N1734D

Part: A/C PACK — ODOR (ACM BAY) · airframe 58,565 hrs · 26,238 cycles

ON TAXI OUT STRONG FUMES REPORTED-RETURNED TO GATE FOR VISUAL INSPECTION. NONE REPORTED. AFTER T/O FUMES REPORTED AGAIN. ISOLATED PACK NR 3, NO CHANGE. ISOLATED NR 1 PACK, SOME DECREASE. REPLACED NR 2 ACM PER M/M. RAN PACKS FOR 2 HOURS. NO FUMES NOTED

Part: ENGINE — LEAKING (NR 3) · airframe 58,550 hrs · 26,231 cycles

ON CLIMBOUT, ALL THE AFT LAV SMOKE DETECTORS WENT OFF. ON RETURN TO GATE, STRONG OIL SMELL AND BLUE HAZE IN CABIN. FOUND NUMBER 3 ENGINE LEAKING OIL AND ENTERING PNEUMATIC SYSTEM. REPLACED ENGINE.

Part: A/C PACK — FAILED (NR 3) · airframe 58,481 hrs · 26,211 cycles

ON TAKEOFF ODOR DETECTED IN CABIN SMELL LIKE AN OVERHEATING PACK SLIGHT HAZE NOTED IN AFT CABIN, 2 LAV SMOKE DETECTORS ACTIVATED BRIEFLY ALL ACM AND PACK INDICATIONS NML. FOLLOWED POM PROCEDURES AND SECURED NR 3 PACK HAZE DISSIPATED FWD TO MCO AND PLAC MEL 21-51-07A.

Part: ACM — SMOKE (ACM BAY) · airframe 58,456 hrs · 26,201 cycles

OILY SMOKE IN AFT CABIN ON CLIMBOUT. ISOLATED NR 1 ENG AND PACK, SMOKE DISSIPATED. FOLLOWED AIR CONDITIONING SMOKE PROCEDURE IN POM. ENDED UP WITH 1 PACK OFF AND OTHER SWITCHES LATCHED. REPLACED NR 1 ACM AND INNER DUCT HOUSING TO THE HEAT EXCHANGER. REPLACED COALESCER BAG. C/W DUCT BURN OUT PER MM. OPS CHECKS OK.

Part: HOUSING — LEAKING (NR 1 ENGINE) · airframe 58,417 hrs · 26,192 cycles

NR 1 ENG OIL QTY DROPPED FROM 16 TO 4 QTS IN 1.5 HRS OIL QTY DECREASED TO ZERO, ENGINE SHUTDOWN PER POM 23-107. RAPID DECREASE IN OIL QTY OIL PRESS REMAINED ABOVE 40 PSI UNTIL LANDING. FOUND GEARBOX CHIP DET MISSING FROM HOUSING AND OIL LEAKING OUT. REPLACED CHIP DET AND HOUSING SERVICED OIL RAN ENG. CHECKS GOOD. CHIP DET (P/N VB3504)

Part: ACM — FAILED (NR 3) · airframe 57,718 hrs · 25,963 cycles

ON CLIMBOUT WITH 3 PACKS ON, CABIN FILLED WITH LIGHT BLUE SMOKE. REPLACED NR 3 ACM.

Part: COMPUTER — FAILED (NAVIGATION) · airframe 57,489 hrs · 25,891 cycles

DURING NAV ACCURACY CHECK AFTER TAKEOFF, NR 2 AND NR 3 INS NOT WITHIN TOLERANCE. REPLACED NR 2 AND NR 3 CAROUSELS.

Part: ENGINE — FAILED (NR 1)

BIRD STRIKE ON NR 1 ENGINE AT LIFTOFF. ENGINE BEGAN TO VIB, SURGE, STALL AND TGT ROSE TO 900 DEGS FOR GREATER THAN 30 SECS. REPLACED ENGINE.

Part: TIRE — FAILED (MLG)

NR 3 RT TIRE THREW RECAP ON LANDING. RUPTURING 2 HYD LINES CAUSING A LOSS OF C-SYSTEM HYD FLUID ON TAXI IN. REPLACED TIRE AND LINES.

