N14062

Part: SKIN — CORRODED (BS 1761)

INSPECTION FOUND LOWER FUSELAGE SKIN CORRODED WITH A PULLED RIVET AT STA 1761 BETWEEN STRINGER 45R AND 47R. REPAIRED IAW SRM 51-71-00.

Part: DOOR SILL — CORRODED (CARGO BAY)

INSPECTION FOUND FORWARD CARGO DOOR JAMB LOWER AFT CORNER DOOR SILL CORRODED. THE DOOR SILL WAS REPAIRED IAW SRM 53-70-00.

Part: SUPPORT — CORRODED (RT MLG)

INSPECTION FOUND THE RT MLG CYLINDER SUPPORT FRAME CORRODED IN ATTACHMENT BOLT HOLES. REPAIRED IAW ECRA 5743-01013.

Part: ACTUATOR — LEAKING (NLG DOWNLOCK)

THE NLG WAS VERY SLOW TO EXTEND AND INDICATE DOWN WHEN GEAR WAS LOWERED DURING TEST FLIGHT WHILE AIRCRAFT WAS IN D-CHECK AT MAN. MAINTENANCE FOUND THE NLG DOWNLOCK ACTUATOR LEAKING INTERNALLY. THE ACTUATOR WAS REMOVED AND REPLACED IAW MM 32-35-00.

Part: STIFFENER — CORRODED (BS 475)

INSPECTION FOUND CORROSION AT LOWER LT CORNER OF DOOR IN AVIONICS COMPT AT REAR PRESSURE BULKHEAD STA 475, LT HORIZONTAL AND VERTICAL BEHIND GUSSET PLATE. THE AREA WAS REPAIRED IAW SRM 53-12-01.

Part: FRAME — CORRODED (BS 450)

INSPECTION FOUND CORROSION IN FRAME AND INTERCOSTALS IN AVIONICS BAY AT STA 450 BETWEEN STRINGER 44 AND 64L. THE AREA WAS REPAIRED IAW SRM 53-30-00.

Part: LONGERON — CRACKED (BS 1129)

INSPECTION FOUND A 2 INCH CRACK IN LONGERON AT STA 1129, STRINGER 36R. THE LONGERON WAS REMOVED AND REPLACED IAW SRM 53-10-00.

Part: LONGERON — CRACKED (BS 1129)

INSPECTION FOUND A 2 INCH CRACK IN LONGERON AT STA 1129, STRINGER 36L. THE LONGERON WAS REMOVED AND REPLACED IAW SRM 53-00-00.

Part: BULKHEAD — FRETTED (BS 1521)

INSPECTION FOUND, FRETTING ON CLG AFT PRESSURE BULKHEAD AT STA 1521. A REPAIR WAS ACCOMPLISHED IAW DOUGLAS DRAWING 90-53-1022.

Part: ANGLE — CRACKED (VERT STAB)

INSPECTION FOUND A 1.2 INCH CRACK IN RT LOWER VERTICAL STABILIZER DRAG ANGLE AT FORWARD CENTER SPAR POSITION. THE ANGLE WAS REPAIRED IAW SRM 53-20-00, FIGURE 3.

Part: FRAME — CRACKED (LT MLG)

THE A/C LOST NR 3 HYDRAULIC SYSTEM AND GEAR UNSAFE LIGHT ILLUMINATED WHILE INBOUND TO EWR. THE A/C WAS TAKEN OUT OF SERVICE FOR T/S. INITIAL FINDINGS REVEALED THE LT MLG RETRACT ACTUATOR SUPPORT FRAME ASSEMBLY WAS CRACKED. THE SUPPORT FRAME WAS REMOVED AND REPLACED. THE BOLTS WERE TORQUED IAW SRM 51-31-01, PAGE 41 AND ECRA 5740-01817. THE LT MLG RETRACT ACTUATOR WAS REMOVED AND REPLACED IAW MM 32-33-01. THE DAMAGED HYDRAULIC LINES WERE REPAIRED AND LEAKED CHECKED. THE HYDRAULIC SYSTEM WAS SERVICED. A GEAR SWING WAS PERFORMED AND OPERATION CHECKED GOOD.

