FLT 2167 THE CREW REPORTED A NR 1 BLEED LEAK MESSAGE IN FLIGHT. THE AIRCRAFT DIVERTED INTO CLE. MAINTENANCE INSPECTED AND REPLACED THE LEFT PYLON DUCT TEMP SENSOR S0791. OPERATIONAL CHECKS WERE GOOD.

Part: INVERTER — INOPERATIVE (CABIN) · airframe 22,698 hrs · 12,193 cycles

DURING ROUTINE MAINTENANCE THE EMERGENCY LIGHT EXIT SIGN WAS FOUND INOPERATIVE. MAINTENANCE REPLACED THE EMERGENCY LIGHT NR 3 INVERTER. OPERATIONAL CHECKS WERE GOOD.

Part: CONTROL PANEL — INOPERATIVE (SMOKE DETECTION) · airframe 21,235 hrs · 11,409 cycles

FLIGHT 2142 - OKC - FLIGHT CREW REPORTED LAV SMOKE DETECTOR WOULD NOT TEST AT GALLEY PANEL. MX REMOVED AND REPLACED LAV SMOKE DETECTOR PANEL AND PERFORMED OPERATIONAL CHECK SUCCESSFULLY. ACFT WAS APPROVED TO RETURN TO SERVICE.

Part: INVERTER — INOPERATIVE (CABIN) · airframe 21,129 hrs · 11,345 cycles

FLIGHT 2201 - RIC - DURING ROUTINE MAINTENANCE, RIC MX FOUND RT ESCAPE HATCH LOWER EMERGENCY EXIT SIGN INOPERATIVE. MX REMOVED AND REPLACED INVERTER AND PERFORMED OPERATIONAL CHECK SUCCESSFULLY. ACFT WAS APPROVED TO RETURN TO SERVICE.

Part: BATTERY — OVERTEMP (NR 2) · airframe 20,818 hrs · 11,169 cycles

ATL - BATTERY 2 OVERTEMP. TYS REMOVED AND REPLACED NR 2 MAIN BATTERY.

Part: ELECTRONIC UNIT — INOPERATIVE (LANDING GEAR) · airframe 20,763 hrs · 11,139 cycles

FLIGHT 2626 - EWR - FLIGHT CREW REPORTED AIR GROUND FAIL INDICATION ON EICAS DURING TAXI OUT. EWR MX REMOVED AND REPLACED LGEU AND PERFORMED OPERATIONAL CHECK SUCCESSFULLY. ACFT WAS APPROVED TO RETURN TO SERVICE.

Part: PROBE — FALSE ACTIVATION (FUEL SYSTEM) · airframe 20,520 hrs · 11,003 cycles

TYS - A/C WAS EN ROUTE TO IAH FROM LEX WHEN THE CREW GOT A FUEL IMBALANCE INDICATION IN FLIGHT RESULTING IN A 1200LBS DIFFERENCE AT FL230. AIRCRAFT DIVERTED. MAINTENANCE RELEASED ACFT IAW MEL 28-40-00/2 CATEGORY "B". IAH MAINTENANCE REMOVED AND REPLACED LEFT NR 2 FUEL TANK UNIT IAW MM 28-41-02. OPS CHECKED GOOD AND C/W REVERSED DDP PROCEDURES AND CLEARED MEL. AIRCRAFT RETURNED TO SERVICE.

Part: GENERATOR — FOD (NR 2) · airframe 20,319 hrs · 10,888 cycles

DURING CLIMB, FLIGHT CREW REPORTED SMOKE IN CABIN. CREW PERFORMED AIR RETURN AND LANDED ACFT UNEVENTFULLY. MX FOUND BIRD STRIKE ON ENG NR 2 AND INGESTION IN MAIN GENERATOR NR 2. MX R & R MAIN GENERATOR NR 2 AND PERFORMED OPS CHECK SUCCESSFULLY. ACFT WAS APPROVED TO RETURN TO SERVICE.

Part: CHARGER — INOPERATIVE (CABIN) · airframe 19,666 hrs · 10,539 cycles

IAH - DURING MAINTENANCE INSPECTION THE FORWARD OVERWING EMERGENCY EXIT LIGHT WAS FOUND TO BE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE NUMBER ONE BATTERY CHARGER, OPERATIONALLY TESTED WITH NO DEFECTS, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SILL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 19,119 hrs · 10,229 cycles

HEAVY CORROSION ON SERVICE DOOR SILL AROUND HOLES FOR FLOOR PANEL 232CF. REMOVED AND REPLACED SILL IAW EMB SRM 51-40-02.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · corrosion level 2 · airframe 19,119 hrs · 10,229 cycles

CENTER OMEGA BEAM CORRODED AT FRM 20. REMOVED AND REPLACED OMEGA BEAM IAW SRM 51-40-02.

