N16883

Part: ANGLE — CRACKED (STA 389) · airframe 51,488 hrs · 37,800 cycles

INSPECTION FOUND A 1.25" CRACK IN FORWARD CARGO COMPARTMENT BELTFRAME SIDEWALL SUPPORT ANGLE AT STA 389, L25L. A DOUBLER WAS INSTALLED IAW 5320-01263.

Part: WEB — CRACKED (STA 1338) · airframe 48,863 hrs · 36,436 cycles

INSPECTION FOUND A 1/2" CRACK IN WEB AT FORWARD FACE OF AFT BULKHEAD STA 1338 BETWEEN LONGERON 25L AND 26L. FILLER AND DOUBLER WERE INSTALLED IAW SRM 51-70-4.

Part: PANEL — SHORTED (ANTI-ICE SYS) · airframe 46,067 hrs · 34,920 cycles

THE LEFT WING UPPER ANTI-ICE BLANKET CONNECTION PANEL WAS DISCOVERED TO BE BURNED DUE TO A SHORT CIRCUIT. THE LEFT WING UPPER INTERFACE PLATE WAS REMOVED AND REPLACED AND THE UPPER WING SURFACE HEATERS WERE PLACARD INOPERATIVE. APPROPRIATE CIRCUIT BREAKERS WERE PULLED AND COLLARED. TROUBLESHOOTING FOUND ALL THREE ZONES RIBBONS DAMAGED IN THE INTERFACE UNIT. THE ETOPS SYSTEM WAS DEACTIVATED IAW FCD 3010-01250. THE INCIDENT IS BEING EVALUATED BY THE MANUFACTURER AND ENGINEERING. *S/D* AMENDED STC SA6061NM IS BEING OBTAINED THAT CORRECTS THE SYSTEM ELECTRICAL DISCREPANCY TO PREVENT REOCCURRENCE.

Part: CABLE — OUT OF RIG (TAILCONE) · airframe 45,998 hrs · 34,877 cycles

THE TAIL CONE DROP TEST FAILED FROM ALL THREE RELEASE HANDLES (AFT ENTRANCE, INTERIOR, AND EXTERIOR). THE TAIL CONE SYSTEM CABLES WERE RIGGED AND A FUNCTIONAL CHECK WAS GOOD IAW MM 53-53-00.

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND A 1 INCH CRACK ACROSS FASTENER IN VERTICAL STABILIZER LEADING EDGE AT RT SIDE JUST BELOW RIGHT LOWER VOR ANTENNA. REPAIRED IAW ECRA 5530-01285.

Part: SKIN — GOUGED (FUSELAGE) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND FUSELAGE SKIN GOUGED AND PUNCTURED BELOW FWD BAGGAGE BIN DOOR JAMB AT STA 375, LONGERON 30. A REPAIR WAS INSTALLED IAW ECRA 5330-02999.

Part: ATTACH ANGLE — CRACKED (VERTICAL STAB) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND A .5 INCH CRACK AT AFT END OF RT VERTICAL STABILIZER ATTACH ANGLE, STA 1485. THE CRACKED AREA WAS REMOVED AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-05, FIGURE 23 AND 23A.

Part: PAN — CORRODED (PAX DOOR) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND AFT ENTRY LOWER DOOR JAMB PAN CORRODED. REPAIRED IAW SRM 53-05, FIGURE 34 AND 51-01, ITEM 3B1.

Part: FLOORBEAM — CORRODED (CABIN) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND RT LAV FLOORBEAM CORRODED NEAR O/B END AT CUSP, STA 1338, L18R. A REPAIR WAS INSTALLED IAW ECRA 5310-04059.

Part: SKIN — CRACKED (FUSELAGE) · airframe 45,998 hrs · 34,877 cycles

A PERMANENT REPAIR WAS INSTALLED WHERE A PREVIOUSLY PERFORMED INTERIM REPAIR HAD BEEN MADE FOR A 2 INCH CRACK IN LT FUSELAGE SKIN AT STA 133 BETWEEN LONGERON 18L AND 19L. THE PERMANENT REPAIR WAS INSTALLED IAW ECRA 5330-02996.