Part: BLADE — FAILED (NR 3 ENGINE)

NR 3 ENG MADE A LOUD BANG WITH EGT RISING TO 800 DEGREES AND N1 DROPPING TO 80 PERCENT WHILE EN ROUTE. THE ENGINE POWER WAS REDUCED TO IDLE AND OIL QUANTITY BEGAN TO DROP. THE ENG WAS SHUTDOWN AND THE ACFT WAS DIVERTED TO BSB WHERE IT LANDED WITHOUT INCIDENT. MX REMOVED AND REPLACED NR 3 ENG. *S/D* ENGINE DISASSEMBLY IDENTIFIED THE PRIMARY CAUSE OF THE ENGINE FAILURE TO BE SEPARATION OF A STAGE 2 HPT BLADE. DURING CLOSER EXAMINATION IT WAS DETERMINED THAT THE BLADE HAD FAILED IN THE SHANK AREA. METALLURGICAL ANALYSIS HAS CONFIRMED FATIGUE ALONG THE CONVEX SIDE OF THE BLADE. IN ADDITION, SOME UNEXPECTED MATERIALS HAVE BEEN FOUND ON THE FRACTURE SURFACE.

Part: SKIN — DAMAGED (BS 1900-1921)

INSPECTION FOUND IMPACT DAMAGE TO FUSELAGE SKIN AT STA 1900 TO 1921 BETWEEN STRINGERS 7L AND 8L. THE SKIN WAS REPAIRED IAW SRM 53-20-00, FIGURE 6.

Part: SKIN — DAMAGED (BS 1901-1921)

INSPECTION FOUND IMPACT DAMAGE TO SKIN AT STA 1901 TO 1921, STRINGER 7R AND SHEAR TIE HAD A 1.5 AND 1 INCH CRACK AT STA 1921 BETWEEN STRINGER 7R AND 8R. THE SKIN AND SHEAR TIE WERE REPAIRED IAW SRM 53-20-00, FIGURE 6.

Part: TEE SECTION — CORRODED (BS 1986)

INSPECTION FOUND T-SECTION CORRODED AT STA 1986, LONGERONS 50R AND 51R. THE T-SECTION WAS REPLACED IAW SRM 53-10-00.

Part: INTERCOSTAL — CORRODED (BS 1975)

INSPECTION FOUND INTERCOSTAL CORRODED AT STA 1975, LONGERON 47R AND 48R. THE INTERCOSTAL WAS REPLACED IAW SRM 53-10-00.

Part: BEAM — CORRODED (BS 1879)

INSPECTION FOUND SUPPORT BEAMS CORRODED AT STA 1879, X = 4 TO 33 AND X = -4 TO -33. THE SUPPORT BEAMS WERE REPLACED IAW SRM 53-22-00.

Part: BEAM — CORRODED (BS 1834-1879)

INSPECTION FOUND SUPPORT BEAM CORRODED AT STA 1834 TO 1879, LAV F, X= -33. THE SUPPORT BEAM WAS REPLACED IAW SRM 53-22-00.

Part: BEAM — CORRODED (BS 1879-2007)

INSPECTION FOUND LT GALLEY SUPPORT BEAM CORRODED AT STA 1879 TO 2007, X = 24. THE SUPPORT BEAM WAS REPLACED IAW SRM 53-22-00.

Part: BEAM — CORRODED (BS 1841-1887)

INSPECTION FOUND INBOARD SUPPORT BEAM AND LATERAL SUPPORT BEAM CORRODED AT STA 1841 TO 1887, LAV F. THE SUPPORT BEAMS WERE REMOVED AND REPLACED IAW SRM 53-22-00.

Part: BEAM — CORRODED (BS 1899)

INSPECTION FOUND FLOORBOARD SUPPORT BEAM CORRODED AT STA 1899, X = 0 TO +20. THE SUPPORT BEAM WAS REPLACED IAW SRM 53-22-00.

Part: BEAM — CORRODED (BS 1879)

INSPECTION FOUND LATERAL SUPPORT BEAMS CORRODED AT STA 1879, X= +38 TO +53 AND X= -38 TO -53. THE SUPPORT BEAMS WERE REPLACED IAW SRM 53-22-00.

Part: BEAM — CORRODED (BS 1834-1879)

INSPECTION FOUND SUPPORT BEAM CORRODED AT STA 1834 TO 1879, LAV E. THE SUPPORT BEAM WAS REPLACED IAW SRM 53-22-00.

Part: FLOORBEAM — CORRODED (BS 395-433)

INSPECTION FOUND FLOORBEAM CORRODED AT L-1 DOOR, STA 395 TO 433. THE FLOORBEAM WAS REPLACED IAW SRM 53-27-00.

Part: BEAM — CORRODED (BS 1913-2007)

INSPECTION FOUND LONGITUDINAL SUPPORT BEAM CORRODED AT LAV G, STA 1913 TO 2007. THE SUPPORT BEAM WAS REPLACED IAW SRM 53-22-0.

