N196WQ

Part: DOOR — OUT OF ADJUST (EMERGENCY EXIT) · airframe 9,594 hrs · 9,336 cycles

CREW REPORTED THAT THE ACFT WOULD NOT PRESSURIZE. CREW RAN QRH AND WENT TO MANUAL MODE THEN AUTO MODE WITH SOME POSITIVE RESULTS. CONTROL AND INDICATION BECAME INTERMITTENT WITH PRESSURIZATION FLUCUATIONS. CREW ELECTED TO RETURN TO DEPARTURE, DID NOT DECLARE AN EMERGENCY AND LANDED AND TAXIED TO GATE WITHOUT INCIDENT. MAINTENANCE INSPECTED AND FOUND PRESSURE LEAK AT FORWARD EMERGENCY DOOR. MAINTENANCE ADJUSTED DOOR IAW AMM AND OPS CHECKED GOOD. ACFT IS GOOD FOR SERVICE.

Part: HANDLE — UNSECURE (CARGO DOOR) · airframe 9,495 hrs · 9,224 cycles

CREW RECEIVED A FUSELAGE MASTER WARNING LIGHT. CREW FOLLOWED QRH, DID NOT DECLARE AN EMERGENCY AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND FOUND AFT CARGO DOOR HANDLE POPPED OUT AND NOT SECURE. MAINTENANCE PERFORMED OPS CHECKED OF AFT CARGO DOOR IAW AMM, RESECURED HANDLE AND OPS CHECKED GOOD. ACFT IS GOOD FOR SERVICE.

Part: PSU — DISLODGED (SEAT 20CD) · airframe 9,467 hrs · 9,194 cycles

CREW REPORTED THAT THE PASSENGER SERVICE UNIT OVER SEATS 20 C & D FELL OUT. MAINTENANCE SECURED PSU IAW AMM AND OPS CHECKED GOOD.

Part: HANDLE — UNSECURE (CARGO DOOR) · airframe 9,350 hrs · 9,067 cycles

CREW RECEIVED AN AFT CARGO DOOR WARNING INDICATION. CREW LEVELED OFF AT 10,000 FT, CABIN WAS NOT PRESSURIZING AND CREW ELECTED TO RETURN. AN EMERGENCY WAS NOT DECLARED AND LANDED WITHOUT INCIDENT. ON ARRIVAL, MX FOUND DOOR HANDLE WAS IN THE OUT POSITION. MX INSPECTED THE DOOR AND LATCHED/UNLATCHED NUMEROUS TIMES IAW AND OPS CHECKED GOOD. ACFT IS GOOD FOR SERVICE.

Part: SKIN — DENTED (FUSELAGE) · airframe 9,332 hrs · 9,043 cycles

MULTIPLE DENTS ON LT SIDE AFT OF ICE SHIELD IAW RD NR 8/4-53-5620. MX FABRICATED PATCH FOR INSTALL OVER SKIN.

Part: ATTACH FITTING — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, MX FOUND CORROSION ON FWD FLOOR FITTING ATTACHMENT POINT FOR G3 GALLEY. MX R & R FWD FLOOR FITTING IAW SRM 51-41-00.

Part: BEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, MX FOUND CORROSION ON FWD EMERGENCY EXIT DOOR SURROUND LOWER BEAM TO BE OUT OF ALLOWABLE LIMITS. MX R & R LOWER EDGE BEAM IAW SRM 51-42-05,51-40-07, AND DWG 85329511.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX FOUND RT INBD SEAT TRACK, CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW IAW SRM 51-42-05, 51-40-15, AND 51-40-07.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND CORROSION OUT OF LIMITS ON RT OTBD SEAT TRACK AT X32.4 TO X71.2. MX R & R SEAT TRACK IAW SRM 51-42-00.

Part: ACCESS PANEL — CORRODED (ZONE 500) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND CORRODED COUNTERSINKS ON FUEL PANEL 521BT TO BE OUT OF ALLOWABLE LIMITS. MX R & R FUEL PANEL IAW AMM 57-11-06.