Part: SKIN — CHAFED (FUEL TANK) · airframe 19,119 hrs · 10,229 cycles

VENTRAL TANK LOWER SKIN HAS A CHAFED AREA. REPAIRED SKIN IAW EC2810-01053.

Part: SENSOR — FAULTY (NR 1 ENG OIL) · airframe 18,911 hrs · 10,120 cycles

IAH FLT NR 2124, THE CREW REPORTED A HIGH OIL TEMP IN CRUISE ON THE NR 1 ENGINE. THE AIRCRAFT DIVERTED INTO CLE AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND REPLACED THE NR 1 ENGINE TEMP/PRESSUE SENSOR. OPERATIONAL CHECKS WERE GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 16,880 hrs · 9,004 cycles

AIRCRAFT IN FOR A A-CHECK INSPECTION WHEN THE LT FORWARD EMERGENCY LIGHT FLOOR STRIP WAS FOUND TO BE INOP. MAINTENANCE REPLACED THE LT FORWARD FLOOR STRIP IAW EMB AMM 33-50-12. OPS CHECK GOOD AND WAS RELEASED TO SERVICE.

Part: UNKNOWN — ODOR (COCKPIT)

CLE FLIGHT NR 2285 THE CREW REPORTED A BURNING SMELL IN THE COCKPIT WHEN THE WINDSHIELD HEAT COMES ON AND GOES AWAY WHEN WINDSHIELD HEAT IS TURNED OFF. MX INSPECTED AND PERFORMED OPS CHECKS AND COULD NOT DUPLICATE BURNING SMELL. THE NR 1 WINDSHIELD GROUND WIRE WAS RETORQUED BUT NO DAMAGE WAS FOUND TO EITHER NR 1 OR NR 2 WINDSHIELD HEAT WIRING.

Part: UNKNOWN — ODOR (COCKPIT)

CLE FLIGHT NR 2641 THE CREW REPORTED A STRONG BURNING SMELL EVERYTIME THRUST WAS REDUCED TO IDLE IN FLIGHT. THE SMELL WENT AWAY WHEN THRUST WAS INCREASED. MX INSPECTED AND PERFORMED ENGINE GROUND RUNS AT VARIOUS POWER SETTINGS AND PACK SETTINGS AND COULD NOT DUPLICATE BURNING SMELL. OPS CHECKS WERE GOOD.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 9,461 hrs · 5,072 cycles

SHV - DURING C-CHECK THE LEFT OMEGA BEAM WAS FOUND TO BE CORRODED BETWEEN FRAMES 24-25. MAINTENANCE REMOVED THE DAMAGED AREA AND INSTALLED A DOUBLER REPAIR IAW EMB 145XR SRM 52-00-10. THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 9,461 hrs · 5,072 cycles

SHV - DURING C-CHECK THE LEFT OMEGA BEAM WAS FOUND TO BE CORRODED AT FRAME 20. MAINTENANCE REMOVED THE DAMAGED AREA AND INSTALLED A DOUBLER REPAIR IAW EMB 145XR SRM 53-00-10. THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SMOKE — DETECTED (COCKPIT)

CREW REPORTED A STRONG ODOR OF SMOKE IN THE COCKPIT AND CABIN UPON TAKEOFF. THE CREW RETURNED TO IAH AND LANDED WITHOUT INCIDENT WHERE MAINTENANCE PERFORMED TROUBLESHOOTING TO DETERMINE THE ORIGIN OF THE SMOKE. THE ENGINE AND BLEED SYSTEMS WERE RUN AND THE SMOKE ODOR COULD NOT BE DUPLICATED. THE DISCREPANCY WAS CLEARED AND THE AIRCRAFT RETURNED TO SERVICE.

Part: TERMINAL BLOCK — MELTED (COCKPIT)

THE CREW REPORTED EXTREME ELECTRICAL SMOKE SMELL DURING THE LAST 20 MINUTES OF FLIGHT. NO VISUAL SMOKE WAS NOTED. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED AND FOUND THE FIRST OFFICER'S WINDSHIELD TERMINAL BLOCK WAS MELTED. THE WINDSHIELD WAS REPLACED AND OPERATIONAL CHECKS WERE GOOD.

Part: BATTERY — ARCED (MASTER) · airframe 1,800 hrs · 992 cycles

SMOKE ODOR IN COCKPIT. A/C ENGINES WERE RAN WITH PACKS OPERATING. COULD NOT DUPLICATE THE SMOKE ODOR. UPON FURTHER INVESTIGATION, BATTERY TERMINAL SHOWED SIGNS OF ARCING. BATTERY REPLACED AND OPERATIONALLY CHECKED GOOD WITH NO REPEAT OF THE SMOKE ODOR IN THE COCKPIT. A/C FERRIED TO CLE WHERE FURTHER INSPECTION REVEALED THE NR 1 WINDSHIELD TERMINAL STRIP WAS BURNED. WINDSHIELD WAS REPLACED, TEST FLIGHT CHECKED GOOD.