Part: ENGINE — FAILED (NR 1)

ENG FLAME-OUT OCCURED 5 MINUTES AFTER T/O ON CLIMBOUT. APPARENTLY RESULTED FROM FAILURE OF NR 1 ENG FUEL HP SOV. REPLACED ENGINE.

Part: POWER SUPPLY — INOP (CABIN)

EMERGENCY EXIT LIGHT FLOOR TRACK INOP FWD CABIN. REPLACED POWER SUPPLY.

Part: BATTERY PACK — DISCHARGED (1L DOOR)

FWD EMER EXIT LIGHTS ILLUM TWICE DURING FLIGHT. FOUND BATTERY PACK AT 1L DOOR OPS INTERMITTENTLY. REPLACED SAME, OPS CK GOOD.

Part: O-RING — LEAKING (NR 1 ENGINE)

ENG NR 1 SHUTDOWN IN FLT DUE TO HIGH FUEL FLOW AND FUEL USED INDICATIONS WITH ENG AT IDLE F/F IND. 9,500 TO 10,000 LBS. POM COMPLIED WITH FOR HIGH FUEL USE AND ENG SHUTDOWN. FOUND O-RING SEAL LEAKING AT FUEL FILTER FUEL LINE. REPLACED SEAL PER MM AND ENG RUN LEAK CK OK.

Part: SKIN — CRACKED (WS 570)

TWO FASTENER HOLES WERE FOUND CRACKED IN THE LOWER WING SKIN AT THE END OF THE SKIN SPLICE STRAP AT STRINGER 10, IWS 570. THE CRACKS ARE THE SUBJECT OF SID AD 95-20-04, R1 (ITEM 57-3-4). THE CRACKS WERE REMOVED BY OVERSIZING THE HOLES WITH AN INSURANCE CUT. THE HOLES WERE BUSHED AND ORIGINAL TYPE FASTENERS INSTALLED PER ER/A 364728-14AD, REV A.

Part: VALVE — MALFUNCTIONED (NR 3 PACK)

NR 2 PACK OVHRHEAT ON TAXI OUT, SMOKE AND FUMES IN THE CABIN. ALSO, NR 3 PACK CAN NOT BE CONTROL WITH SWITCH IN COCKPIT. REPLACED FLOW CONTROLLED VALVE, NO HELP. REPLACED NUMBER 3 TURBINE BYPASS VALVE.

Part: PACK VALVE — SEIZED (NR 3)

ON TAXI OUT, CABIN FILLED WITH SMOKE FOUND NR 3 PACK VALVE NOT FULLY CLOSED. REPLACED PACK VALVE.

Part: FRAME — CRACKED (BS 983)

DURING THE ACCOMPLISHMENT OF SI 7-63916-12AD, OPN 88 NDT FOUND A .75 INCH LONG CRACK IN THE LWR HORIZONTAL WEB OF THE STA 983 FRAME. REPAIRED FRAME PER LCC-7622-325 AND LCC-7622-328 WITH THE EXCEPTION THAT THE LCC-7622-328-110 AND -112 FITTINGS WILL BE MODIFIED TO ACCOMMODATE A MISMATCH.

Part: SKIN — DENTED (BS 293)

THE FUSELAGE SKIN WAS FOUND WITH A DEEP DENT AT FS 293 BETWEEN STR 15 AND 16. REMOVAL OF THE DAMAGE RESULTS IN A CUT OUT SIZED 4.5 LONG (FWD / AFT) BY 2.5 WIDE (UP/DOWN). REPAIR DOUBLER AND TRIPLER FROM 0.063 2024-T3 AL CLAD MATERIAL. TAPER EDGES, FILLER FROM 0.090 2024-T3 CLAD AL, CHEM-FILM.

Part: SKIN — DENTED (BS 860-866)

THE FUSELAGE SKIN BETWEEN STA 860 TO 866 AND STR 48 TO 50 WAS FOUND DENTED AND REQUIRED CUTOUT. THE CUTOUT, THROUGH THE SKIN AND THE L-2 DOOR SURROUND DOUBLER, MEASURES 6 FORE/AFT BY 12 CIRCUMFERENTIALLY. THE SKIN PANEL IS A BONDED ASSEMBLY CONSISTING OF A 0.068 2024-T3 CLAD SKIN WITH A 0.022 2024-T3 CLAD BONDED DOUBLER. THE L-2 DOOR SURROUND DOUBLER IS M/F FROM 0.071 2024-T3 CLAD. REPAIR PARTS FROM 2024-T3 PER FIGURE, TAPER EDGES, CHEM-FILM TREAT, CONICAL WASHERS.