Part: DUCT — CORRODED (ZONE 300) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX FOUND TUBE ON BLEED AIR DUCT CORRODED BEYOND ALLOWABLE LIMITS. MX R & R BLEED AIR DUCT IAW AMM 21-51-66.

Part: ACCESS PANEL — CORRODED (ZONE 600) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, MX FOUND COROSION IN COUNTERSINKS ON FUEL ACCESS PANEL 623AT TO BE OUT OF ALLOWABLE LIMITS. MX R & R FUEL ACCESS PANEL IAW AMM 57-11-01.

Part: ACCESS PANEL — CORRODED (ZONE 500) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX FOUND CORROSION ON FUEL PANEL 521AT COUNTERSINKS, FOUND TO BE OUT OF ALLOWABLE LIMITS. MX R & R FUEL PANEL IAW AMM 57-11-06.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, MX FOUND LT INBD SEAT TRACK, CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW SRM 51-40-05, AND 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND RT INBD SEAT TRACK AT BS 116 TO 176 CORRODED BEYOND LIMITS. MX REPLACED SEAT TRACK IAW SRM 51-40-07, 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND RT INBD SEAT TRACK AT BS X229.5 TO X569.5 CORRODED BEYOND LIMITS. MX R & R SEAT TRACK IAW SRM 51-40-15, 51-41-00, AND 51-42-05.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

WHILE ACFT WAS IN FOR HEAVY CHECK. MX FOUND RT OTBD SEAT TRACK, PN 85328261-105, CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW IAW SRM 51-42-05; 51-40-15;51-40-07; AND 51-42-15. ACFT IS STILL CURRENTLY OUT OF SERVICE FOR HEAVY CHECK COMPLETION.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, MX FOUND LT FORWARD INBD SEAT TRACK, BS 61 & 94 CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW SRM 51-42-05 & 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND CORROSION ON THE NR 1 LT OTBD SEAT TRACK. MX R & R SEAT TRACK IAW SRM 51-40-01 AND 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX FOUND RT OTBD SEAT TRACK, CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW SRM 51-40-7 AND 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND CORROSION ON THE LT OTBD SEAT TRACK, MX R & R SEAT TRACK IAW SRM 51-40-07 AND 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND LT OTBD SEAT TRACK CORRODED. MX R & R SEAT TRACK IAW SRM 51-42-05, 51-40-15, 51-40-07.

Part: ATTACH ANGLE — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX FOUND CORROSION ON SUPPORT ANGLE ON FWD PAX DOOR LOCATED UNDER FORWARD HINGE SHAFT TO BE OUT OF LIMITS. MX R & R SUPPORT ANGLE IAW SRM 51-40-07 & 51-42-05.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND LT OTBD SEAT TRACK CORRODED OUT OF LIMITS FROM BS 346 TO 377. MX R & R SEAT TRACK IAW SRM 51-40-07, 51-42-45, 51-40-15,51-42-05.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

WHILE ACFT WAS IN FOR MX. MX FOUND SEAT TRACK, CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW SRM 51-42-05; 51-42-15; AND 51-40-15. ACFT OUT OF SERVICE.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX FOUND RT OTBD SEAT TRACK, CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW SRM 51-40-07 AND 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, MX FOUND CORROSION TO BE OUT OF LIMITS ON RT INBD SEAT TRACK LOCATED AT FUSELAGE BS 236 TO 321. MX R & R SEAT TRACK IAW SRM 51-40-07 & 51-40-15.