Part: SKIN — DENTED (FUSELAGE) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND LT FUSELAGE SKIN DENTED AT CUSP LINE, STA 256. REPAIRED IAW ECRA 5330-02995.

Part: BEAM — CORRODED (MID CARGO DOOR) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND MID CARGO LOWER DOOR JAMB BEAM CORRODED AT SCREW HOLES. REPAIRED BEAM IAW SRM 53-05, FIGURE 63.

Part: WEB — CORRODED (LAVATORY) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND WEB CORRODED AT RT LAV STA 1338 (BULKHEAD OUTER WEB BELOW FLOOR). THE WEB SECTION WAS REMOVED AND A NEW WEB SECTION WAS SPLICED IN IAW SRM 51-70-4, FIGURE 1.

Part: FITTING — CRACKED (STA 1338) · airframe 45,998 hrs · 34,877 cycles

INSPECTION FOUND A 6 INCH CRACK IN FITTING THAT CONNECTS BELTFRAME TO FLOORBEAM AT RT LAV STA 1338. THE FITTING WAS REMOVED AND A NEW FITTING WAS INSTALLED IAW SRM 51-30-5.

Part: BATTERY — INOPERATIVE (CABIN) · airframe 45,035 hrs · 34,344 cycles

THE OVERHEAD EMERGENCY LIGHTS WENT DIM THEN OUT WITH THE EMERGENCY LIGHTS SWITCH IN TEST POSITION. TWO BATTERIES IN BATTERY PACK WERE REMOVED AND REPLACED. OPERATIONAL CHECKS WERE GOOD.

Part: FRAME — CRACKED (BS 1463)

INSPECTION FOUND A 7 INCH CRACK IN CANTED FRAME WEB AT STA 1463. THE WEB WAS REMOVED AND REPLACED IAW SRM 51-30-2 AND 51-30-5.

Part: FRAME — CRACKED (BS 1437)

INSPECTION FOUND A 7 INCH CRACK IN WEB ON RT BELL FRAME IN TAIL COMPARTMENT AT STA 1437. A NEW WEB WAS INSTALLED IAW SRM 53-01.

Part: SEAT TRACK — CORRODED (LT COCKPIT)

INSPECTION FOUND CAPTAIN'S I/B AFT SEAT TRACK CORRODED. A NEW SEAT TRACK WAS INSTALLED IAW SRM 51-30-4.

Part: SUPPORT — CORRODED (BS 636)

INSPECTION FOUND FLOOR SUPPORT CORRODED IN MAIN BAGGAGE BIN AT STA 636, LT SIDE. A NEW FLOOR SUPPORT WAS INSTALLED IAW SRM 51-50-0.

Part: SHOCK STRUT — LOW PRESSURE (NLG)

A RED GEAR UNSAFE LIGHT REMAINED ILLUMINATED UPON GEAR RETRACTION AFTER TAKEOFF. THE GEAR WAS CYCLED WITH NO CHANGE. THE AIRCRAFT WAS RETURNED TO EWR. MAINTENANCE SERVICED THE NOSE GEAR SHOCK STRUT WITH NITROGEN PER EC 3200-01200 AND A DIP WAS ISSUED TO PERFORM A FULL SERVICE PER MM 32-21-02 AT THE FIRST OVERNIGHT STATION WITH MAINTENANCE CAPABILITY.

Part: CONDUIT — DAMAGED (RT WING)

THE RT WING FORWARD FUEL TANK BOOST PUMP CIRCUIT BREAKERS POPPED AFTER TAKEOFF. THE CIRCUIT BREAKERS WERE RESET AND THE REAR FUEL TANK BOOST PUMP CIRCUIT BREAKER POPPED IMMEDIATELY. THE FORWARD BOOST PUMP CIRCUIT BREAKER POPPED SHORTLY AFTERWARD. THE FLIGHT CONTINUED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE A AND C PHASE CIRCUIT BREAKERS POPPED ON FORWARD PUMP AND THE B-PHASE CIRCUIT BREAKER POPPED ON AFT PUMP. THE ELECTRICAL CONNECTORS FOR BOTH RT WING BOOST PUMPS SHOWED EVIDENCE OF ARCING AND INSULATION DAMAGE. THE ELECTRICAL CONDUITS FOR BOTH BOOST PUMPS WERE REMOVED AND REPLACED. IN ADDITION, BOTH BOOST PUMPS WERE REMOVED AND REPLACED, LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: ANGLE — CORRODED (BS 1155-1212)

