N187JB

Part: NONE — NONE · airframe 42,988 hrs · 27,982 cycles

FLT#320, JFK-DTW, (AIRCRAFT PERFORMED AN AIR TURN BACK). ' BLEED 1 FAIL CLIMBING THROUGH 17500.' (SUPPLEMENTAL TO FOLLOW).

Part: BEARING — DIRTY (RT AILERON) · airframe 42,966 hrs · 27,972 cycles

FLT#1575, FLL-KIN. (AIRCRAFT PERFORMED AN AIR TURN BACK TO FLL). ' RIGHT AILERON DOES NOT CENTER WHEN CONTROL COLUMN CENTERS. IN-FLIGHT AILERON ALSO DID NOT CENTER; ACCOMPLISHED EC E2717023-01. L/H AND R/H AILERON FUSELAGE SECTOR BEARING CLEANING W/O REMOVING THE BEARING ASSY. CONTROL WHEELS OPERATE NORMALLY.'

Part: KNOB — ACTIVATION ERROR · airframe 42,345 hrs · 27,552 cycles

FLT # 625, EWR-CHS(AIR TURN BACK TO EWR). AIR RETURN TO EWR, UNABLE TO PRESSURIZE; PRESSURIZATION KNOB WAS SET TO MANUAL POSITION. KNOB PLACED IN AUTO POSITION. PERFORMED PRESSURIZATION TEST IAW AMM 21-30-00. ALL OPS CHKS GOOD. A/C OK FOR CONT SVC .

Part: SKIN — CHAFED (LT WING TE FLAP) · airframe 40,542 hrs · 26,407 cycles

DURING HEAVY MAINTENANCE, CHAFING MARKS WERE REPORTED AT THE LH WING INBOARD AFT FLAP (PN 190-38006-403/ SN 00009) UPPER SKIN AT RIB 1A. SEE REF /1/ ETI FOR DETAILS. THE MARKS ARE 2 PLIES DEEP CAUSING DAMAGE TO THE COPPER MESH. IT IS REPORTED THE DAMAGED IS CAUSED BY THE CONTACT WITH LOOSE RIVETS ON THE WING TO BODY FAIRING. EMBRAER WAS CONTACTED AND ADVISED TO PERFORM TAP TESTS, REF /4/ SRM, AND REPAIR COPPERFOIL MESH OR BONDING PLATE, IF APPLICABLE; EMBRAER APPROVED THIS REPAIR PER REF /2/ ETD AND IS CLASSIFIED AS MAJOR.

Part: SKIN — CRACKED (RT WING) · airframe 40,542 hrs · 26,407 cycles

DURING HEAVY MAINTENANCE, CRACK DISCOVERED AT RIB 10 AND SPAR II LOWER SKIN RH WING L=1.375""; (REF TOMX NR 00055) ACCOMPLISHED REPAIR IAW EMBRAER ETD2021-190-006388 REV. C, TOMX ETI 190-21-623 REV 3, AND JETBLUE EC E21-282-01. MAJOR REPAIR.

Part: SKIN — CRACKED (RT WING) · airframe 40,542 hrs · 26,407 cycles

DURING HEAVY MAINTENANCE, CRACK DISCOVERED AT RH WING LOWER SKIN RIB 8 L=0.250""; (REF TOMX NR 00080) AREA WAS REPAIRED PER ETD2021-190-006717 REV. A, TOMX ETI-190-21-628 REV 3, AND JETBLUE EC E21-276-01. MAJOR REPAIR.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 40,199 hrs · 26,220 cycles

FLT 1318, JFK-BOS. RT FWD EXTERNAL EMERGENCY LIGHT WILL NOT ILLUMINATE. R & R EMERGENCY LIGHT, IAW AMM 33-50-25.

