N12201

Part: FUEL SYS — FALSE INDICATION · airframe 41,696 hrs · 27,744 cycles

FUEL WING 1 INDICATED ZERO ON DEPARTURE FOLLOWED BY FUEL LOW LEVEL 1/2 EICAS MESSAGE. INSPECTED AND FOUND REFUEL SWITCH IN THE OPEN POSITION ON REFUEL PANEL. CLOSED REFUEL SWITCH. NO FAULTS ON REPEATER. FUEL INDICATIONS OPS CHECK OKAY AT THIS TIME. NO FAULTS NOTED AT THIS TIME.

Part: CONTROLLER — FAILED (CABIN PRESSURE) · airframe 41,441 hrs · 27,515 cycles

DURING CLIMBOUT AUTO PRESS INCREASED UNCONTROLLED, MANUAL MODE OPERATED NORMAL. USING FIM TROUBLESHOOT TO DIGITAL CONTROLLER, DIGITAL CONTROLLER ERROR CODE READER FOUND MULTIPLE FAILURE CODES. REMOVED AND REPLACED DIGITAL CONTROLLER. PERFORMED OPS CHECKS IN AUTO AND MANUAL MODE. NO NOISE OR LEAKS NOTED. OPS AND LEAK CHECKS SATISFACTORY.

Part: DOOR — BINDING (ZONE 800) · airframe 40,684 hrs · 26,788 cycles

MAIN CABIN DOOR WONT OPEN. REMOVED EXCESSIVE PAINT AT TOP MCD FLAPPER FOLDER. DOOR OPEN AND CLOSE CORRECTLY, OPS CHECK SAT.

Part: FLASHLIGHT — MALFUNCTIONED (ZONE 200) · airframe 40,569 hrs · 26,664 cycles

FORWARD CABIN FLASHLIGHT INOPERATIVE. RAN FUNCTIONAL CHECK. OPS CHECK SAT.

Part: FLOOR SUPPORT — CORRODED (ZONE 200) · corrosion level 2 · airframe 40,378 hrs · 26,482 cycles

CORROSION FOUND ON RH OMEGA BEAM AT FR20. REMOVED DAMAGED AREA ON RH OMEGA BEAM AT FR20. COMPLETED HIGH FREQUENCY EDDY CURRENT INSPECTION. NO CRACK INDICATIONS FOUND AROUND AREA OF CORROSION REMOVED AT THIS TIME. FABRICATED REPAIR PARTS EXTERNAL DOUBLER AND 2 ANGLES. PARTIALLY INSTALLED REPAIR PARTS ON RH OMEGA BEAM AT FR20. COMPLETED INSTALLED REPAIR PARTS ON RH OMEGA BEAM AND ANGLES AT FR20 SERVICE DOOR AREA.

Part: CHANNEL — CORRODED (ZONE 200) · corrosion level 2 · airframe 40,378 hrs · 26,482 cycles

WHILE REMOVING GUSSET BEAM HAT FOUND CORROSION ON BEAM HAT SECTION ASSY OUT OF LIMITS. REMOVED CORROSION IN TWO PLACES DAMAGE A AND DAMAGE B AND FOUND OUT OF LIMITS ON BOTH DAMAGES. CUT OUT DAMAGE DIMENSIONS. DAMAGE A = 2.18" X 1.09" AND DAMAGE B = 1.8" X 1.09". ACCOMPLISHED HFEC INSPECTION. NO INDICATION OF ADDITIONAL DAMAGE OR CRACKS FOUND AT THIS TIME. MAKING A REPAIR PART INTERNAL DOUBLERS 2 EA AND FILLER 1EA ON TWO PLACES DAMAGE A AND DAMAGE B. LOCATED HOLES AND COUNTER SKINS DOUBLERS. INSTALLED REPAIR PARTS DAMAGE A AND B AT RH OMEGA SHAPED BEAM FR 59 - FR 60.

Part: BULKHEAD — GOUGED (ZONE 100) · airframe 40,378 hrs · 26,482 cycles

FOUND FWD BULKHEAD SKIN TO BE GOUGED IN FWD AVIONICS BAY. REMOVED AND REPLACED ANGLED SHOP HEADS ON RIVETS. INSTALLED REMAINING RIVETS AND FILLER. INSPECTED RIVETS AND FILLER.

Part: BULKHEAD — GOUGED (ZONE 100) · airframe 40,378 hrs · 26,482 cycles

FOUND FWD BULKHEAD SKIN TO BE GOUGED IN FWD AVIONICS BAY. REMOVED DAMAGE AT FWD BULKHEAD SKIN IN FWD AVIONICS BAY. PERFORMED ULTRASONIC THICKNESS INSPECTION ON THE DAMAGED AREA ON THE FWD PRESSURE BULKHEAD. NOMINAL THICKNESS 0.034" LOWEST PART OF THE DAMAGED 0.024". MADE LAYOUT AND DRILLED HOLES. MADE FILLER FOR FWD BULKHEAD REPAIR WITH 2024-T3 0.032". INSTALLED 94 OUT OF 102 RIVETS.

