N12811

Part: FAN — SEIZED (AIR DISTRIBUTION) · airframe 55,821 hrs · 26,439 cycles

A/C HAD A CHRONIC INFLT PROBLEM WITH AN ELECTRICAL ODOR AFT. TROUBLESHOOTING PERFORMED. SOURCE OF ODOR APPEARED TO BE COMING FROM AFT GALLEY. COFFEEMAKERS, OVENS, & ACCESS PANELS INSPECTED, NO EVIDENCE OF BURNING. PACK BURNOUT PERFORMED & COALESCER BAGS R & R. ALL OVERHEAD LIGHTS & ELECTRICAL PANELS IN 1ST CLASS INSPECTED, NO ODOR OR BURNING. FOUND RECIRC FAN "FROZEN" CAUSING CIRCUIT BREAKERS TO POP. RECIRC FAN R & R, OPS CHK GOOD IAW MM 21-20-12. MAINT CHKED ALL 3 AFT GALLEY OVENS, NO INDICATION OF LOOSE TERMINALS OR ARCING WIRES. TERMINAL STRIP CONNECTIONS & GROUND STUDS SECURE. 2 FLTS FLOWN SINCE REPLACE OF RECIRC FAN, NO CABIN OR GALLEY ODOR REPORTED. SOURCE OF ODOR ATTRIB TO A FAULTY RECIRC FAN.

Part: BELTFRAME — CRACKED (STA 1418) · airframe 52,768 hrs · 24,900 cycles

INSPECTION FOUND A 1" CRACK IN TAIL COMPARTMENT BELTFRAME AT STA 1418, LONGERON 1. REPAIRED BELTFRAME IAW SRM 53-03, FIGURE 4.

Part: WEB — CRACKED (STA 1463) · airframe 52,768 hrs · 24,900 cycles

INSPECTION FOUND TAIL COMPARTMENT BELTFRAME WEB CRACKED AT STA 1463 L18R AND L18L. BOTH CRACKS WERE 2" LONG. THE CRACKS WERE STOP DRILLED AND DOUBLERS WERE INSTALLED IAW SRM 53-01, FIGURE 2.

Part: PAN — CHAFED (CARGO DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND AFT BAG BIN DOOR PAN CHAFED AT STOP PAD AREAS. REPAIRED IAW ECRA 5230-01540.

Part: ANGLE — CRACKED (VERTICAL STAB) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND LT VERTICAL STABILIZER TO FUSELAGE ATTACH ANGLE CRACKED AT STA 1474 - 1485. THERE WERE FIVE CRACKS TOTALING 8 INCHES IN COMBINED LENGTH. THE ATTACH ANGLE WAS REMOVED AND REPLACED IAW SRM 51-30-05 AND 51-30-01.

Part: PAN — CHAFED (CARGO DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND DOOR PAN CHAFED BY DOOR STOP IN TWO PLACES AT AFT SIDE AND THREE PLACES AT FORWARD SIDE, FORWARD BAGGAGE BIN. REPAIRED IAW ECRA 5230-01540.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND A HALF INCH CRACK IN LONGERON 4 LT AT STA 160. THE LONGERON WAS REPAIRED IAW ECRA 5310-04005.

Part: CABLE — OUT OF RIG (TAILCONE) · airframe 48,460 hrs · 22,600 cycles

THE FORCE REQUIRED TO DROP THE TAIL CONE USING INTERIOR AND EXTERIOR RELEASE HANDLES EXCEEDED 35 POUNDS. THE TAIL CONE RELEASE SYSTEM CABLES WERE ADJUSTED IAW MM 53-53-00.

Part: FRAME — WORN (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND A HOLE WORN INTO FRAME WEB AT STA 1380 AT LT AIR CONDITIONING TEMP CONTROL VALVE. REPAIRED FRAME WEB IAW SRM 53-01.

Part: BEAM — CRACKED (SERVICE DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND A 1 INCH CRACK IN FORWARD SERVICE DOOR LOWER FORWARD BEAM. THE BEAM WAS REMOVED AND REPLACED IAW SRM 51-30-2.

Part: PAN — WORN (CARGO DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND FORWARD CARGO BIN LOWER DOOR PAN WORN IN TWO PLACES BY DOOR STOPS. TWO STRAPS WERE INSTALLED IAW ECRA 5330-02819.

Part: PAN — WORN (CARGO DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND FORWARD CARGO DOOR OUTER PAN WORN AT DOOR STOP PADS. REPAIRED AFT STOPS IAW ECRA 5330-02819.

Part: PAN — CRACKED (CARGO DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND MID CARGO BIN DOOR PAN CRACKED AT FORWARD AND AFT LATCH. REPAIRED IAW SRM 52-05, FIGURE 26A.

