N231US

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 62,202 hrs · 65,306 cycles

PASSENGER CABIN EMERGENCY FLOOR ESCAPE PATH LIGHTING FOUND TO BE INOPERATIVE WHILE PERFORMING A SERVICE CHECK. MX FOUND A SHORT IN THE EMERGENCY EXIT FLOOD LIGHT. A WIRE HAD BROKEN AWAY FROM THE LIGHT SOCKET AND GROUNDED. WIRE WAS REPAIRED AND THE SYS OPS CHECKED GOOD IAW MM 33-21-27.

Part: WIRE — DAMAGED (EMERGENCY LIGHTS) · airframe 61,828 hrs · 64,926 cycles

CABIN OVERHEAD EMERGENCY LIGHTS FOUND INOPERATIVE DURING PERFORMANCE OF AN A-CHECK. MX REPLACED BATTERY PACKS WITH SERVICEABLE. AFTER REPLACEMENT OF BATTERY PACKS, MX FOUND LAST ROW OF EMERGENCY LIGHT REMAINED INOPERATIVE. MX FOUND A PINCHED & FRAYED WIRE UNDER CARPET MOLDING. REPAIRED WIRE AND ALL SYS OPERATIONALLY CHECKED GOOD IAW MM 33-53-0.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHTS) · airframe 61,762 hrs · 64,877 cycles

RT AFT NACELLE LIGHT DOES NOT ILLUMINATE WITH EMERGENCY LIGHT SWITCH. FOUND DURING SERVICE CHECK. MX REPLACED THE EMERGENCY POWER SUPPLY IAW MM33-53-00. ACFT RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE) · airframe 59,091 hrs · 63,106 cycles

LONGERON 25 LEFT HAD CRACK INDICATIONS AT BOTH ATTACH FASTENERS TO FRAME AT FS 160. REMOVED AND REPLACED DAMAGED SECTION IAW DC9 SRM.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 59,091 hrs · 63,106 cycles

CUSP WEB CRACKED AT FS 218, LEFT BUTT LINE 44. INSTALLED REPAIR DOUBLER IAW DC9 SRM 53-01.

Part: STOP FITTING — CRACKED (OVERWING EXIT) · airframe 59,091 hrs · 63,106 cycles

RIGHT AFT OVERWING EXIT DOOR HAD CRACK AT UPPER STOP. REPAIRED RIGHT AFT OVERWING EXIT DOOR AT UPPER STOP IAW DC9 SRM 52-05.

Part: ANGLE — CRACKED (FUSELAGE) · airframe 58,801 hrs · 62,887 cycles

RIGHT ANGLE CRACKED STA 69.550 TO 83.550 X = 10.00. REPLACED ANGLE IAW DC9 SRM 51-30-2.

Part: BRACKET — CRACKED (FUSELAGE) · airframe 58,801 hrs · 62,887 cycles

RIGHT VERTICAL BRACKET CRACKED, STA 69.55 AND X = 10.00. REPLACED BRACKET IAW DC9 SRM 51-30-2 AND 51-30-5.

Part: BRACKET — CRACKED (FUSELAGE) · airframe 58,801 hrs · 62,887 cycles

LEFT VERTICAL BRACKET CRACKED, STA 69.55 AND X = 10.00. REPLACED BRACKET IAW DC9 SRM 51-30-2 AND 51-30-5.

Part: FRAME — CRACKED (FUSELAGE) · airframe 58,801 hrs · 62,887 cycles

CENTER FRAME LEFT END CRACKED MORE THAN 1.12 INCH, BUT LESS THAN 2.50 INCH, STA 83.55 AND X = 10.00. REPAIRED FRAME IAW DC9 SRM 53-03, FIGURE 34.

Part: FRAME — CRACKED (BS 73) · airframe 58,801 hrs · 62,890 cycles

DURING INSPECTION TO COMPLY WITH AD 2002-21-09 AND S/B 53-290 NOSE SKIN, STA 73, LBL 10, P/N 5911403-3 FOUND CRACKS ON THE AFFECTED FRAMES, P/N 9911505-5/-6/-7. THE -7 FRAME WAS CRACKED 0.0625 INCHES BEYOND THE 1.125 INCH LIMIT. THE MOD REQUIRED BY S/B 53-290 AND SR09530268-7013 COCKPIT REPAIR, FRONT WINDOW LOWER SILL SURROUND WAS ACCOMPLISHED. AIRCRAFT WAS RETURNED TO SERVICE AT THE COMPILATION OF MOD.