Part: FLOORBEAM — BENT (ZONE 100) · airframe 40,378 hrs · 26,482 cycles

BAGGAGE COMPARTMENT FLOOR STRUCTURE T-PROFILE BETWEEN LH AND CENTER OMEGA BEAMS AT FRAME 65 DAMAGED AND BENT. REMOVED BAGGAGE COMP FLOOR STRUCTURE T-PROFILE ON LH OMEGA BEAM FR65. INSTALLED T-PROFILE BETWEEN LH AND CENTER OMEGA BEAMS AT FRAME 65.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 39,237 hrs · 25,506 cycles

LAV SMOKE IN FLIGHT. COMPLIED WITH FIM. NO SMOKE/ABNORMAL SMELL IN THE CABIN/COCKPIT, PERFORMED HIGH POWER ENGINE RUN 3 MIN. NO SMOKE ABNORMAL SMELL IN CABIN/COCKPIT. OPS CHECK SAT.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 39,133 hrs · 25,406 cycles

BURNING SMELL IN FLIGHT. PACK 2 IN MANUAL MODE, ALL THE WAY COLD. CREW PUT THE PACK 2 BACK IN AUTO MODE, AND THE SMELL SEEMED TO CLEAR. ALL INDICATIONS NORMAL, NO EICAS MESSAGES. POWER SETTING NEAR IDLE WHEN IT HAPPENED. NO SMOKE BAGGAGE/LAV ALARMS OR VISIUAL INDICATIONS. COCKPIT AND CABIN, STRONG SMELL, SMELLED LIKE A BURNING MATCH, NO VISIBLE INDICATIONS IN COCKPIT, A SLIGHT HAZE IN THE CABIN, AROUND ROW 9 AND 11, LASTED 3-5 MINUTES. DURING DECENT, 21,000FT DESCENDING BLEED 1/2 ON, APU BLLED OFF, CROSS BLEED AUTO, BOTH PACKS ON. HAPPENED IN ICING CONDITIONS, DID NOT DEICE PRIOR TO TAKEOFF. COMPLIED WITH FIM. NO SMELL PRESENT. NO FAULTS FOUND. VISUALLY INSPECTED #2 ACM. NO DEFECTS NOTED AT THIS TIME.

Part: ACCESS PANEL — DAMAGED (NR 1 NACELLE) · airframe 38,998 hrs · 25,279 cycles

E1 2 ACCESS PANELS OPEN UPON LANDING. PERFORMED GVI OF E1. NO DEFECTS FOUND. INSPECTED E1 COWLING (INTERNALLY AND EXTERNALLY) AND SURROUNDING AREA. FOUND THE AIR START VALVE ACCESS PANEL AND THE OIL SERVICE PANEL WERE LEFT OPEN IN FLIGHT. NO DAMAGE WAS OBSERVED ON THE AIR START VALVE ACCESS PANEL AND THE PANEL WAS SECURED CLOSED. THE OIL SERVICE DOOR HINGE WAS FOUND BENT AND DISTORTED. FOUND 3 AREAS OF SCRATCHES/CRACKS ON THE LOWER COWL CAUSED BY THE OIL SERVICE DOOR. EACH SECTION OF DAMAGE ON THE LOWER COWL WAS NO MORE THAN 3 INCHES IN LENGTH AND FURTHER THAN 6 INCHES FROM EACH OTHER. DURING THE ATTEMPT TO RESECURE THE OIL SERVICE DOOR, THE RIVETS WERE REMOVED FROM THE OIL SERVICE DOOR HINGE. REMOVED AND REPLACED E1 LOWER COWLING.

Part: LIGHT — INOPERATIVE (UNKNOWN) · airframe 38,962 hrs · 25,250 cycles

SERVICE DOOR EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED SERVICE DOOR EXTERNAL EMERGENCY LIGHT. OPS CHECK FAIL. REMOVED AND REPLACED SERVICE DOOR EXTERNAL EMERGENCY LIGHT ASSEMBLY. OPS CHECK GOOD.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 38,485 hrs · 24,801 cycles

RH EMERGENCY EXIT DOOR LINER NEEDS ADJUSTED DOWN. ADJUSTED RH EMERGENCY EXIT DOOR LINER.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 38,485 hrs · 24,801 cycles

LH OVERWING EMERGENCY EXIT DOOR IS BINDING AND WILL NOT OPEN. ADJUSTED LH EMERGENCY EXIT DOOR LINER

Part: DISPLAY — BURNED (NOT REPORTED) · airframe 38,285 hrs · 24,609 cycles

EICAS WENT BANK. LOSS OF ELECTRICAL POWER TO EICAS. REMOVED EICAS DISPLAY UNIT, FOUND BURNING SMELL COMING FROM EICAS DISPLAY UNIT. OPS CHECK DONE, NO FURTHER BURNING SMELL DETECTED.

Part: LAMP — INOPERATIVE · airframe 37,607 hrs · 23,976 cycles

SERVICE DOOR EXTERNAL EMERGENCY LIGHT INOP. R/R SERVICE DOOR EMERGENCY LIGHT LAMP. OP CHECK SAT.