Part: SKIN — CORROSION (BS 1645)

CORROSION FOUND AT STA 1645 AND STR 29 AFTER BULGE FOUND. A 12 BY 5 SECTION OF SKIN AND DOUBLER WERE TRIMMED TO REMOVE IT. ER/A INSTALLED REPAIR DOUBLER.

Part: PACK VALVE — MALFUNCTIONED (RT PACK)

SMOKE FROM AIR CONDITIONING THROUGHOUT CABIN, MID CABIN TEMP 200 DEGREES NR 3 PACK ACM DISCHARGE TEMP 140 DEGREES. LOCKED NR 3 PACK VALVE CLOSED, FWD TO MCO AND PLACARD PER MEL 21-21-01A.

Part: DUCT — RUPTURED (NR 2 ENGINE)

NR 2 ENG PNEUMATIC DUCT RUPTURE AFT OF BAGGAGE BIN WALL IN NR 3 BIN DAMAGING DUMP CHUTE TO AFT LAVATORIES RESULTED IN J-AREA OVHT AND AFT CARGO HOT LIGHT.

Part: LIGHT — INOPERATIVE (CABIN)

3R EXTERIOR EMER EXIT LGT INOP. RELAMPED. CKS OK

Part: BATTERIES — DISCHARGED (CABIN)

EMERGENCY FLASHLIGHT AT R4 DOOR INOP REPLACED BATTERY AND BULB. CKS OK.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

CABIN EMERGENCY EXIT SIGNS AT 2L AND LT CLASS DIVIDER INOP. REPLACED PWR SUPPLY, TESTS OK.

Part: MEGAPHONE — INOPERATIVE (CABIN)

FWD MEGAPHONE INOP. REPLACED FWD MEGAPHONE, OPS CK NORMAL.

Part: PACK — SMOKING (NR 3)

SMOKE IN AFT CABIN DURING FLT - ISOLATED NR 3 PACK AND APPEARED TO CLEAR - PACK TEMPS NORMAL. CORR. ACTN. CHKD ALL 3 A/C PACKS AND OK. RAN SYSTEMS ON GROUND WITH NO ODORS OR VISIBLE POLLUTANTS IN CABIN. RENDERED NR 3 PACK INOP PER MEL 21-51-07A AND PLACED ON MCO AND PLACARD.

Part: DUCT — CRACKED (AIR COND COMPT)

DURING CLIMB-OUT THROUGH FL 220, A MUFFLED BANG WAS HEARD. AFT OVERFLOW VALVE WENT FULL CLOSED AND FWD VALVE SLOWLY WENT CLOSED. AS AIRCRAFT CLIMBED THROUGH FL 280, LEVEL AT FL 350 CBN, CLIMB AT 100 FPM. UNLATCHED COOL AIR OVRBD SWITCH. DESCENDED TO FL 240 BEFORE CABIN RATE WOULD DESCEND. FOUND SEAL DISCONNECTED BETWEEN NR 2 WATER SEPARATOR Y-DUCT AND THE AFT GROUND A/C CHECK VALVE. NR 2 SEPARATOR WAS CRACKED. REPLACED NR 2 SEPARATOR AND DUCT ASSY. RAN ENGINES AND NR 2 PACK, OPERATION AND LEAK CHECK GOOD.

Part: PACK — FAILED (NR 1)

AFTER TAKEOFF, WHEN PACKS TURNED ON THERE WAS A LOUD GRINDING NOISE PLUS SMOKE AND FUMES IN COCKPIT AND CABIN. TURNED OFF NR 1 PACK SMOKE AND FUMES DISSIPATED. NR 1 PACK WAS REPLACED, OPERATION NORMAL.

Part: BLKHD ANGLE — CRACKED (FS 1363)

DURING LETTER CHECK, FOUND FS 1363 BULKHEAD LOWER CHORD ANGLE CRACKED BETWEEN STRINGER 18 AND STRINGER 19. REPAIRED PER SRM 53-11-00 PG 931.