Part: PROX SWITCH — INOPERATIVE (LANDING GEAR)

WHEN GEAR WAS EXTENDED FOR LANDING, THERE WERE NO GREEN LIGHTS INDICATED ON FORWARD PANEL OR SECOND OFFICER'S PANEL. THE GEAR WAS CYCLED AND INDICATIONS WERE NORMAL. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE PROXIMITY CONTROL SWITCH UNIT AND OPERATIONAL CHECKS WERE NORMAL.

Part: HYD LINE — CHAFED (NR 1 HYD SYST)

THE NR 1 HYDRAULIC SYSTEM FLUID QUANTITY AND PRESSURE DROPPED TO ZERO WHILE EN ROUTE. THE AIRCRAFT WAS DIVERTED TO LGW WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE HYDRAULIC LINE TO LT ENGINE DRIVEN HYDRAULIC PUMP CHAFED THROUGH. THE HYDRAULIC LINE WAS REMOVED AND REPLACED, LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: HYD LINE — RUPTURED (LT ENGINE)

THE AIRCRAFT LOST NR 1 HYDRAULIC SYSTEM FLUID AFTER FLAP RETRACTION DEPARTING MAD. FUEL WAS DUMPED AND THE AIRCRAFT WAS RETURNED TO MAD WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 1 ENGINE LT ENGINE DRIVEN PUMP PRESSURE LINE TO MANIFOLD RUPTURED. THE PRESSURE LINE WAS REPLACED, THE NR 1 HYDRAULIC SYSTEM WAS SERVICED TO FULL. THE NR 1 ENGINE WAS RUN AND NO LEAKS WERE NOTED.

Part: WAT SEP BAGS — DIRTY (AC PACK)

THE FLIGHT ATTENDANTS REPORTED AN ODOR OF ELECTRICAL SMOKE WHILE ON APPROACH. THE AIRCRAFT LANDED AT EWR WITHOUT INCIDENT. MAINTENANCE INSPECTED THE AIRCRAFT FOR AN ELECTRICAL FAILURE AND FOUND NO FAULTS. ALL THREE WATER SEPARATOR BAGS WERE FOUND EXTREMELY SOILED. THE WATER SEPARATOR BAGS WERE REMOVED AND REPLACED. THE PACKS WERE RUN WITH AND WITHOUT ENGINES OPERATING AT HIGH AND LOW POWER AND NO ODOR WAS PRODUCED. IN ADDITION, LIGHTS AND AUDIO/VIDEO EQUIPMENT WERE ALL CHECKED WITH NO TROUBLE FOUND.

Part: SKIN — DAMAGED (CARGO DR CUTOUT)

KUL - INSPECTION FOUND IMPACT DAMAGE AT LOWER AFT SECTION OF FORWARD CARGO DOOR CUT-OUT. THE AREA WAS REPAIRED IAW ECRA 5330-02370. (X)

Part: SKIN — CRACKED (LT HORIZ STAB)

KUL - INSPECTION FOUND A DENT AND 1.25 INCH CRACK IN THE TOP SKIN OF THE LT HORIZONTAL STABILIZER INBOARD PANEL. A FILLER AND DOUBLER REPAIR WAS INSTALLED IAW SRM 51-71-00 AND A FIBERGLASS REPAIR WAS INSTALLED IAW SRM 57-71-00, PAGE 65. (X)

Part: ANGLE — CRACKED (BS 2123)

KUL - INSPECTION FOUND TWO 1 INCH CRACKS IN ANGLE AT STA XCW 14 LT AND XCW 14 RT, BS 2123. A REPAIR WAS CARRIED OUT PER SRM 53-00-01, PAGE 7. (X)

Part: FRAME — DAMAGED (BS 1841)

KUL - INSPECTION FOUND A .50 INCH DIAMETER HOLE IN FRAME, STA 1841, ABOVE CENTER CARGO FLOOR AREA ON LT SIDE. THE FRAME WAS REPAIRED IAW ECRA 5310-03243. (X)

Part: SPAR CAP — CRACKED (WS 1043)

KUL - INSPECTION FOUND A 6 INCH CRACK JUST ABOVE RADIUS ON FORWARD SIDE OF RT WING AFT LOWER SPAR CAP AT STA 1043. THE SPAR CAP WAS REPAIRED IAW ECRA 5710-01720. (X)

Part: VALVE — LEAKING (HORIZ STAB)

FLT NR 10 - EWR - THE NR 1 HYDRAULIC SYSTEM BEGAN TO LOSE FLUID WHILE EN ROUTE FROM IAH TO ORY. THE QUANTITY DROPPED STEADILY. THE AIRCRAFT WAS DIVERTED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE LOWER PRIMARY TRIM CONTROL VALVE LEAKING. THE LOWER PRIMARY TRIM CONTROL VALVE WAS REMOVED AND REPLACED IAW MM 27-43-03, PAGE 501. LEAK AND OPERATIONAL CHECKS WERE GOOD. (M)