Part: SEAT TRACK — CORRODED (BS 644) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND RT INBD SEAT TRACK HAS CORROSION AT BS 644. MX R & R SEAT TRACK IAW SRM 51-40-07 AND 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY MAINTENCANCE. MX FOUND RT INBD SEAT TRACK CORRODED AND OUT OF LIMITS AT FUSELAGE BS 644. R & R SEAT TRACK IAW SRM 51-40-07 & 51-40-15.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX FOUND RT INBD SEAT TRACK CORRODED BEYOND ALLOWABLE LIMITS AT FUSELAGE BS 321. MX R & R SEAT TRACK IAW SRM 51-40-07 & 51-40-05.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK. MX RT INBD SEAT TRACK AT FUSELAGE BS -39.00 TO 1.00 CORRODED BEYOND ALLOWABLE LIMITS. MX R & R SEAT TRACK IAW SRM 51-40-07 & 51-40-15.

Part: FITTING — CORRODED (ZONE 800) · corrosion level 2 · airframe 9,332 hrs · 9,043 cycles

DURING HEAVY CHECK, FOUND FWD EMERGENCY DOOR LOWER DOOR BRACKETS ON THRESHOLD SHOWS EVIDENCE OF CORROSION. MX R & R TWO STOP FITTINGS IAW SRM 51-41-00, AND AMM 52-23-00, SHEET 4, FIG 504 RT.

Part: HANDLE — OUT OF POSITION (CARGO DOOR) · airframe 84,900 hrs · 8,211 cycles

FLIGHT 4864 RETURNED TO THE FIELD IS AUS DUE TO THE CARGO DOOR LIGHT ILLUMINATED. NO EMERGENCY WAS DECLARED. THE FLIGHT LANDED SAFELY AND IT WAS FOUND THAT THE HANDLE WAS POPPED OUT.

Part: CABLE ASSY — BENT (MLG) · airframe 7,874 hrs · 7,585 cycles

WHILE PERFORMING TC32-000-0C2 CABLE FROM CAN MECH TO MLG UNLOCK ACTUATOR IN RT NACELLE IS BENT AT THE SWAGED END. CABLE ASSY IS PART OF THE EMERGENCY ALTERNATE EXTENSION FOR THE LANDING GEAR SYSTEM. TC32-000-0C2 IS THE REPEAT INSPECTION REQUIRED BY AD 2011-15-09.

Part: CABLE — BENT (LANDING GEAR) · airframe 7,871 hrs · 7,584 cycles

WHILE PERFORMING TC 32-000-0C2 CABLE FROM CAM MECH GOING FWD IS BENT WHERE CABLE TURNS INTO ADJUSTABLE TURNBUCKLE. OTHER END OF TURNBUCKLE CONNECTS TO CLEVIS FORKEND/BARREL SPRING ASSY. TC 32-000-0C2 IS THE REPEAT INSPECTION REQUIRED BY AD 2011-15-09.

Part: DOOR — UNSECURE (CARGO BAY) · airframe 7,368 hrs · 7,125 cycles

AT ABOUT 70 KTS REAR CARGO DOOR LIGHT ILLUMINATED. NORMAL BREAKING. PERFORMED OPERATIONAL CHECK OF THE AFT CARGO DOOR IAW Q400 AMM 52-31-00-710-801, OPS CHECKED GOOD. WARNING LIGHT WENT OUT WHEN DOOR SECURED.

Part: PROXIMITY SENSOR — MALFUNCTIONED (LT MLG) · airframe 6,999 hrs · 6,789 cycles

LEFT MAIN GEAR UNSAFE LIGHT INTERMITTENTLY COMES ON. GEAR HANDLE INTERMITTENTLY COMES ON AT SAME TIME. REPLACED LT MLG NR 1 DOWNLOCK PROXIMITY SENSOR IAW 32-61-06. ALSO REPLACED LT MLG NR 2 DOWNLOCK PROXIMITY SENSOR IAW Q400 AMM 32-61-06. PERFORMED OPERATIONAL TEST OF THE EXTENSION AND RETRACTION SYSTEM IAW Q400 AMM 32-31-00.