INSPECTION FOUND CORROSION ON AFT BAGGAGE BIN Z-ANGLE FROM STA 1155 TO 1212. A REPAIR DOUBLER AND STRAPPER WAS INSTALLED IAW SRM 53-05, FIGURE 63.

Part: DOUBLER — CRACKED (NLG WW)

INSPECTION FOUND A .2187 INCH CRACK IN REPAIR DOUBLER AT NOSE WHEEL WELL LEFT AFT DOOR HINGE CUTOUT. A NEW REPAIR DOUBLER WAS INSTALLED IAW SRM 51-30-2.

Part: SKIN — IMPACTED (BS 237)

INSPECTION FOUND IMPACT DAMAGE TO LT FUSELAGE SKIN, CAUSED BY JETWAY, AT STA 237 AFT OF MAIN CARGO DOOR. NEW SKIN WAS INSTALLED IAW ECRA 5330-01203, SRM 51-30-2, 51-30-5, 51-20-0.

Part: WEB — CORRODED (BS 218)

INSPECTION FOUND CORROSION ON WEB INBOARD OF CUSP AT STA 218, LT SIDE. DOUBLERS WERE INSTALLED IAW ECRA 5310-03343.

Part: FRAME — CRACKED (BS 1463)

INSPECTION FOUND 3 CRACKS IN CANTED FRAME WEB ON RT SIDE AT STA 1463. THE CRACKS WERE .5 TO 1 INCH LENGTH. THE WEB WAS REPLACED IAW SRM 51-30-2, 51-30-5 AND 53-14-4.

Part: DOOR PAN — CRACKED (CARGO DOOR)

INSPECTION FOUND A .5 INCH CRACK AT BOTTOM FORWARD STOP PAD OF FORWARD BAGGAGE BIN DOOR PAN. A DOUBLER WAS INSTALLED IAW ECRA 65C0123.

Part: ANGLE — CRACKED (CARGO D00R)

INSPECTION FOUND A 2 INCH CRACK IN FORWARD BAGGAGE BIN INTERNAL ANGLE AT BOTTOM AFT STOP FITTING. A REPAIR WAS INSTALLED IAW ECRA 5230-01335.

Part: WIRE — BURNED (BS 1083-1205)

TWENTY-FOUR LIGHTING WIRES FOUND WITH BURNT SHIELDING ON RIGHT SIDE OF AIRCRAFT BETWEEN STATION 1083 AND 1205. REMOVED AND REPLACED BURNT WIRE BUNDLE AND REPLACED WIRES FROM CONNECTOR TO CONNECTOR WITH NO SPLICES PER MM 3300. REFERENCE MCDONNELL DOUGLAS AD 96-11-13.

Part: CLIPS — OUT OF ADJUST (TAILCONE)

THE INTERIOR TAILCONE RELEASE HANDLE PULLED FROM CLIPS AT 50 POUNDS. THE CLIPS WERE ADJUSTED IAW MM 53-53-00.

Part: CLIPS — OUT OF ADJUST (TAILCONE)

THE EXTERIOR TAILCONE RELEASE HANDLE PULLED FROM CLIPS AT 20 POUNDS. THE CLIPS WERE ADJUSTED IAW MM 53-53-00.

Part: ACCESS PANEL — LOOSE SCREWS (LT WING)

THE AIRCRAFT WAS RETURNED TO TPA AFTER FUEL WAS REPORTED LEAKING FROM TOP OF LEFT WING. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND EVIDENCE OF FUEL LEAKAGE FROM LT WING PANEL 1303C AND THERE WERE SEVERAL LOOSE SCREWS. THE PANEL SCREWS WERE RETORQUED IAW MM 28-00-00, PAGE 216. THE TANK WAS FUELED TO FULL. PRESSURE AND LEAK CHECKS WERE GOOD.

