N19621

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 45,792 hrs · 24,547 cycles

LEFT MAIN LANDING GEAR RED LIGHT ILLUMINATED WHEN GEAR WAS RAISED. LANDING GEAR EXTENDED NORMAL. SIMULATED GEAR RETRACTION AND EXTENSION WITH PLATES AND FERRIS METAL BLOCKS. ALL CHECK NORMAL.REF MM 32-61-00. A/C OK TO CONTINUE. CREW DECLARED EMERGENCY LANDING IN EWR.

Part: APU — DEFECTIVE (APU BAY) · airframe 45,268 hrs · 24,249 cycles

APU FUEL LEAK INTERNALLY INSIDE APU ITEM PLACED ON PLACARD APU INOP NEEDS APU WHILE TROUBLESHOOTING FUEL SMELL DISCREPANCY ON L/P 8809346, IDENTIFIED APU AS SOURCE OF SMELL. REPLACED BURNER CAN ASSEMBLY WITH NO SUCCESS AND NOTICED RAW FUEL DRIPPING FROM CIRCUMFERENTIAL FLANGE JOINING COMPRESSOR SECTION AND HOT SECTION AT 6 O`CLOCK POSITION. RECOMMEND APU R&R.

Part: TRANSFORMER — UNSERVICEABLE (ELECTRICAL SYS) · airframe 42,930 hrs · 22,982 cycles

SMELLED ELECTRIC ODOR DURING CLIMBOUT OF EWR. CHANGED ATA 2400 TO 2430. PERFORMED INSP TASK 05-51-95-200-801C2. FOUND BATTERY O/H AND EXT PWR C/B'S TRIPPED. R&R''D BATT & BATT CHGR. FOUND NO OTHER DEFECTS W/ PARTS OR WIRING. NO FAULTS NOTED W/ EXT PWR SYS. RAN ENGS DUE TO CREW REPORT ON FORM 46.6020. A/C OPS CHECKS GOOD PER AMM 24-31-11 AND 24-31-21. OK FOR SERVICE. ROTABLE PARTS CHANGE WAS INDICATED - TT # 1235218 SN OFF 03226 TT # 1425874 S/N OFF 00734 CHARGER, BATTERY OFF 99-2426-9-0004 3226 ON 99-2426-9-0004 3171 BATTERY, AIRCRAFT OFF 99-2434-9-9002 0734 ON 99-2434-9-9002 1261. FLT/CHK 0084 NON ROUTINE LINE MIS REPORTED STA ATL 27 AUG 10 ATA 02400 STRONG ELECTRIC ODOR IN COCKPIT SHORTLY AFTER T/O. ATA 02400 PERFORMED INSP AND OPERATION CHKS PER TASK 05-51-95-200-801. FOUND NO UNUSUAL ODORS IN ACFT. R&R`D RECIRC FILTER & FOUND DIRTY W/ SLIGHT ODOR. R&R`D RECIRC FAN PER AMM 21-21-22 AS PRE CAUTIONARY AND REPLACED COALESCER BAGS PER 21-51-41. AIRCRAFT OK FOR SERVICE. ROTABLE PARTS CHANGE WAS INDICATED - TT # 1445301 S/N OFF 02616 FAN, AIR, DISTR OFF 03-2168-9-0001 2616 ON 03-2168-9-0001 2834 A/C 0621 DEF 2100 LOG 8579202 FLT/CHK 1142 NON ROUTINE LINE SCHEDULED ATL 27AUG10.

Part: BEAM — CRACKED (L1 DOOR) · airframe 42,670 hrs · 22,835 cycles

L1 DOOR, LOWER FWD GATE BEAM, IS CRACKED ABOVE THREE HI-LOK FASTENERS OF LOWER STOP PIN FITTING. REPAIRED PER ECRA 5210-02165.

Part: HINGE FITTING — CRACKED (DOOR FRAME) · airframe 42,670 hrs · 22,835 cycles

SUPPORT TASK - L-1 DOOR UPPER HINGE HAS CRACK INDICATION AT HOLE MARKED NR 4 ON FIG 4 OF EA 5330-03736. INSTALLED REPAIR DOUBLERS IN REF EC/RA 5330-04040.

Part: HINGE FITTING — BROKEN (FUSELAGE) · airframe 42,670 hrs · 22,835 cycles

SUPPORT TASK - REMOVE UPPER HINGE FITTING ON L-1 DOOR. REMOVED AND RE-INSTALLED NEW FITTING P/N 65C34670-1, REF SRM 51-4 0-02.

Part: HINGE FITTING — BROKEN (FUSELAGE) · airframe 42,670 hrs · 22,835 cycles

SUPPORT TASK - REMOVE LOWER HINGE FITTING ON L-1 DOOR. REMOVED AND RE-INSTALLED NEW FITTING P/N 65C36075-1 REF SRM 51-40-02.