Part: UNKNOWN — MALFUNCTIONED (ITT) · airframe 6,986 hrs · 6,772 cycles

IN CRUISE THE LEFT ITT SHOWED 257 DEG C AND THE RIGHT SHOWED 706 DEG C ALL OTHER INDICATIONS WERE NORMAL AND NO CAUTION LIGHTS. FOLLOWED Q400 FIM 73-20-00 SUB TASK 73-20-00-810-006 SECTION A UP TO AND INCLUDING STEP 3, NO MAJOR ITT DIFFERENCE WAS NOTED DURING ENG RUNS, FAULT CODE 973 DID NOT REOCCUR AND ALL OTHER PARAMETERS NORMAL.

Part: UNKNOWN — ODOR (CABIN) · airframe 6,840 hrs · 6,638 cycles

DURING CRUISE CLOSE TO TOD, F/A NOTIFIED FLIGHT CREW THAT THERE WAS A STRANGE SMELL IN THE CABIN. THE FIRST OFFICER INSPECTED THE CABIN AND DETERMINED THAT THERE WAS AN UNKNOWN SMELL THAT DID NOT SEEM TO BE CAUSED BY SOMETHING BURNING. AS A PRECAUTION, CREW RAN QRC AND QRH AND REQUESTED PRIORITY TO MSY AS THE NEAREST SUITABLE AIRPORT DUE TO ALTITUDE. FLIGHT LANDED WITHOUT FURTHER INCIDENT. MX AND CREW PERFORMED OPERATIONAL TEST OF THE BLEED AIR SYSTEM AND COULD NOT DUPLICATE SMELL. OPS CHECKED GOOD.

Part: HANDLE — UNSECURE (CARGO DOOR) · airframe 5,889 hrs · 5,754 cycles

CARGO LIGHT ILLUMINATED DURING FLIGHT. THERE WAS NO LOSS OF PRESSURIZATION. CREW DESCENDED BELOW FL100 AS A PRECAUTION AND LANDED IN CLE WITHOUT FURTHER COMPLICATIONS. CAPTAIN INSTRUCTED CLE GROUND PERSONNEL NOT TO TOUCH THE CARGO DOOR UNTIL HE VISUALLY INSPECTS IT. DURING HIS POST FLIGHT CHECK, HE NOTED THAT THE CARGO DOOR HANDLE WAS FULLY EXTENDED.

Part: PROXIMITY SENSOR — OUT OF ADJUST (CARGO DOOR) · airframe 5,884 hrs · 5,750 cycles

AFT BAGGAGE DOOR LIGHT ILLUMINATED IN FLIGHT, RETURNED TO FIELD. RE-ADJUSTED AFT BAG DOOR PROX SENSOR.

Part: DOOR — UNSECURE (CARGO BAY) · airframe 5,883 hrs · 5,749 cycles

AFT BAGGAGE DOOR NOT SECURED PROPERLY, LANDED WITH NO FURTHER INCEDENT. PERFORMED OPS CHECK OF AFT BAGGAGE DOOR OPS CHECKED GOOD. NO FAULT FOUND.

Part: HANDLE — UNSECURE (DOOR) · airframe 5,573 hrs · 5,458 cycles

DURING CRUISE, CREW NOTICED "FUSELAGE DOOR" INDICATION. THERE WAS NO INDICATION OF PRESSURIZATION LOSS, BUT CREW ELECTED TO DIVERT TO ALB AS A PRECAUTION. MECHANIC VERIFIED THAT THE DOOR HANDLE WAS POPPED OUT ANT THE INDICATION WENT AWAY ONCE HANDLE WAS SECURED. MECHANIC RE-CHECKED THE DOOR AND INDICATION AND FOUND IT TO BE FUNCTIONAL. FAA HAS BEEN NOTIFIED BY DIRECTOR OF FLIGHT OPERATIONS. RE-SECURED DOOR, OPS CHECKED GOOD.