Part: BATTERY — FAILED (EMERGENCY LIGHTS) · airframe 39,720 hrs · 25,899 cycles

FT # 824, MCO-DCA. DURING OPE CHECK OF EMERGENCY LIGHTS FOUND RH OVERWING FAIRING EMRG LIGHTS INOP; R & R MID LH EMERGENCY LIGHT POWER UNIT. OPS CHECK GOOD REF AMM 33-50-01

Part: SKIN — CRACKED (LT WING) · airframe 37,387 hrs · 24,205 cycles

DURING HEAVY MAINTENANCE, FOUND WITH CRACK DAMAGE ON THE LT WING LEADING EDGE SKIN (P/N 190-31693-401) CUT-OUT BETWEEN RIB 19/20 AND A DENT (4.970" L X 1.885" W X 0.049" D) BETWEEN RIBS 20/21. THESE DAMAGES WERE OUTSIDE THE LIMITS OF THE SRM AND WAS CONTACTED FOR REPAIR DISPOSITION. PROVIDED REF /2/ ETD WHICH PROVIDED APPROVAL TO REPAIR THE CRACK AS PER REF /4/ SRM & THE DENT AS PER REF /3/ SRM AS PERMANENT REPAIR. AEROMAN ISSUED REF /1/ EA TO ACCOMPLISH THE REPAIR AS PER REF /2/ WITHOUT DEVIATION. EC/TC E19-240-01 ACCOMPLISHES THE REPAIR AS PER REF /1/ EA WITHOUT DEVIATION; THIS REPAIR HAS BEEN APPROVED BY REF /2/ ETD. THIS REPAIR HAS BEEN CLASSIFIED AS MAJOR.

Part: CAM — OUT OF POSITION (L1 DOOR SLIDE) · airframe 35,534 hrs · 22,849 cycles

L1 DOOR SLIDE, FOUND THE CAM ROTATED 90 DEGREES, UNABLE TO INSERT SAFETY PIN. THE SLIDE WAS UNSERVICEABLE. R & R THE L1 DOOR SLIDE ASSY IAW AMM 25-65-01. ALL CHECKED NORMAL

Part: FAN — FAILED (RECIRCULATION) · airframe 32,149 hrs · 20,420 cycles

AT FL 380 WE EXPERIENCED A "SMOKE IN RECIRC BAY " EICAS MESSAGE IN CABIN AND FUMES THROUGHOUT. EMERGENCY DESCENT, EMERGENCY DECLARED AND DIVERTED. R & R THE RECIRCULATION FAN FILTERS IAW AMM 21-24-02. R & R THE RECIRCULATION FANS IAW AMM 21-24-01. OPS & LEAK CHECKED GOOD. NO ODORS NOTED.

Part: FAN — FAILED (RECIRCULATION) · airframe 32,149 hrs · 20,420 cycles

AT FL 380, EXPERIENCED A SMOKE IN RECIRC BAY EICAS MESSAGE IN CABIN AND FUMES THROUGHOUT. EMERGENCY DECLARED. DIVERTED. R & R THE RECIRCULATION FAN FILTERS IAW AMM 21-24-02. R & R RECIRCULATION FAN IAW AMM 21-24-01. OPS & LEAK CHECKED GOOD. NO ODORS NOTED.

Part: FAN — ODOR (RECIRCULATION) · airframe 32,145 hrs · 20,418 cycles

RECIRCULATION, SMOKE EICAS DURING DESCENT. RAN QRH AND MESSAGE WENT AWAY. SMELLED AN ELECTRICAL ODOR, WENT AWAY AFTER RECIRCULATION FAN TURNED OFF. ACCOMPLISHED SMOKE INPECTION IAW FIM 21-20-00-810, ISOLATED TO REC SYS WHEN ACTIVATED. ACCOMPLISHED FIM TASK 26-1000-810. FOUND RECIRCULATION FANS AT FAULT. DEACTIVATED LT AND RT RECIRCULATION FANS AND MFD ECS SYNOPTIC PAGE.

Part: BRACKET — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON THE AFT CARGO DOOR CUT OUT, TRIM ATTACH BRACKETS ALONG LWR SILL HAVE SURFACE CORROSION, 4 TOTAL 1 FR 77 + 10.5" 2 FR 78 + 4" , 3 FR 78 + 13", 4 FR 79 + 5". R&R 4 EA ATTACH BRACKETS IAW SRM 51-41-01.

Part: PANEL — CORRODED (FRAME 87) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON THE AFT GALLEY AT FRAME 87, RBL 1 FASTENER. REPLACED AFT GALLEY/ LAV PANEL , TREATED, PRIMED , AND PAINTED IAW SRM 53-23-10, 51-42-03, 51-23-04, 51-23-05, AND 51-23-06.