Part: NONE — INOPERATIVE · airframe 37,336 hrs · 23,722 cycles

LH FWD EXTERNAL EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED LH FWD EXTERNAL EMERGENCY LIGHT BULB. REMOVED AND REPLACED LH FWD EXTERNAL EMERGENCY LIGHT ASSEMBLY. OPS CHECK GOOD AT THIS TIME.

Part: PUMP — LEAKING · airframe 36,561 hrs · 23,054 cycles

E1 HYD PUMP FAIL ON EICAS AFTER TAKE OFF. REMOVED AND REPLACED #1 EDP. OPS CHECK AND LEAK CHECK SAT AT THIS TIME

Part: LAMP — INOPERATIVE · airframe 36,560 hrs · 23,053 cycles

SIDE HINGED MAIN DOOR EXTERNAL EMERGENCY LIGHT NOT WORKING. REMOVED AND REPLACED EXTERNAL EMERGENCY DOME LIGHT ASSEMBLY AND BULB. OPS CHECK SAT

Part: NONE — NONE · airframe 36,292 hrs · 22,809 cycles

MAIN CABIN DOOR EMERGENCY LIGHT INOPERATIVE. R&R LIGHT BULB. OPS CHECK SAT.

Part: NONE — NONE · airframe 36,209 hrs · 22,736 cycles

RH SIDE EMERGENCY LIGHT STRIP FROM SEAT 3C TO 5C NOT GLOWING. CHECKED RH EMERGENCY ILLUMINE-SCENT STRIP BETWEEN ROW 3D TO 5D. FOUND EMERGENCY ILLUMINE-SCENT STRIP TO FUNCTION NORMALLY.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 36,059 hrs · 22,603 cycles

MCD ENTRANCE EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED MAIN DOOR EMERGENCY LIGHT LAMP. OPS CHECK SAT

Part: CABIN PRESSURE — FAULTED · airframe 35,732 hrs · 22,326 cycles

AIRCRAFT FAILED TO PRESSURIZE. PERFORMED CMC AND DFDR DOWNLOAD. PERFORMED PRESSURIZATION CONTROL SYSTEM OPERATIONAL CHECK. OPS CHECK SAT, NO DEFECTS NOTED. PER FDR DOWNLOAD ENGINE BLEEDS WERE IN THE OFF POSITION DURING FLIGHT AND ON DURING APPROACH.

Part: SWITCH — FAILED (MAIN DOOR) · airframe 35,643 hrs · 22,243 cycles

FA UNABLE TO OPEN MAIN DOOR, EXCESSIVE FORCE REQUIRED TO OPEN. R&R FWD TOP MICRO-SWITCH COVER ON MAIN DOOR. PERFORMED MAIN DOOR INTERNAL ACTUATING HANDLE TEST. DYNAMO-METER READS 80 FT-LBS OVER THE LIMIT. MEASUREMENT OF SKIN GAP BETWEEN MAIN DOOR AND FUSELAGE REQUIRED TO DETERMINE NECESSARY ADJUSTMENTS. PERFORMED MAIN DOOR INTERCONNECTING RODS RIGGING CHECK. FOUND RIG PIN C COULD NOT BE INSERTED INCLUDING PIN C. DOOR OPERATES NORMALLY WITH TRIM OFF. FOUND BOTH FWD & AFT LOWER LATERAL GUIDE SEATS TO HAVE WEAR & REQUIRE REPLACEMENT. PERFORMED PRELIMINARY CHECK OF INTERNAL ACTUATING HANDLE WITH TRIM OFF. GOT VALUE OF 48 LBS ON THE DYNAMO-METER, REQUIRES TO BE RE-ACCOMPLISHED ONCE TRIMS ON DUE TO PRIOR CHECK USED WRONG UNIT OF MEASURE. PRESSURIZED AIRCRAFT. NO BINDING OF DOOR NOTED. INSTALLED MCD TRIM AND R&R FWD AND AFT LWR LATERAL GUIDE SEATS. RIG CHECK SAT. PERFORMED ANOTHER PRESSURIZATION AND GOT A HANDLE FORCE VALUE OF 40 LBS. FORCE CHECK SAT. NO FURTHER DEFECTS NOTED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 35,636 hrs · 22,236 cycles

LH FUSE, RF2, CRACKS SUSPECTED AROUND RIVETS AT FR 77-78-79-80 BTW STR 3L-9L. LH FUSE RF2 BTW FR 77-80 AND BTW STR 3L-9L CRACKS REMOVED. LH FUSE RF 2 CRACKS AROUND RIVETS AT FR 77-80 BTW STR 3L-9L REPAIRED. AT FR 79, BTW STR 5L-6L, 2 CONSECUTIVE CRACKED HOLES REPAIRED WITH PATCH DOUBLER.

Part: SKIN — DENTED (PAX DOOR) · airframe 35,636 hrs · 22,236 cycles

DENT FOUND ON PAX DOOR BTW STR 8-10 BTW STA X4746-4903. ON PAX DOOR, BTW STA X4684, 5-X4903 AND BTW STR 8L-10L PAINT STRIP FOR INVESTIGATION. SKIN REPAIRED ON PAX DOOR. DVI USING 30X MAGNIFYING GLASSES C/OUT. NO FAULT.