Part: T3 BLADE — BROKEN (NR 1 ENGINE)

THE NR 1 ENGINE FAILED WITH LOSS OF OIL WHILE EN ROUTE. THE AIRCRAFT WAS DIVERTED TO JAX WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND METAL IN THE NR 1 ENGINE TAILPIPE. THE NR 1 ENGINE WAS REMOVED AND REPLACED. THE SDR WILL REMAIN OPEN FOR PART INFORMATION PENDING INVESTIGATION. *S/D* SHOP FINDINGS REVEALED A BROKEN T-3 BLADE.

Part: WIRE — SHORTED (CABIN)

EWR - FLT 0621 - INSPECTION FOUND THE EMERGENCY AISLE PATH LIGHTING BEYOND ROW 25, INOPERATIVE. MAINTENANCE FOUND A SHORT IN WIRING AND A BLOWN FUSE AT ROW 30 DEF. THE FUSE WAS REPLACED AND THE SECTION AT ROW 30 DEF WAS REWIRED. (X)

Part: COFFEEMAKER — LEAKING (AFT GALLEY)

EWR - FLT 0341 - CREW REPORTED SMOKE COMING FROM THE AFT GALLEY WHILE ON APPROACH TO EWR. THE GALLEY CIRCUIT BREAKERS WERE PULLED AND THE SMOKE DISAPPEARED. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE AFT GALLEY AND FOUND THE UPPER AFT COFFEEMAKER LEAKING. THERE WAS NO EVIDENCE OF FIRE. THE COFFEEMAKER WAS REMOVED AND REPLACED AND OPERATION CHECKED GOOD. NO OTHER DISCREPANCIES WERE NOTED. (X)

Part: ENGINE — FLAMED OUT (APU)

FLT NR 0692 - EWR - THE APU FLAMED OUT AT FL 290, OPERATION OF THE APU CHECKED GOOD AT ALL ALTITUDES BELOW FL 290. MAINTENANCE PERFORMED AN OPERATIONAL CHECK OF THE APU ON THE GROUND AND NO DEFECTS WERE NOTED. (M)

Part: EEL BATTERIES — DISCHARGED (CABIN)

FLT NR 0344 - EWR - INSPECTION FOUND THE OVERHEAD EMERGENCY CEILING LIGHTS INOPERATIVE IN FIRST CLASS SECTION. THE BATTERIES FOR THE OVERHEAD LIGHTS IN FIRST CLASS WERE REMOVED AND REPLACED AND OPERATION OF THE LIGHTS WAS RESTORED. (W)

Part: EEL BATT — DISCHARGED (CABIN)

FLT NR 0344 - EWR - INSPECTION FOUND THE OVERHEAD EMERGENCY CEILING LIGHTS IN AFT CABIN INOPERATIVE. THE BATTERIES AND POWER SUPPLY CHARGER FOR THE OVERHEAD LIGHTS IN AFT CABIN WERE REMOVED AND REPLACED AND OPERATION OF THE LIGHTS WAS RESTORED. (W)

Part: EEL BATTERIES — DISCHARGED (CABIN)

BOS - FLT 345 - INSPECTION FOUND THE OVERHEAD EMERGENCY LIGHTS IN THE FIRST CLASS CABIN INOPERATIVE. THE OVERHEAD EMERGENCY LIGHT BATTERIES WERE REMOVED AND REPLACED AND OPERATION OF THE LIGHTS WAS RESTORED. (W)

Part: EEL BATT PACK — DISCHARGED (CABIN)

FLT NR 0342 - EWR - ALL THE OVERHEAD EMERGENCY LIGHTS IN FIRST CLASS SECTION OF CABIN WERE FOUND INOPERATIVE DURING A PREFLIGHT CHECK. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACK IN THE AFT OVERHEAD AND OPERATION OF THE OVERHEAD EMERGENCY LIGHTS IN FIRST CLASS CABIN WAS RESTORED. (W)