Part: SHEAR TIE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, IT WAS FOUND THAT THE FRONT OF FWD CARGO FR 16 LEFT OF STR 27 L + 1" SHEAR TIE CORRODED. R&R CORRODED SHEAR TIE IAW E190 SRM 51-41-01 , 51-40-02.

Part: PANEL — CORRODED (FRAME 87) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON THE AFT GALLEY AT FRAME 87, RBL 1, AT RBL 3.5 , LBL 2.5, LBL 33, AND LBL 38. REPLACED AFT GALLEY & LAV PANEL. TREATED , PRIMED, AND PAINTED IAW SRM 53-23-10, 51-42-03, 51-23-04, 51-23-05, AND 51-23-06.

Part: INTERCOSTAL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, IT WAS FOUND THAT THE LT OF FLOOR STRUCTURE, FWD LAV, CORRODED IN SEVERAL AREAS AS MARKED FROM FRAME 12 THRU FRAME 15 FWD LAV FLOOR SUPPORT STRUCTURE. R&R WEB & INTERCOSTAL PER SRM51-40-02.

Part: ATTACH BRACKET — CORRODED (DOOR SILL) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK, CORROSION WAS DISCOVERED ON THE AFT CARGO DOOR CUT OUT, TRIM ATTACH BRACKETS ALONG LOWER SILL, R & R THE ATTACH BRACKETS IAW SRM 51-41-01, FIG 1, & FIG 2.

Part: ATTACH BRACKET — CORRODED (FRAME 78) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK, CORROSION WAS DISCOVERED ON THE AFT CARGO DOOR CUT OUT, TRIM ATTACH BRACKETS ALONG LOWER SILL HAD SURFACE CORROSION, R & R THE ATTACH BRACKETS IAW SRM 51-41-01, FIG 1, & FIG 2.

Part: SHEAR TIE — CORRODED (FRAME 16) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, IT WAS FOUND THAT THE FRONT OF FWD CARGO AT FRAME 16, LEFT OF STRINGER 28R, SHEAR TIE CORRODED. R & R SHEAR TIE IAW SRM 51-41-01, 41-40-02, AND 51-23-05.

Part: FLOOR SUPPORT — CORRODED (FRAMES 12-15) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, FOUND THE FLOOR SUPPORT FROM FRAMES 12 - 15. R & R THE FLOOR SUPPORT IAW SRM 51-40-02.

Part: FLOOR SUPPORT — CORRODED (FRAMES 12-14) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, IT WAS FOUND THAT THE FLOOR SUPPORT, FWD GALLEY IS CORRODED IN SERVERAL AREAS. FRAMES 12 - 14. R & R THE FLOOR SUPPORT IAW 51-40-02.

Part: PANEL — CORRODED (FRAME 88) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISOVERED ON THE AFT GALLEY & LAV FWD FRAME 88, LBL 8.5. R & R THE AFT GALLEY & LAV PANEL IAW SRM 53-23-10, 51-42-03, 51-23-04, 51-23-05, AND 51-23-06.

Part: FLOOR SUPPORT — CORRODED (FRAMES 17-19) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, IT WAS FOUND THAT THE AFT GALLEY DOOR FLOOR SUPPORT CORRODED IN SEVERAL AREAS FROM FRAME 17 - 19. R & R THE FLOOR SUPPORT IAW SRM 51-40-03, AND 51-40-02.

Part: PANEL — CORRODED (FRAME 88) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED ON THE AFT GALLEY, LAV FWD FRAME 88, LBL 8.5. R & R AFT GALLEY/LAV PANEL IAW 53-23-10, 51-42-03, 51-23-04, 51-23-05, AND 51-23-06

Part: FLOOR SUPPORT — CORRODED (FRAMES 12-14) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, FOUND THAT THE GALLEY FLOOR SUPPORT CORRODED IN SEVERAL AREAS FROM FRAMES 12 - 14. R & R THE FLOOR SUPPORT IAW 51-40-02.

Part: ATTACH BRACKET — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, IT WAS NOTICED THAT AFT CARGO DOOR CUT OUT, TRIM ATTACH BRACKETS ALONG LWR SILL HAVE SURFACE CORROSION, 4 TOTAL 1 FR 77 + 10.5" 2 FR 78 + 4" , 3 FR 78 + 13", 4 FR 79 + 5". R&R 4 EA ATTACH BRACKETS IAW SRM 51-41-01.