Part: YOKE — CRACKED (ENGINE) · airframe 35,636 hrs · 22,236 cycles

2X CRACKS FOUND ON PYLON YOKES UPPER FLANGE 2X HOLE LOCATION. DAMAGES HOLES (2X) ON PYLON YOKES UPPER FLANGES AT LH AND RH ENG TO PYLON JUNCTION OVERSIZED AT 8.306 MM (0.326 IN). BUSHINGS FLUSH-PYLON AND (2X) BUSHINGS PYLON LOCALLY FABRICATED. DAMAGED HOLES (2X) ON PYLON YOKES UPPER FLANGE AT LH + RH ENG TO PYLON.

Part: FRAME — CRACKED (FRM 59) · airframe 35,636 hrs · 22,236 cycles

FR 59 CRACKED AT LH SIDE AT FLOOR LEVEL. FR59 AT LH SIDE AT FLOOR LEVEL REPAIRED.

Part: STRINGER — CORRODED (FRMS 23-24 S18R) · airframe 35,636 hrs · 22,236 cycles

STR 18 RH BTW FR 23-24 CORRODED. STR 18 RH BTW FR 23-24 CORROSION BLENDED OUT OF LIMITS BTW FR 23-24, RH STR 18 SOLID RIVETS (X9) REMOVED FOR SHEET METAL ACCESS. STR 18 RH BTW FR 22-24 REPAIRED.

Part: STRINGER — BENT (FRMS 12A-13 S20R) · airframe 35,636 hrs · 22,236 cycles

BLEND FOUND ON STR 20S BTW FR 12A-13. AREA ON STR 20S BTW FR 12A-13 STRIPPED AND ONE RIVET REMOVED FOR INVESTIGATION. DAMAGED AREA REMOVED. SKIN REPAIRED ON STR 20S BTW FR 12A-13

Part: UNKNOWN — MALFUNCTIONED (EMERGENCY LIGHT) · airframe 35,215 hrs · 21,835 cycles

DEN - FLIGHT 3938 THE EMERGENCY LIGHT STRIP AT SEAT 3A WOULD NOT GLOW. THE LIGHT STRIP WAS PLACED ON MEL 33-50-01, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE. ON 04/07 THE IAH MAINTENANCE INSPECTED THE AIRCRAFT, OPERATIONALLY TESTED THE EMERGENCY LIGHTS WITH NO DEFECTS NOTED, REMOVED THE MEL, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: CONTROL MODULE — INOPERATIVE (CABIN) · airframe 32,169 hrs · 19,604 cycles

GSO - FLIGHT 4011, THE CREW REPORTED THAT THE EMERGENCY LIGHT BUTTON ON THE FA PANEL WAS INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE FA CONTROL MODULE, OPERATIONALLY TESTED WITH NO DEFECTS AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: WINDOW POST — CRACKED (COCKPIT) · airframe 34,157 hrs · 27,593 cycles

CRACK ON LT LATERAL POST WINDSHIELD POST. INSTALLED REPAIR TO LT LATERAL POST FOR COCKPIT WINDSHIELD IAW EC/TC SB145-53-0079R1.

Part: CHECK VALVE — LEAKING (LT WING) · airframe 30,169 hrs · 18,209 cycles

AIRCRAFT DEVELOPED A FUEL LEAK DURING DEPARTURE FROM LEFT WING. AIR RETURNED TO DEPARTURE SAFELY. MX REMOVED AND REPLACED THE LT WING FUEL FLAP VALVE, LEAK CHECKED GOOD. ACFT WAS APRROVED FOR RETURN TO SERVICE.

Part: INVERTER — INOPERATIVE (EMERGENCY LIGHT) · airframe 27,475 hrs · 16,297 cycles

THE CREW REPORTED THAT THE EMERGENCY EXIT LIGHT NEAR MAIN CABIN DOOR WAS INOPERATIVE. MAINTENANCE R & R THE NR 1 EMERGENCY LIGHT INVERTER, OPERATIONALLY TESTED WITH NO DEFECTS NOTED, AND THE ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: FITTING — CRACKED (ENGINE MOUNT) · airframe 26,272 hrs · 15,451 cycles

DURING C-CK. LT ENGINE FWD LOWER YOKE IS CRACKED. R & R LT ENGINE FWD LOWER FITTING IAW EC5450-01179. ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: COFFEEMAKER — ODOR (GALLEY) · airframe 23,129 hrs · 13,305 cycles

NR 1 COFFEEMAKER PRODUCING A BURNING ODOR. MX R & R NR 1 COFFEEMAKER AND OPS CHECKED GOOD. ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: CONNECTOR — UNSECURE (EMERGENCY LIGHT) · airframe 22,402 hrs · 12,862 cycles

DURING MX INSPECTION, ROW 18 AFT EMERGENCY EXIT ROW EXIT SIGN WAS FOUND INOPERATIVE. MAINTENANCE INSPECTED AND SECURED A LOOSE CONNECTOR ON THE ROW 18 EMERGENCY EXIT SIGN. OPS CHECKED GOOD. ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: LIGHT — MALFUNCTIONED (CABIN) · airframe 21,992 hrs · 12,601 cycles