Part: HYD PUMP — CASE CRACKED (NR 3 ENGINE)

FLT NR 0005 - IAH - THE HYDRAULIC SYSTEM 3 ELEVATOR OFF LIGHT ILLUMINATED AND THE NR 3 HYDRAULIC QUANTITY AND PRESSURE DECREASED TO ZERO IN FLIGHT. THE EMERGENCY CHECKLIST WAS COMPLIED WITH AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 3 ENGINE RIGHT HYDRAULIC PUMP CASE CRACKED. BOTH NR 3 ENGINE RIGHT AND LEFT HYDRAULIC PUMPS WERE REPLACED. THE HYDRAULIC SYSTEM WAS SERVICED. THE HYDRAULIC CONTROLS WERE OPERATED WHILE ENGINE WAS RUNNING WITH NO LEAKS OR OTHER DISCREPANCIES NOTED. (M)

Part: EEL PIN — LOOSE (CABIN)

LAX - FLT NR 0063 - ROWS 19-33, INCLUDING OVERWING EMERGENCY LIGHTS COME ON WHEN POWER IS SHUTOFF. FOUND PIN 'V' DISARMED, PUSHED PIN BACK IN AT CONNECTOR. (M)

Part: TRAILING EDGE — MISSING (RT ELEVATOR)

FLT NR 0011 - ORY - A WALK AROUND INSPECTION, FOUND RIGHT INBOARD ELEVATOR TRAILING EDGE STRIP MISSING (APPROXIMATELY 24 INCHES). A PERMANENT REPAIR WAS PERFORMED PER SRM 55-30-00, FIGURE 2. (M)

Part: EEL BATTERY — DISCHARGED (LT OVERWING)

FLT NR 0012 - LAX - THE EMERGENCY LIGHTS WOULD NOT TEST DURING A PREFLIGHT CHECK. MAINTENANCE FOUND THE L-1 DOOR AND LEFT OVERWING BATTERY PACKS INOPERATIVE. THE FORWARD CENTER BATTERY CHARGER WAS ALSO FOUND INOPERATIVE. BOTH OF THE BATTERY PACKS AND THE BATTERY CHARGER WERE REMOVED AND REPLACED. OPERATION OF THE EMERGENCY LIGHTS CHECKED GOOD. (M)

Part: EEL BATTERY — DISCHARGED (L-1 DOOR)

FLT NR 0012 - LAX - THE EMERGENCY LIGHTS WOULD NOT TEST DURING A PREFLIGHT CHECK. MAINTENANCE FOUND THE L-1 DOOR AND LEFT OVERWING BATTERY PACKS INOPERATIVE. THE FORWARD CENTER BATTERY CHARGER WAS ALSO FOUND INOPERATIVE. BOTH OF THE BATTERY PACKS AND THE BATTERY CHARGER WERE REMOVED AND REPLACED. OPERATION OF THE EMERGENCY LIGHTS CHECKED GOOD. (M)

Part: EEL BATT CHARGER — INOPERATIVE (CABIN)

FLT NR 0012 - LAX - THE EMERGENCY LIGHTS WOULD NOT TEST DURING A PREFLIGHT CHECK. MAINTENANCE FOUND THE L-1 DOOR AND LEFT OVERWING BATTERY PACKS INOPERATIVE. THE FORWARD CENTER BATTERY CHARGER WAS ALSO FOUND INOPERATIVE. BOTH OF THE BATTERY PACKS AND THE BATTERY CHARGER WERE REMOVED AND REPLACED. OPERATION OF THE EMERGENCY LIGHTS CHECKED GOOD. (M)

Part: ACCELEROMETER — INOPERATIVE (NR 2)

FLT NR 0500 - FRA - THE STALL WARNING ACTIVATED MOMENTARILY DURING CLIMB-OUT WITH AUTO SLAT DEPLOYMENT. MAINTENANCE FOUND THE NR 2 LINEAR ACCELERAOMETER UNIT AT FAULT. THE ACCELEROMETER UNIT WAS REPLACED AND A BITE TEST WAS SUCCESSFULLY ACCOMPLISHED. (Z)

Part: SUPPORT — CORRODED (FS 1887)

BFM - A MAIN CABIN FLOOR SUPPORT WAS FOUND CORRODED AT STA 1887 FROM LBL 30 TO LBL 48. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 51-10-01. (X)

Part: BULKHEAD — CORRODED (CTR MLG WW)

BFM - INSPECTION FOUND CENTER MLG WHEELWELL AFT BULKHEAD CORRODED FROM LBL 31 TO RBL 31. THE BULKHEAD WAS REPAIRED IAW SRM 51-00. (X)