Part: PANEL — CORRODED (FRAME 87) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISCOVERED AFT GALLEY, LAV FWD FRAME 88, LBL 8.5. R & R THE PANEL IAW SRM 53-23-10 , 51-42-03, 51-23-04, 51-23-05, AND 51-23-06.

Part: DOOR SILL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, IT WAS FOUND THAT THE RT OF FLOOR STRUCTURE , FWD GALLEY, WERE CORRODED IN SEVERAL AREAS OF GALLEY FLOOR SUPPORT FROM FRAME 12 THRU FRAME 14. R AND R FLOOR SILL PER 51-40-02.

Part: PANEL — CORRODED (CABIN) · corrosion level 2 · airframe 31,210 hrs · 19,759 cycles

DURING HEAVY CHECK MAINTENANCE, CORROSION WAS DISOVERED AT FRAME 88, LBL 8.5. REMOVED AND REPLACED AFT GALLEY - LAV PANEL IAW SRM 53-23-10 , 51-42-03, 51-23-04, 51-23-05, AND 51-23-06.

Part: CONTROL MODULE — FAILED (NLG STEERING) · airframe 30,020 hrs · 18,922 cycles

ON LANDING GEAR EXTENSION, AN AMBER STEER FAIL MESSAGE APPEARED. A RESET WAS PERFORMED, PER THE QUICK REFERENCE HANDBOOK, AND RESET WAS SUCESSFUL. REMOVED AND REPLACED STEERING CONTROL MODULE AND REMOVED AND REPLACED NR 2 FEED SENSOR & RIGGED. PERFORMED SOFTWARE LOAD CHECK AND PERFORMED OPS CHECK. OPS CHECK PASSED AND SOFTWARE LOAD CHECK PASSED.

Part: SENSOR — FAILED (NLG STEERING) · airframe 30,020 hrs · 18,922 cycles

ON LANDING GEAR EXTENSION, AN AMBER STEERING FAIL MESSAGE APPEARED. RESET WAS PERFORMED, IAW THE QUICK REFERENCE HANDBOOK, AND RESET WAS SUCESSFUL. REMOVED AND REPLACED STEERING CONTROL MODULE AND REMOVED AND REPLACED NR 2 FEED SENSOR & RIGGED. PERFORMED SOFTWARE LOAD CHECK AND PERFORMED OPS CHECK. OPS CHECK PASSED AND SOFTWARE LOAD CHECK PASSED.

Part: WARNING LIGHT — ILLUMINATED (L2 DOOR) · airframe 26,294 hrs · 16,368 cycles

ON CLIMB, RECEIVED L2 DOOR INDICATION ON EICAS AMBER, DECLARED AN EMERGENCY AND DIVERTED BACK TO DEPARTURE. R & R L2 DOOR INDICATION HARNESS IAW AMM 52-72-21, OPS CHECK GOOD.

Part: ACM — FAULTY (RIGHT) · airframe 24,674 hrs · 15,310 cycles

F/A REPORTED FUMES IN THE CABIN. ACCOMPLISHED FIM 21-20--810-810A, FOUND PACK NR 2 AT FAULT. R & R NR 2 ACM IAW AMM 21-51-00. OPS CHECKED NORMAL.

Part: CONTACTOR — FAILED (NR AC BUSS) · airframe 22,612 hrs · 13,986 cycles

CREW REPORTED AT 15,000 FT, DOWN TO EMERGENCY POWER. LOSS OF POWER TO AC BUSS 1 AND DC BUSS 1. STARTED APU, WOULD NOT CONNECT TO AC BUSS 1. HAD MULTIPLE EICAS MESSAGES WITH "AVNX MAU 1B FAIL". AIRCRAFT DIVERTED. R & R BUSS TIE CONTACTOR (BTC) 1 IAW AMM 24-51-07. OPS CHECKED OK. R & R SPDA AC POWER MODULE AS PRECAUTIONARY IAW AMM 24-51-13.