Part: SKIN — GOUGED (CARGO DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND FORWARD CARGO DOOR SKIN GOUGED AT DOOR BOTTOM. REPAIRED IAW SRM 52-03, FIGURE 7.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND AFT CARGO BIN LEFT AND RIGHT TIEDOWN TRACKS CORRODED AROUND NUT PLATE HOLES AT STA 1022. THE TIEDOWN TRACKS WERE REMOVED AND REPLACED IAW SRM 51-10-3 AND 51-30-5.

Part: FLOORBEAM — GOUGED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND A HOLE GOUGED IN CABIN FLOORBEAM AT STA 396. A REPAIR WAS INSTALLED IAW SRM 53-05 SHEETS 1, 2 & 3.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND A .5 INCH CRACK IN LONGERON 2R JUST OVER BELTFRAME AT STA 1429. A NEW SECTION OF LONGERON WAS SPLICED IN IAW SRM 53-02, FIGURE 18, SHEET 2.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND RT O/B SEAT TRACK CORRODED IN FORWARD GALLEY AREA AT STA 218-266. THE SEAT TRACK WAS REPLACED IAW SRM 53-05, FIGURE 4F.

Part: BELTFRAME — CORRODED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND AFT BAG BIN BELTFRAME CORRODED AT STA 1238, LONGERON 24L. THE CORROSION WAS REMOVED, TREATED, AND PRIMED IAW SRM 53-01, FIGURE 1.

Part: SKIN — DENTED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND FUSELAGE SKIN DENTED AT STA 389, LONGERON 29R TO 30. A REPAIR WAS INSTALLED IAW ECRA 5330-02800.

Part: BELTFRAME — CORRODED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND BELTFRAME CORRODED ON AFT SIDE AT STA 541 FROM LONGERON 29L TO 29R. THE CORROSION WAS REMOVED, TREATED AND PRIMED AREA IAW SRM 51-10-3 AND REINSTALLED FASTENERS IAW SRM 51-30-5.

Part: PAN — CRACKED (CARGO DOOR) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND AFT BAG BIN DOOR EXTERIOR HANDLE PAN GOUGED WITH A 1 INCH CRACK. THE PAN WAS REMOVED AND REPLACED IAW MM 51-30-02.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND A .5 INCH CRACK IN MAIN CABIN FLOOR SUPPORT AT STA 826 UNDER RIGHT I/B SEAT TRACK. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 51-30-1.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND FORWARD R-1 ENTRY SLIDE ARMING BAR ATTACHED FORWARD AND AFT FLOOR SUPPORTS CORRODED. THE SUPPORTS WERE REMOVED AND NEW ONES WERE INSTALLED IAW SRM 51-30-1.

Part: SEAT TRACK — CRACKED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND A .75 INCH CRACK IN MAIN CABIN FLOOR SUPPORT AT STA 927 BELOW LT O/B SEAT TRACK. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 51-30-0.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND LT CENTER SEAT TRACK CORRODED ON BOTH SIDES OF FLOOR SUPPORT FLANGES FROM FS 1041 - 1309. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 51-30-00.

Part: SKIN — DENTED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND FUSELAGE SKIN DENTED AND GOUGED AT STA 120-133, LONGERON 23R. A REPAIR WAS INSTALLED IAW SRM 53-04, FIGURE 38.

Part: SKIN — DENTED (FUSELAGE) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND LT FUSELAGE SKIN DENTED AT STA 712, LONGERON 20L. A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-04, FIGURE 38.

Part: LINE — FRAYED (EMERGENCY EXIT) · airframe 48,460 hrs · 22,600 cycles

INSPECTION FOUND THE LEFT AND RIGHT OVERWING EMERGENCY ESCAPE LINES FRAYED AT ATTACH HOOK. THE EMERGENCY ESCAPE LINES WERE REMOVED AND REPLACED IAW MM 25-60-00.

Part: ACTUATOR — BURNT (SPOILER)

THE CO-PILOT OBSERVED SMOKE COMING FROM THE THROTTLE QUADRANT AFTER TAKEOFF FROM COS. THE ELECTRICAL FIRE/SMOKE OF UNKNOWN ORIGIN EMERGENCY LIST WAS INITIATED AND THE AIRCRAFT WAS RETURNED TO COS WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE AUTO SPOILER ACTUATOR BURNT WITH CIRCUIT BREAKER POPPED. THE AUTO SPOILER ACTUATOR WAS REMOVED AND REPLACED IAW MM 27-62-05. IN ADDITION, THE SPOILER CONTROL BOX WAS REMOVED AND REPLACED IAW MM 27-62-07. OPERATIONAL CHECKS WERE GOOD.