PILOT REPORTED THE AFT FACING CABIN OVERHEAD EMERGENCY EXIT SIGN INOPERATIVE. MAINTENANCE RESET THE EMERGENCY LIGHT SYSTEM AND PERFORMED AND OPS CHECKD GOOD. ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SIGN — INOPERATIVE (EMERGENCY LIGHT) · airframe 18,817 hrs · 10,596 cycles

DURING MX INSPECTION, THE AFT EMERGENCY EXIT SIGN WAS FOUND INOPERATIVE. MX R & R THE AFT EMERGENCY EXIT SIGN WITH OPS CHECK SUCCESSFUL. ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: FLAPPER VALVE — LEAKING (FUEL SYSTEM) · airframe 16,942 hrs · 9,377 cycles

THE CREW REPORTED THAT THEY LOST 400LBS OF FUEL FROM THE LEFT WING AFTER TAKEOFF. THE ACFT RETURNED TO DEPARTURE, WHERE IT LANDED WITHOUT INCIDENT. MX R & R THE FLAPPER VALVE ON THE LT WING , LEAK CHECK WITH NO DEFECTS NOTED AND THE ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SIGN — INOPERATIVE (CABIN) · airframe 16,423 hrs · 9,040 cycles

THE CREW REPORTED THAT THE EMERGENCY EXIT SIGN ABOVE THE F/A SEAT WAS INOPERATIVE. MX R & R THE SIGN ASSY, OPS TESTED WITH NO DEFECTS, AND THE ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: INVERTER — INOPERATIVE (EMERGENCY LIGHT) · airframe 16,423 hrs · 9,040 cycles

THE CREW REPORTED THAT THE EMERGENCY EXIT SIGN ABOVE THE F/A SEAT WAS INOPERATIVE. MX R & R THE EMERGENCY LIGHT INVERTER, OPERATIONALLY TESTED WITH NO DEFECTS, AND THE ACFT WAS APPROVED FOR RETURN TO SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 16,176 hrs · 8,866 cycles

DURING ROUTINE MX, THE FORWARD CABIN EMERGENCY LIGHT WAS FOUND INOPERATIVE. MX REPLACED THE FORWARD CABIN EMERGENCY LIGHT. OPS CHECKS WERE GOOD.

Part: ENGINE — SMOKE (NR 1) · airframe 15,621 hrs · 8,514 cycles

FLT 4405 THE CREW REPORTED SMOKE IN THE COCKPIT AND CABIN AT FL360 ACCOMPANIED WITH STRONG BURNING ODOR. THE ACFT DIVERTED INTO PIT AND LANDED WITHOUT INCIDENT. MX INSPECTED AND REPLACED THE NR 1 ENGINE. OPS CHECKED GOOD.

Part: SKIN — CRACKED (FUSELAGE) · airframe 14,712 hrs · 7,949 cycles

SHV - DURING C-CHECK THE LT AFT UPPER SKIN WAS FOUND TO BE CRACKED AROUND A RIVET AT FRAME 78 AND STRINGERS 5L-6L. MAINTENANCE REAMED OUT THE CRACKED AREA AND PERFORMED A DOUBLER REPAIR IAW EMB 145XR SRM 53-23-01. THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SKIN — CRACKED (FUSELAGE) · airframe 14,712 hrs · 7,949 cycles

SHV - DURING C-CHECK THE RT AFT UPPER SKIN WAS FOUND TO BE CRACKED AROUND A RIVET AT FRAME 78 AND STRINGERS 5R-6R. MAINTENANCE REAMED OUT THE CRACKED AREA AND PERFORMED A DOUBLER REPAIR IAW EMB 145XR SRM 53-32-01 FIG 204. THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: INVERTER — INOPERATIVE (CABIN) · airframe 14,591 hrs · 7,862 cycles

STL - THE CREW REPORTED AN EMERGENCY LIGHTS NOT ARMED MESSAGE INTERMITTANT ON EICAS, AND NOT ALL LIGHTS WORKING. MAINTENANCE REMOVED AND REPLACED THE NR 6 EMERGENCY LIGHT INVERTER, OPERATIONALLY TESTED WITH NO DEFECTS NOTED. THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: DISPLAY — FAILED (COCKPIT) · airframe 14,551 hrs · 7,838 cycles

GRR - FLIGHT 2027, THE CREW REPORTED THAT THE CAPTAINS MFD SCREEN BLACKED OUT IN FLIGHT FOLLOWED BY A SMELL OF SMOKE RESEMBLING BURNT WIRING, WITH NO EICAS MESSAGE. THE AIRCRAFT LANDED GRR WITHOUT INCIDENT WHERE MAINTENANCE INSPECTED THE AIRCRAFT AND PLACED THE CAPTAINS MFD ON MEL, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE. THE AIRCRAFT SUBSEQUENTLY LANDED AT IAH WHERE MAINTENANCE REMOVED AND REPLACED THE CAPTAINS MFD OPERATIONALLY TESTED WITH NO DEFECTS OR SMELL NOTED, REMOVED THE MEL, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 12,959 hrs · 6,954 cycles

RIC - DURING ROUTINE MAINTENANCE, RIC MX FOUND EMERGENCY EXIT LIGHT IN AISLE AT ROW 12 INOPERATIVE. MX RECONNECTED EMERGENCY LIGHT AND PERFORMED OPERATIONAL CHECK SUCCESSFULLY. ACFT WAS APPROVED TO RETURN TO SERVICE.