Part: UNKNOWN — MALFUNCTIONED (COMM SYSTEM) · airframe 19,760 hrs · 12,155 cycles

FLT 750 SJU-MCO, LOST ENTIRE COM SYSTEM COMING THROUGH 8000 FT. COULD NOT TRANSMIT / RECEIVE ON EITHER RADIO 1 OR RADIO 2. ALSO COULD NOT COMMUNICATE VIA INTERCOM SYSTEM TO FLT ATTENDANTS. RESET PACIC IAW 44-11-01. FUNCTION CHECK GOOD. NO OTHER FAULTS OR DISCREPANCIES FOUND.

Part: COFFEEMAKER — ODOR (GALLEY) · airframe 16,122 hrs · 9,895 cycles

FLT 1060 AUS-JFK, FLIGHT ATTENDANT REPORTED A SMELL IN THE GALLEY. POWER TO COFFEE POTS AND LIGHTS WERE TURNED OFF SMELL WENT AWAY. REMOVED CEILING PANEL AND LTV PANEL, COFFEEMAKERS, LIGHT BALLAST, CB PANELS BALLAST EMERGENCY CONNECTORS AND INSPECTED ALL AREA FOR ELECTRICAL SMELL. NONE NOTED REF AMM 25-30-00, 24-00-00 PERFORMED FIM 21-20-00-810-A. NO ELECTRICAL SMELL NOTED. RAN ENGINES NR 1 AND NR 2 PER AMM 72-00-00-760-112/118. NO ABNORMAL SMELLS NOTED. REPLACED NR 1 COFFEEMAKER IN FWD GALLEY PER AMM 25-35-00.

Part: COFFEEMAKER — ODOR (GALLEY) · airframe 16,122 hrs · 9,895 cycles

FLT 1060, AUS-JFK, FLIGHT ATTENDANT REPORTED A SMELL IN THE GALLEY. POWER TO COFFEE POTS & LIGHTS WERE TURNED OFF, SMELL WENT AWAY. REMOVED CEILING PANEL AND LTV PANEL, COFFEE MAKERS, LIGHT BALLAST, CB PANELS BALLAST EMERGENCY CONNECTORS AND INSPECTED ALL AREA FOR ELECTRICAL SMELL. NO ELECTRICAL SMELL NOTED REF AMM 25-30-00, 24-00-00 PERFORMED FIM 21-20-00-810-A. RAN ENGINES NR 1 AND NR 2 PER AMM 72-00-00-760-112/118. NO ABNORMAL SMELLS NOTED. REPLACED NR 2 COFFEE MAKER IN FWD GALLEY PER AMM 25-35-00.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 15,793 hrs · 9,689 cycles

FLT 6403 JFK-BNA, ON HEAVY MAINTENANCE CHECK FOUND FWD FUSELAGE LT FLOORBEAM HAS CORROSION AT SEVERAL AREAS. REMOVED AND REPLACED LT FLOORBEAM FRAME 12 TO FRAME 20 AS PER SRM 51-40-02, 51-41-02 AND 51-41-01.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 15,793 hrs · 9,689 cycles

FLT 6403 JFK-BNA, ON HEAVY MAINTENANCE CHECK AT BNA FOUND FWD FUSELAGE RT FLOORBEAM HAS CORROSION AT SEVERAL AREAS. REMOVED AND REPLACED RT FLOORBEAM AT FR 13 TO FR20 AS PER SRM 51-40-02.

Part: LINE — OUT OF POSITION (BLEED AIR SYS) · airframe 15,329 hrs · 9,395 cycles

FLT 960 MCO-BOS, AIR TURNBACK TO MCO DUE TO BLEED 1 MESSAGE FOLLOWED BY BLEED 2 LEAK MESSAGE. THE CREW FOLLOWED QRH PROCEDURES, BLEED 1 RESET AND BLEED 2 SELECTED OFF. FOUND NR 2 ENGINE BLEED LINE ON TOP OF PYLON ATTACHED TO AIR STARTER BRACKET CRACKED AT WELD. REMOVED AND REPLACED LINE AS PER 36-11-04 OPS AND LEAK CHECK OK.

Part: ACTUATOR — WORN (RT MLG) · airframe 13,914 hrs · 8,602 cycles

FLT 515 EWR-FLL, DURING OVERNIGHT CHECK AT FLL FOUND RT MLG RETRACT ACTUATOR BUSHING/BEARING HAS MIGRATED. THE A/C MX FERRIED FROM FLL-MCO FOR ACTUATOR R/R.