Part: WARNING SYSTEM — MALFUNCTIONED (BLEED AIR SYS) · airframe 5,558 hrs · 5,441 cycles

NUMBER 2 BLEED HOT LIGHT ILLUMINATED DURING TAKEOFF ROLL. TAXIED OFF THE RUNWAY, RAN CHECKLIST AND CHECKED WITH MAINTENANCE. ALL INDICATIONS WENT BACK TO NORMAL AND REQUESTED TO GO BACK IN SEQUENCE.

Part: LOCK — ENGAGED (NLG) · airframe 4,154 hrs · 4,108 cycles

THE NOSE LANDING GEAR DID NOT RETRACT UPON SELECTION OF THE LANDING GEAR HANDLE TO THE UP POSITION. THE SUBSEQUENT LANDING GEAR SYSTEM INSPECTION REVEALED THAT THE NOSE GEAR GROUND LOCK WAS STILL ENGAGED. THE NOSE GEAR GROUND LOCK WAS DISENGAGED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: TRANSDUCER — FAILED (OIL PRESSURE) · airframe 2,421 hrs · 2,391 cycles

AT 13000 LT ENGINE OIL PRESSURE WAS AT 117 PSI, OIL PRESSURE WAS FLUCTUATION. LT ENGINE SHUTDOWN AND DIVERTED TO ALB. REMOVED AND REPLACED LEFT ENGINE OIL PRESSURE TRANSDUCER IAW AMM 79-31-01-000-801 AND 79-31-01-400-801 FOUND OPERATIONAL CHECKS GOOD, NO LEAKS NOTED.

Part: CONNECTOR — DIRTY (OIL PRESS XDCER) · airframe 2,421 hrs · 2,390 cycles

LEFT ENGINE OIL PRESS AT 178 PSI, ENGINE SHUTDOWN IN FLIGHT, DIVERTED TO KDTV DUE TO OIL PRESSURE. DISCONNECT P55 CONNECTOR OIL PRESS TRANSDUCER, CLEANED CONNECTOR AND RE-CONNECTED IAW AMM 70-00-15. OPS CHECK GOOD IAW AMM.

Part: SENSOR — MALFUNCTIONED (EMERGENCY EXIT)

FORWARD EMERGENCY EXIT LIGHT ILLUMINATED IN FLIGHT. OPENED DOOR AND INSPECTED SENSOR, CLEANED 7 LUBED SENSOR. OPERATIONAL CHECK OF DOOR CHECKS GOOD. LIGHT IS EXTINGUISHED.

Part: PROXIMITY SENSOR — DIRTY (EMERGENCY EXIT) · airframe 2,016 hrs · 1,983 cycles

FORWARD EMERGENCY EXIT DOOR LIGHT ILLUMINATED. CLEANED PROXIMITY SENSOR OPS CHECK GOOD.

Part: APU — CONTAMINATED (APU BAY) · airframe 1,773 hrs · 1,749 cycles

APU ON SMOKE FILLED ENTIRE AIRPLANE, EVACUATED. IN PROCESS OF DE-ICING. FOUND CAUSE OF SMOKE TO BE GLYCOL INDUCTION FROM RUNNING APU. APU DEFERRED IAW MEL 49-00-1. CAT D ID NR 33748.

Part: HANDLE — UNSECURE (CARGO DOOR)

ACFT RETURNED TO FIELD AFTER TAKEOFF. AFT CARGO DOOR LIGHT ILLUMINATED AFTER TAKEOFF. FOUND AFT CARGO DOOR HANDLE NOT PROPERLY SECURED. RESEATED DOOR AS REQUIRED. NO FURTHER ACTION REQUIRED AT THIS TIME. (K)

Part: HANDLE — UNSECURE (AFT CARGO DOOR)

ON CLIMB-OUT, CREW GOT AFT DOOR WARNING LIGHT, AIRCRAFT RETURNED TO FIELD. MX CALLED AND VERIFIED HANDLE WASN'T STOWED, RESECURED HANDLE OPS CHECK OK.