Part: SMOKE DETECTOR — FALSE ACTIVATION (CARGO BAY) · airframe 12,950 hrs · 6,950 cycles

IAH - FLIGHT 2320, DURING CLIMBOUT THE CREW REPORTED A BAGGAGE SMOKE INDICATION THAT REMAINED ON UNTIL TOUCHDOWN. THE CREW DISCHARGED THE FIRE BOTTLES, AND THE AIRCRAFT LANDED AT OAH WITHOUT INCIDENT. MAINTENANCE INSPECTED THE AIRCRAFT FOUND NO EVIDENCE OF SMOKE OR FIRE, AND REMOVED AND REPLACED BOTH SMOKE DETECTORS, OPERATIONALLY TESTED WITH NO DEFECTS, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SMOKE DETECTOR — FALSE ACTIVATION (CARGO BAY) · airframe 12,950 hrs · 6,950 cycles

IAH - FLIGHT 2320, DURING CLIMBOUT THE CREW REPORTED A BAGGAGE SMOKE INDICATION THAT REMAINED ON UNTIL TOUCHDOWN. THE CREW DISCHARGED THE FIRE BOTTLES, AND THE AIRCRAFT LANDED AT OAH WIOTHOUT INCIDENT. MAINTENANCE INSPECTED THE AIRCRAFT FOUND NO EVIDENCE OF SMOKE OR FIRE, AND REMOVED AND REPLACED BOTH SMOKE DETECTORS, OPERATIONALLY TESTED WITH NO DEFECTS, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: BLEED VALVE — STICKING (NR 1 ENGINE) · airframe 12,814 hrs · 6,875 cycles

IAH FLT 2568 THE CREW REPORTED ON CLIMB THRU FL340 TO FL350 THE NR 1 ENGINE ITT SPIKED INTO THE AMBER RANGE REACHING 917. PULLED BACK AND THE ITT REDUCED AND THEN THE POWER WAS ADVANCED AND ALL INDICATIONS WERE NORMAL. EICAS DISPLAYED WAS E1 EXCEEDANCE. MAINTENANCE INSPECTED AND REPLACED THE NR 1 ENGINE COMPRESSOR BLEED VALVE. OPERATIONAL CHECKS WERE GOOD.

Part: AIR DUCT — BLOWN (AC BAY) · airframe 12,042 hrs · 6,438 cycles

TYS - A/C EN ROUTE FROM MSY TO EWR WHEN CREW STARTED HAVING ISSUES WITH PRESSURIZATION. DIVERTED INTO TYS WHERE MAINTENANCE FOUND THE AC CONNECTION BLOWN OFF. MAINTENANCE RE-SECURED THE DUCT, OPS CHECK GOOD. A/C CONTINUED ON TO EWR AT 13:16.

Part: O-RING — BLOWN (BLEED AIR SYS) · airframe 11,657 hrs · 6,231 cycles

IAH - FLIGHT 2617, DURING CLIMBOUT OF IAH THE CREW REPORTED A BLEED 1 LEAK INDICATION. THE AIRCRAFT RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE O-RINGS ON THE NUMBER ONE COUPLING. LEAK CHECKED WITH NO DEFECTS, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: LIGHT — INOPERATIVE (SEAT 12 A) · airframe 11,604 hrs · 6,203 cycles

TYS - A/C WAS IN FOR A-CHECK WHEN THE EXIT SIGN AT ROLL 12A WAS FOUND TO BE INOP. MAINTENANCE REMOVED AND REPLACED THE EXIT SIGN IAW EMB 145XR AMM 33-50-10. OPS CHECK GOOD AND WAS RELEASED.

Part: INVERTER — INOPERATIVE (CABIN) · airframe 11,112 hrs · 5,944 cycles

DURING ROUTINE MAINTENANCE THE EMERGENCY EXIT SIGN IN FRONT OF SEAT 3B WAS FOUND INOPERATIVE. MAINTENANCE INSPECTED AND REPLACED THE NR 3 EMERGENCY LIGHT INVERTER. OPERATIONAL CHECKS WERE GOOD.