Part: BYPASS VALVE — INOPERATIVE · airframe 13,655 hrs · 8,443 cycles

AT ALTITUDE CABIN AND COCKPIT TEMP STEADILY ROSE TO 34 DEG. IN COCKPIT AND 29 DEG IN THE CABIN.THE AIR THROUGH THE VENTS WAS VERY HOT. COCKPIT AND CABIN TEMP CONTROLLERS WERE BOTH SET TO FULL COLD 18 DEG. T/S PER FIM TASK 21-51-00-810-A NR 2 PACK BYPASS VLV FAULTING. SWAPPED NR 1 & 2 BYPASS VALVES. FAULT FOLLOWED SWAPPED NR 1 & 2 VALVES BACK. R & R NR 2 PACK BYPASS VALVE PER 21-51-10-04 CK GOOD. VALVES SWAPPED PER 21-51-10-04.

Part: SIGN — FAILED (EMERGENCY LIGHTS) · airframe 11,065 hrs · 6,878 cycles

FLT 1710 CUN-MCO - DURING ROUTINE MAINTENANCE CHECK IN MCO FOUND EMERGENCY LIGHT ON CEILING PANEL JUST AFT OF EMERGENCY EXIT INOP. MX REMOVED AND REPLACED NR 3 EMERGENCY LIGHT POWER UNIT IAW AMM33-50-01, OPS CHECK GOOD. A/C RETURNED TO SERVICE.

Part: ACTUATOR — FAILED (SLATS) · airframe 10,921 hrs · 6,780 cycles

FLT NR JB411 BOS-TPA, UPON SELECTION OF FLAPS 1 RECEIVED SLAT FAIL EICAS MESSAGE, STICK SHAKER ANTICIPATED, AOA LIMIT FAIL AND SPOILER FAULT CAS MESSAGES. RAN QRH PROCEDURES. MESSAGES DID NOT CLEAR, DECLARED EMERGENCY UNEVENTFUL LANDING IN TPA. MX TROUBLESHOOTING PER FIM 27-81-810-802A FOUND LT WING SLAT NR 5 AND 6 DRIVE MOTOR TORQUE LIMITERS TRIPPED. REMOVED AND REPLACED NR 5 AND 6 SLAT ACTUATORS IAW AMM 27-81-01. ALSO HAD FLT CONTROL NO DISPATCH MESSAGE P-ACE FAULT, ACCOMPLISHED FIM 27-03-00-810-949-A. REMOVED AND REPLACED NR 3 P-ACE IAW AMM 27-03-03-000-801-A. OPS CHECKS NORMAL, AIRCRAFT RETURNED TO SERVICE.

Part: ACM — FAILED (NR 1) · airframe 10,759 hrs · 6,684 cycles

FLT 592 MCO-HPN - ON TAKEOFF PACK 1 FAIL EICAS MESSAGE AND SMELL OF SMOKE AND RUMBLE WITH PACK ON. QRH 2-9 RUN AND PACK DE-SELECTED SMOKE SMELL AND NOISE CEASED, WITH DISPATCH CONCURRENCE OK TO CONTINUE TO HPN. TSM OF ATA 21 AND SMOKE SMELL FLOW CHART USED APPLIED MEL FOR PACK NR 1. REMOVED AND REPLACED NR 1 AIR CYCLE MACHINE IAW AMM 21-51-05, OPS AND LEAK CHECK TEST OK, THIS CLEARS MEL MDDR 65814 MX-4 UPDATED.

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION FOUND ON FLOORBEAM, 11 INCHES FROM LT-BUTT-LINE, BETWEEN FRAMES 85 AND 87. (K)

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION FOUND ON FLOORBEAM, 11 INCHES FROM LEFT-BUTT-LINE, BETWEEN FRAMES 85 AND 87. (K)

Part: HYDRAULIC LINE — LEAKING (HYDRAULIC SYSTEM) · airframe 7,875 hrs · 5,048 cycles

FLT NR 1081 JFK-CLT AIR RETURN TO JFK, HYD 2 LO QTY EICAS FOLLOWED BY HYD 2 LO PRESS. C/W QRH PROCEDURE. REMOVED AND REPLACED NR 2 ENG EDP AND LEAKING HYD PRESSURE LINE AS PER 29-11-01. LEAK CHECK OK IAW AMM 29-11-00.