Part: WEB — CRACKED (FUSELAGE) · airframe 42,670 hrs · 22,835 cycles

EA 5310-04659 OP 02 WEB CRACKED AT STA 303.9 AT OVAL HOLE FOR STRINGER 16L. INSTALLED REPAIR WEB AT STA 303.9 AT OVAL HOLE FOR STR 16L PER EA 5310-04659 OP 02.

Part: SEAL — FAILED (FWD CARGO DOOR) · airframe 41,641 hrs · 22,309 cycles

AT CRUISE ALT 320 CABIN PRESSURE 8000 DIFF 7.6. CABIN CONTINUED TO CLIMB AT 500 FT/MIN AND CABIN ALT EXCEED 900FT DIFF FELL TO 6.6. MANUAL PRESSURE NO HELP. OUTFLOW SHOWED FULL. REF N/R 4993693 & 4993694 FOR OPS & HEALTH CHECKS, R & R BAD DOOR SEAL & DOOR SILL REF N/R 4993696, 4993695 & 4997354.

Part: UPLOCK ACTUATOR — INOPERATIVE (LT MLG) · airframe 38,723 hrs · 20,787 cycles

LEFT LANDING GEAR WOULD NOT REMAIN IN UP AND LOCKED POSITION AFTER TAKEOFF, LANDING NORMAL SINK RATE. OVERWEIGHT LANDING 114.9. REMOVED AND REPLACED LEFT INBOARD MAIN LANDING GEAR UPLOCK ACTUATOR, AND LUBED LEFT MAIN LANDING GEAR PER AMM 32-32-41. OPERATIONAL CHECKS GOOD, OK TO CONTINUE.

Part: SOCKET — DEFECTIVE (CABIN) · airframe 37,340 hrs · 20,061 cycles

SEAT TRACK EMERGENCY LIGHT AT 12 BC INOPERATIVE. REPLACED LIGHT SOCKET ASSEMBLY AT SEAT 12 BC, OPERATIONAL CHECKED GOOD.

Part: FRAME — CRACKED (BS 360 S8-9L) · airframe 36,681 hrs · 19,723 cycles

PAX CABIN HAS FRAME CRACKED AT STA 360 BETWEEN STRINGER 8L AND 9L. TRIMMED OUT CRACKED AREA INSTALLED REPAIR DOUBLERS AND REPLACED CLIP PER ECRA 5310-04706.

Part: FRAME — CRACKED (BS 827 S9L) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 827 ABOVE STRINGER 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04710.

Part: FRAME — CRACKED (BS 747 S9L) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 747 ABOVE STRINGER 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 867 S9R) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 867 ABOVE STRINGER 9R. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 867 S9L) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 867 ABOVE STRINGER 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 827 S9R) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 827 ABOVE STRINGER 9R. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04710.

Part: FRAME — CRACKED (BS 867 S9L) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 867 ABOVE STRINGER 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 400 S8L) · airframe 36,681 hrs · 19,723 cycles

PAX CABIN HAS FRAME CRACKED AT STA 400 BETWEEN STRINGER 8L AND 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 440 S8-9R) · airframe 36,681 hrs · 19,723 cycles

PAX CABIN HAS FRAME CRACKED AT STA 440 BETWEEN STRINGER 8R AND 9R. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 787 S9L) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 787 ABOVE STRINGER 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 787 S9R) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 787 ABOVE STRINGER 9R. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 747 S9R) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 747 ABOVE 9R. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FITTING — CORRODED (HORIZONTAL STAB) · airframe 36,681 hrs · 19,723 cycles

RT HORIZONTAL STAB FORWARD UPPER LUG HAS CORROSION. REMOVED SLEEVE AND BUSHINGS. REMOVED CORROSION AND PERFORMED REQUIRED INSPECTIONS PER ECRA 5510-01915. FABRICATED AND INSTALLED REPAIR SLEEVE AND FLANGE BUSHINGS PER SRM 55-10-10.

Part: FRAME — CRACKED (BS 907 S9L) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 907 ABOVE STRINGER 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FITTING — CORRODED (HORIZONTAL STAB) · airframe 36,681 hrs · 19,723 cycles

RT HORIZONTAL STAB FORWARD LOWER LUG HAS CORROSION. REMOVED SLEEVE AND BUSHINGS, REMOVED CORROSION AND PERFORMED REQUIRED INSPECTIONS PER ECRA 5510-01915. FABRICATED AND INSTALLED REPAIR SLEEVE AND FLANGE BUSINGS PER SRM 55-10-10.