Part: WIRE — LOOSE (CABIN) · airframe 10,747 hrs · 5,752 cycles

TUS - FLIGHT 2630, DURING PREFLIGHT INSPECTION THE CREW REPORTED AN EMERGENCY EXIT LOCATOR AT THE EXIT ROW TO BE INOPERATIVE. CONTRACT MAINTENANCE RE-SECURED THE WIRING TO THE EXIT IDENTIFIER, OPERATIONALLY TESTED WITH NO DEFECTS, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 10,507 hrs · 5,628 cycles

IAH - FLIGHT 2010, DURING PRE-FLIGHT INSPECTION THE CREW REPORTED AN EXIT ROW CEILING LIGHT TO BE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE AFFECTED CEILING LIGHT, OPERATIONALLY TESTED WITH NO DEFECTS. THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SIGN — INOPERATIVE (CABIN) · airframe 10,517 hrs · 5,635 cycles

MCI - FLIGHT 2669, DURING POST-FLIGHT INSPECTION THE CREW REPORTED THAT THE AFT EMERGENCY EXIT SIGN WAS FOUND TO BE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE AFFECTED SIGN, OPERATIONALLY TESTED WITH NO DEFECTS NOTED, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: SIGN — MALFUNCTIONED (CABIN) · airframe 10,325 hrs · 5,527 cycles

CLE FLT 2101 THE CREW REPORTED THE OVERHEAD EMERGENCY EXIT SIGN WAS INOPERATIVE. MAINTENANCE INSPECTED AND PERFORMED OPERATIONAL CHECKS AND NO DEFECTS WERE FOUND.

Part: INVERTER — INOPERATIVE (CABIN) · airframe 9,686 hrs · 5,185 cycles

RIC MX - DURING ROUTINE MAINTENANCE, MX FOUND ROW 12 OVERHEAD FWD FACING EXIT SIGN IS INOPERATIVE. MX REMOVED AND REPLACED INVERTER AND PERFORMED OPERATIONAL CHECK SUCCESSFULLY. ACFT WAS APPROVED TO RETURN TO SERVICE.

Part: CARBON SEAL — FAILED (NR 4) · airframe 9,198 hrs · 4,923 cycles

ALB FLT 2983 - THE CREW REPORTED SMOKE HAZE IN THE COCKPIT SHORTLY AFTER TAKEOFF THEN DISSIPATED. ALSO REPORTED A LAV SMOKE WARNING MSG ON THE EICAS FOR ABOUT A MINUTE. MAINTENANCE INSPECTED AND REPLACED THE NR 1 ENGINE. THE TEAR DOWN REPORT FROM ROLLS ROYCE INDICATED THE PRIMARY CAUSE OF SMOKE/HAZE IN THE COCKPIT WAS THE NR 4 CARBON SEAL. THE ENGINE WAS REPAIRED TO SERVICEABLE CONDITION.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 9,091 hrs · 4,863 cycles

IAH - FLIGHT 2528, DURING PREFLIGHT THE CREW REPORTED THE SERVICE DOOR EXTERNAL EMERGENCY LIGHT TO BE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE LIGHT BULB, OPERATIONALLY TESTED WITH NO DEFECTS, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: FLAPPER VALVE — LEAKING (RT WING) · airframe 9,021 hrs · 4,825 cycles

FLIGHT 2245 - EWR - FLIGHT CREW REPORTED RIGHT WING LEAKING FUEL. CREW PERFORMED AIR RETURN AND LANDED ACFT UNEVENTFULLY. EWR MX REMOVED AND REPLACED FLAPPER VALVE AND PERFORMED OPERATIONAL CHECK SUCCESSFULLY. ACFT WAS APPROVED TO RETURN TO SERVICE.

Part: COVER — BROKEN (GPU DOOR) · airframe 7,732 hrs · 4,149 cycles

FLT 2925 - EWR - FLIGHT CREW REPORTED A LOUD POP FOLLOWED BY A VIBRATION FROM THE NOSE OF THE AIRCRAFT DURING CLIMBING. CREW PERFORMED AIR RETURN AND LANDED AIRCRAFT UNEVENTFULLY. EWR MX FOUND GPU DOOR OPEN AND LATCH BROKEN. MX REMOVED AND REPLACED GPU DOOR COVER ASSEMBLY AND PERFORMED FUNCTIONAL CHECK SUCCESSFULLY. AIRCRAFT WAS APPROVED TO RETURN TO SERVICE.

Part: STARTER GEN — MALFUNCTIONED (APU) · airframe 6,931 hrs · 3,711 cycles

IAH - FLIGHT 3020, THE CREW REPORTED A BURNING SMELL AFTER THE APU START. THE APU THEN FAILED AND WOULD NOT RESTART. THE AIRCRAFT RETURNED TO THE GATE WHERE MAINTENANCE PLACED THE APU ON MEL 49-00-00 CAT - C CTL NUMBER 157685, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE. THE AIRCRAFT RETURNED TO IAH ON 11/04/08 WHERE MAINTENANCE REMOVED AND REPLACED THE APU STARTER GENERATOR, OPERATIONALLY CHECKED WITH NO DEFECTS, REMOVED THE MEL, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: PUMP — FAILED (FUEL SYSTEM) · airframe 6,881 hrs · 3,682 cycles

IAH - FLIGHT 2196, THE CREW ABORTED TAKEOFF AT 60KIAS DUE TO E2 LOW FUEL PRESSURE MESSAGE ON EICAS. MAINTENANCE PLACED THE FUEL PUMPS ON MEL 28-21-01 CAT C CTL 157306, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE. ON 10/28/08 THE AIRCRAFT RETURNED TO IAH WHERE MAINTENANCE REMOVED AND REPLACED ELECTRIC FUEL PUM 2C, OPERATIONALLY CHECKED WITH NO DEFECTS, CLEARED THE MEL, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: PUMP — FAILED (FUEL SYSTEM) · airframe 6,881 hrs · 3,682 cycles