Part: POWER SUPPLY — DISCHARGED (EMERGENCY LIGHTS)

ON ROUTINE MAINTENANCE, AFT GALLEY OVERHEAD EMERGENCY EXIT LIGHT INOPERATIVE. REMOVED AND REPLACED AFT GALLEY EMERGENCY LIGHT POWER UNIT IAW MM 33-50-01, OPS CHECK GOOD. (K)

Part: POWER SUPPLY — FAILED (EMERGENCY LIGHTS) · airframe 6,935 hrs · 4,519 cycles

FWD DOOR EMERGENCY EXIT SIGN INOP. REMOVED AND REPLACED EMERGENCY LIGHT POWER UNIT, OPS TEST GOOD IAW AMM 33-50-01.

Part: UNKNOWN — ODOR (CABIN) · airframe 3,958 hrs · 2,771 cycles

FLIGHT 1093, JFK-CMH, APPROX 1200Z, RETURNED TO JFK, STRONG ODOR OF BURNING PLASTIC REPORTED BY CABIN CREW IMMEDIATELY AFTER TAKEOFF. SEEMED TO BE STRONGEST IN MID-CABIN. SMOKE SEEN FROM BOTH MAINS AFTER LANDING. DEBRIEF CREW ALSO REPORTED ODOR NOTICED UPON L/G RETRACTION, FOUND ODOR COMING FROM BRAKES 1 TO 4. ALL 4 BRAKES PREVIOUSLY CHANGED DUE CONTAMINATION. RINSED MLGS IAW AMM 12-12-10. PERFORMED OPS CK AND INSPECTION OF BRAKES 1, 2, 3, 4. ALL FUNCTIONS NORMAL. NO DEFECTS NOTED. NO EICAS MSGS PRESENT ON GROUND. NO C/B FOUND OUT. OPS CKS OF BRAKES 1, 2, 3, 4 PERFORMED IAW AMM 32-40-00. ALSO LTV PERFORMED INSPECTION, NO DEFECTS NOTED. NEXT FLIGHT 1008 JFK/BOS PERFORMED NO ODOR NOTED.

Part: FITTING — DAMAGED (CARGO DOOR) · airframe 3,346 hrs · 2,354 cycles

AFT CARGO DOOR OPEN INDICATION AFTER TAKEOFF AT 500 FEET. RETURNED TO JFK AT 5000FT & 210 KIAS. STARTED FEELING VIBRATIONS WHEN ACCELERATING TO 190 KIAS. VB WENT AWAY AT 180 KIAS. VISUAL INDICATION THAT DOOR WAS OPEN. LANDED UNEVENTFULLY. INSPECTED AFT CARGO DOOR & SURROUNDING STRUCTURE AS PER EA E-07-088. REPAIRED DAMAGED AFT CARGO DOOR AFT FRAME ROLLER FITTING & ACCESS COVER AS PER EA E-07-089 & EA E-07-090B PART 1 DOOR FRAME INSPECTION. OPERATION & INDICATOR CHECKED NORMAL. OK FOR SERVICE.

Part: BYPASS VALVE — FAILED (A/C PACK) · airframe 1,757 hrs · 1,235 cycles

INFLIGHT REPORTED BURNING PLASTIC SMELL & HOT AIR BLOWING OUT OF VENTS IN AFT CABIN. SMELL MOVED FORWARD TO COCKPIT. NO SMOKE, TURNED OFF RECIRC FANS. SMELL CONTINUED, RECEIVED PACK NR 2 FAIL EICAS. PERFORMED QRH. DID NOT TURN PACK NR 2 BACK ON, SMELL DISSIPATED. DECLARED EMERGENCY. FOUND PACK NR 2 BYPASS VALVE FILTER CONTAMINATED. REPLACED BYPASS VALVE. FOUND NR 2 ACM CONTAMINATED. CLEANED & INSTALLED BACK ACM. FOUND RT & LT RECIRCULATION FILTERS CONTAMINATED DUE TO INSULATION BLANKET INGESTION. REPLACED RECIRCULATION FILTERS. INSTALLED INSULATION BLANKET AROUND PACK 1 & 2 DUCTS AND RECIRCULATION FILTERS. SECURED ALL DUCTS BACK TOGETHER. BOTH PACK SYSTEM OPS CHECKED OK WITH ENGINE RUNNING.