Part: FRAME — CRACKED (BS 727B S9L) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 727B ABOVE STRINGER 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 907 S9R) · airframe 36,681 hrs · 19,723 cycles

FRAME CRACKED AT STA 907 ABOVE STRINGER 9R. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 440 S8L) · airframe 36,681 hrs · 19,723 cycles

PAX CABIN HAS FRAME CRACKED AT STA 440 BETWEEN STRINGER 8L AND 9L. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: FRAME — CRACKED (BS 400 S8R) · airframe 36,681 hrs · 19,723 cycles

PAX CABIN HAS FRAME CRACKED AT STA 400 BETWEEN STRINGER 8R AND 9R. FABRICATED AND INSTALLED REPAIR PER ECRA 5310-04714.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 36,681 hrs · 19,723 cycles

FORWARD CARGO DOOR CUTOUT FORWARD FRAME HAS A CRACK AT THE NR 5 DOOR STOP. REPLACED FORWARD CARGO DOOR CUT-OUT FORWARD FRAME PER SRM 51-40-02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 30,145 hrs · 16,308 cycles

INSPECTION FOUND FLOORBEAM CORRODED AT ALL NUT CLIPS TOP AND BOTTOM AT STA 986.5, S18L TO S18R. REPAIRED IAW ECRA 5311-01235.

Part: FLAP TRACK — CORRODED (NR 2 FLAP) · airframe 30,145 hrs · 16,308 cycles

INSPECTION FOUND THE NR 2 FLAP TRACK CORRODED IN THE AFT LOWER HOLE WHERE THE TRANSMISSION IS ATTACHED. THE AREA WAS REWORKED IAW CMM 57-53-15.

Part: FLAP TRACK — CORRODED (NR 8 FLAP) · airframe 30,145 hrs · 16,308 cycles

INSPECTION FOUND THE NR 8 FLAP TRACK CORRODED IN AFT O/B HOLE WHERE THE TRANSMISSION IS ATTACHED. THE AREA WAS REWORKED IAW CMM 57-53-15.

Part: FLAP TRACK — CORRODED (NR 1 FLAP) · airframe 30,145 hrs · 16,308 cycles

INSPECTION FOUND THE NR 1 FLAP TRACK CORRODED IN THE AFT UPPER HOLE WHERE THE TRANSMISSION IS ATTACHED. THE AREA WAS REWORKED IAW CMM 57-53-15.

Part: STRUCTURE — WORN (KEELBEAM) · airframe 25,078 hrs · 13,622 cycles

WEAR DAMAGE WAS FOUND AT THE UPPER SURFACE OF THE OUTBOARD FLANGE OF RT KEEL BEAM LOWER STRUCTURE JUST FORWARD OF STA 727 WHILE AIRCRAFT WAS IN MAINTENANCE CHECK AT HOU. THE WEAR WAS CAUSED BY THE FLOATING NUT PLATES ATTACHED TO THE OUTBOARD FLANGE OF THE LOWER STRUCTURE. THE NUT PLATES ARE USED TO ATTACH THE WHEEL WELL FAIRING. THE KEEL BEAM STRUCTURE OUTBOARD FLANGE WAS REPAIRED IAW ECRA 5311-01149.

Part: FRAME — DELAMINATED (RT ELEVATOR) · airframe 18,869 hrs · 10,236 cycles

INSPECTION FOUND THE RT ELEVATOR UPPER AND LOWER CHORD DELAMINATED. THE DELAMINATED AREAS WERE REPAIRED IAW SRM 51-70-17 AND ECRA 5523-01022.

Part: SKIN — GOUGED (CARGO DOOR) · airframe 18,834 hrs · 10,219 cycles

INSPECTION FOUND FORWARD CARGO DOOR EXTERIOR SKIN GOUGED ABOVE HANDLE. A REPAIR DOUBLER WAS INSTALLED IAW SRM 52-00-01, FIGURE 203.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 18,834 hrs · 10,219 cycles

INSPECTION FOUND CABIN FLOORBEAM CORRODED AROUND SCREW HOLES AT STA 986.5, LBL 21 AND LBL 26. DOUBLERS WERE INSTALLED IAW SRM 53-00-51, FIGURE 203 AND INSTALLED SHIM ON INTERCOSTAL IAW ECRA 5310-03585.

Part: COALESCER BAG — CONTAMINATED (LT AND RT PACKS) · airframe 17,320 hrs · 9,370 cycles

THE FLIGHT ATTENDANT REPORTED SMOKE IN THE CABIN AFTER TAKEOFF FROM SMF. THE AIRCRAFT WAS RETURNED TO SMF WHERE IT LANDED WITHOUT INCIDENT. TROUBLESHOOTING BY MAINTENANCE FOUND EVIDENCE OF APU OIL ENTERING THE AIR CONDITIONING PNEUMATIC SYSTEM, BUT THE FAILURE COULD NOT BE DUPLICATED. THE ENGINES AND APU WERE RUN WITH PACKS OPERATING AND AIRCRAFT PRESSURIZED WITH NO EVIDENCE OF SMOKE OBSERVED IN THE CABIN. ALL CHECKS WERE NORMAL. BOTH THE LEFT AND RIGHT PACK COALESCER BAGS WERE REPLACED DUE TO OIL SATURATION.