Part: BEAM — CRACKED (PAX DOOR)

INSPECTION FOUND A 1 INCH CRACK AT FORWARD END AND AFT END OF NR 1 DOOR BEAM OF MAIN CABIN DOOR. A NEW NR 1 MAIN CABIN DOOR BEAM WAS INSTALLED IAW SRM 51-30-1, 51-30-2, AND 51-30-5.

Part: INTERCOSTAL — CRACKED (PAX DOOR)

INSPECTION FOUND A 1 INCH CRACK IN RADIUS OF MAIN CABIN DOOR INTERCOSTAL AFT OF HANDLE TORQUE SHAFT. THE INTERCOSTAL WAS REPLACED IAW SRM 51-30-02 AND 51-30-05.

Part: PIVOT PLATES — CORRODED (LT HOR STAB)

INSPECTION FOUND LT HORIZONTAL STABILIZER INBOARD AND OUTBOARD SET OF PIVOT PLATES CORRODED. THE PIVOT PLATES WERE REPLACED IAW SRM 51-30-5.

Part: SKIN — CRACKED (PAX DOOR)

INSPECTION FOUND A 1 INCH CRACK IN MAIN CABIN DOOR EXTERIOR SKIN AROUND HOLD OPEN HOOK CUTOUT. A DOUBLER WAS INSTALLED IAW SRM 52-05, FIGURE 20A, PAGE 43.

Part: RETRACT MECH — MALFUNCTIONED (NLG)

THE AIRCRAFT WAS STUCK IN GROUND MODE AND THE GEAR WOULD NOT RETRACT AFTER TAKEOFF. QRH PROCEDURES WERE COMPLIED WITH AND THE AIRCRAFT WAS RETURNED TO IAH WHERE IT MADE A NORMAL LANDING. MAINTENANCE CHECKED THE GROUND SENSING SWITCHES IAW MM 32-23-01 AND NO FAULTS WERE FOUND. THE FAILURE COULD NOT BE DUPLICATED. THE NOSE GEAR STRUT WAS SERVICED IAW MM 32-21-02 AND THE NOSE GEAR WAS LUBRICATED.

Part: BUS CONTROL — MALFUNCTIONED (E/E COMPT)

ALL ELECTRICAL POWER FELL OFF LINE AND ARTS WAS INITIATED AFTER TAKEOFF. EMERGENCY POWER WAS TURNED ON, THE APU GENERATOR WAS PUT ON LINE, PARTIAL POWER WAS RESTORED. WHEN ATTEMPTING TO TURN EMERGENCY POWER OFF A LOUD HUM WAS HEARD FROM CIRCUIT BREAKER PANEL. THE EMERGENCY POWER WAS PUT BACK ON AND THE AIRCRAFT WAS RETURNED TO TPA. ALSO, A SLIGHT ELECTRICAL BURNING ODOR WAS OBSERVED. MAINTENANCE FOUND THE LEFT AC BUS LOWER PHASE C-50 AMP CIRCUIT BREAKER POPPED. THE CIRCUIT BREAKER WAS RESET AND THE HUMMING SOUND STOPPED. VOLTAGE DROP ACROSS RELAYS WAS CHECKED WITH NO TROUBLE FOUND. THE AC BUS CONTROL UNIT WAS REPLACED AS A PRECAUTIONARY MEASURE. THE ENGINES WERE RUN AND THE CROSSTIE SYSTEM TESTED GOOD,

Part: AIRSEAL — WORN (NR 1 ENGINE)

THE NR 1 ENGINE SPOOLED DOWN ACCOMPANIED BY A LOUD EXPLOSION WHILE CLIMBING THROUGH FL 310. ABNORMAL PROCEDURES WERE COMPLIED WITH AND THE AIRCRAFT WAS RETURNED TO SFO WHERE IT LANDED WITHOUT INCIDENT. THE NR 1 ENGINE WAS REMOVED AND REPLACED. THE SDR WILL REMAIN OPEN FOR PART INFORMATION PENDING INVESTIGATION. *S/D* SHOP FINDINGS REVEALED A WORN T2 INNER AIRSEAL.

Part: SKIN — CRACKED (WS 242)

IAH - FLT 1707 - INSPECTION FOUND A 5.25 INCH CRACK IN LEFT WING LEADING EDGE SKIN AT STA 242. A DOUBLER REPAIR WAS INSTALLED IAW ECRA 5730-01428. (X)

Part: EEL BATTERIES — INOPERATIVE (CABIN)

FLT NR 0299 - EWR - INSPECTION FOUND THE INTERIOR EMERGENCY EXIT LIGHTS AT ROW 6-9 AND AT ENTRANCE TO COCKPIT DOOR INOPERATIVE. THE BATTERIES AT ROW 7 AND IN THE FORWARD OVERHEAD CEILING COMPARTMENT WERE REPLACED. OPERATION OF THE EMERGENCY EXIT LIGHTS WAS RESTORED. (M)