IAH - FLIGHT 2196, THE CREW ABORTED TAKEOFF AT 60KIAS DUE TO E2 LOW FUEL PRESSURE MESSAGE ON EICAS. MAINTENANCE PLACED THE FUEL PUMPS ON MEL 28-21-01 CAT C CTL 157306, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE. ON 10/28/08 THE AIRCRAFT RETURNED TO IAH WHERE MAINTENANCE REMOVED AND REPLACED ELECTRIC FUEL PUMP 2B, OPERATIONALLY CHECKED WITH NO DEFECTS, CLEARED THE MEL, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: INVERTER — INOPERATIVE (EMERGENCY LIGHTS)

SLC-FLIGHT 7672, DURING PREFLIGHT INSPECTION THE CREW REPORTED THAT THE FORWARD EMEGENCY EXIT SIGN WAS INOPERATIVE. MAINTENANCE OPERATIONALLY CHECKED THE EMERGENCY LIGHTING WITH NO DEFECTS NOTED AND THE ACFT WAS APPROVED FOR RETURN TO SERVICE. DURING POST FLIGHT INSPECTION ON FLIGHT 7672 IN MCI, THE DISCREPANCY REPEATED. MAINTENANCE REMOVED AND REPLACED THE NR 6 EMERGENCY LIGHT INVERTER, OPERATIONALLY CHECKED WITH NO DEFECTS, AND THE ACFT WAS APPROVED FOR RETURN TO SERVICE. (S)

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT)

FLT 7751 - LAX - FLIGHT CREW REPORTED EXIT LIGHT CEILING SIGN AT ROW 12 INOPERATIVE. MAINTENANCE PERSONNEL REMOVED AND REPLACED EXIT LIGHT CEILING SIGN EMERGENCY BATTERY NR 4. OPERATIONALLY CHECKED SATISFACTORY AND ACFT WAS RELEASED TO RETURN FOR SERVICE. (S)

Part: PROXIMITY SWITCH — INOPERATIVE (NLG)

FLT 0117 - ONT - FLIGHT CREW REPORTED A LOUD BANGING NOISE ON GEAR RETRACTION WHILE CLIMBING. FLIGHT CREW RETURNED TO BLOCK. MAINTENANCE INSPECTED, REMOVED AND REPLACED NLG UPLOCK BOX PROXIMITY SWITCH AND PERFORMED A TEST FLIGHT. OPERATIONALLY CHECKED SATISFACTORY AND ACFT WAS RELEASED TO RETURN FOR SERVICE. (S)

Part: SIGN — BURNED OUT (EMERGENCY LIGHTS)

FLT MX - ONT - WHILE PERFORMING ROUTINE CHECK INSPECTION ON CENTER CEILING, FWD EMERGENCY EXIT LIGHT SIGN INOPERATIVE. MAINTENANCE REMOVED AND REPLACED FWD EMERGENCY CEILING EXIT LIGHT SIGN. OPERATIONALLY CHECKED SATISFACTORY AND ACFT WAS RELEASE TO RETURN TO SERVICE. (S)

Part: CONNECTOR — LOOSE (EMERGENCY LIGHTS)

FLT MX - ONT - WHILE PERFORMING 1A CHECK AND OPERATIONAL CHECK OF THE FWD EXIT SIGN AT ROW 12, IT WAS FOUND NOT ILLUMINATING. MAINTENANCE PERSONNEL FOUND LOOSE CONNECTOR AND RE-ADJUSTED. OPERATIONALLY CHECKED SATISFACTORY AND ACFT WAS RELEASED TO RETURN FOR SERVICE. (S)

Part: SWITCH — OUT OF ADJUST (EMERGENCY EXIT) · airframe 455 hrs · 247 cycles

OMA FLIGHT 2078, CREW REPORTED ON T/O ROLL EMERGENCY EXIT OPEN LIGHT INDICATION CAME ON. THE INDICATION WAS THE LEFT WING EMERGENCY EXIT. LIGHT WENT OUT IN FLIGHT. THE EXIT DOOR WAS VERIFIED CLOSED WITH NO PRESSURIZATION LOSS. MAINTENANCE INSPECTED AND RELEASED A/C IAW 52-70-00/3. THE LEFT EMERGENCY EXIT DOOR MICROSWITCH WAS ADJUSTED AND OPERATIONAL CHECKS WERE GOOD. THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: BULB — LOOSE (EMERGENCY LIGHT) · airframe 123 hrs · 65 cycles

IAH - DURING PREFLIGHT INSPECTION THE EMERGENCY EXIT LIGHT ON THE DOOR WAS FOUND TO BE INOPERATIVE. MAINTENANCE REPOSITIONED THE LIGHT BULB, OPERATIONALLY CHECKED WITH NO DEFECTS, AND THE AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.