Part: BATTERY PACK — DISCHARGED (CARGO BAY)

TPA - FOUND THE R2 AND L2 DOOR EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REPLACED THE AFT CARGO BATTERY PACK. (M)

Part: VALVE — FAILED (NR 1 ENGINE)

BWI - FLT 2633 - ON CLIMB-OUT FROM BWI, THE NR 1 ENGINE BLEED TRIP OFF LIGHT ILLUMINATED (RESET WAS SUCCESSFUL) AND THE EGT WENT TO 645 DEGREES FOR 5 SECONDS. ALL OTHER ENGINE INDICATIONS WERE NORMAL. THIS OCCURRED DURING FLAP RETRACTION AT 1,500 FEET. CREW DECLARED AN EMERGENCY AND RETURNED TO FIELD AT BWI. FLIGHT LANDED WITHOUT FURTHER INCIDENT. NO ENGINE SHUTDOWN OCCURRED. MAINTENANCE INSPECTED THE NR 1 ENGINE INLET/EXHAUST AND DUCTING FOR LEAKS. NO DEFECTS NOTED. ACCOMPLISHED TAKEOFF POWER RUN. ALL PARAMETERS NORMAL. REMOVED AND REPLACED NR 1 ENGINE PRESSURE RATION BLEED CONTROL VALVE AND CLEANED SUPPLY FILTER. BLEED SCHEDULE NORMAL. CHECKED NR 1 ENGINE BLEED. OPERATIONAL CHECK NORMAL AT VARIOU

Part: SKIN — CRACKED (FUSELAGE)

TPA - SKIN HAS A 2 INCH CRACK AT BS 964 STR 19L. REPAIRED PER SRM 53-50-3 FIG 1 AND EA 66148. (M)

Part: SKIN — CRACKED (FUSELAGE)

TPA - SKIN HAS A 3 INCH CRACK AT BS 971 STRINGER 21L. INSTALLED DOUBLER PER SRM 53-30-3 FIG 1 AND EA 66147. (M)

Part: UNKNOWN — SMOKE (LAVATORY)

PVD - FLT 2655 - ON CLIMB-OUT FROM PVD, AT APPROXIMATELY 8,000 FEET, THE SMOKE DETECTOR IN THE AFT LAVATORY BEGAN SOUNDING AND A SMELL IN THE AFT CABIN WAS PRESENT. CAPTAIN DECLARED AN EMERGENCY AND THE FLIGHT RETURNED TO FIELD AT PVD. FLIGHT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE GROUND RAN BOTH ENGINES TO SIMULATE CONDITION. NO ODOR OR SOURCE WAS DETECTED. REMOVED AND REPLACED LEFT AND RIGHT WATER SEPARATOR BAGS, LEFT AFT COFFEE MAKER AND AFT LAVATORY SMOKE DETECTOR AS PRECAUTION. SERVICED LEFT ACM TO PROPER LEVEL. FOUND WIRES FOR LIGHT AT AFT LAVATORY MIRROR SHOW EVIDENCE OF AGE DETERIORATION. PROGRAMMED FOR REPLACEMENT. (M)

Part: GASPER FAN — FAILED (CABIN)

IAD - FLT 2800, AFTER CLIMB-OUT FROM BWI, LEVELING OFF AT FL230, CREW NOTICED AN ODOR THROUGHOUT THE COCKPIT AND CABIN. FLIGHT ATTENDANT PULLED CIRCUIT BREAKER FOR COFFEE MAKER AND SMELL SEEMED TO GO AWAY. THREE MINUTES LATER SMELL RETURNED. CREW DECLARED AN EMERGENCY AND DIVERTED THE FLIGHT TO THE NEAREST SUITABLE AIRPORT AT IAD. FLIGHT LANDED WITHOUT FURTHER INCIDENT AND TAXIED TO THE GATE UNDER ITS OWN POWER. MAINTENANCE FOUND THE GASPER FAN CIRCUIT BREAKER TRIPPING. REMOVED AND REPLACED THE GASPER FAN. RESET CIRCUIT BREAKER. OPERATIONAL CHECK GOOD. (M)

Part: BATTERY PACK — DISCHARGED (CARGO COMPT)

CLE - MAINTENANCE FOUND THE LEFT EXTERIOR OVERWING AND LOWER AFT EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACK AND POWER SUPPLY (P/N 60-1321-1). OPERATIONAL CHECK GOOD (M)

Part: DRIVE MOTOR — FAILED (TE FLAPS)

MIA - FLT 2739 - CAPT REPORTED HE WAS EIGHT MILES ON FINAL APPROACH AND HAD JUST SET THE FLAPS TO A SETTING OF 1 DEGREE WHEN THE 'A' SYSTEM HYDRAULICS FAILED. CAPT PULLED OFF APPROACH, DECLARED AN EMERGENCY AND ACCOMPLISHED CHECKLIST FOR 'A' SYSTEM HYDRAULIC FAILURE. FLIGHT LANDED WITHOUT FURTHER INCIDENT AT MIA AND WAS TOWED TO THE GATE. MAINTENANCE REMOVED AND REPLACED THE TRAILING EDGE FLAP DRIVE HYDRAULIC MOTOR. SERVICED HYDRAULICS. OPERATIONAL CHECK GOOD. (M)

Part: SKIN — CRACKED (BS 884)

PHL - DURING RON, FOUND 2.5 INCH CRACK IN SKIN AT STATION 884 AT STRINGER 24 RT. INSTALLED DOUBLER REPAIR AT STRINGER AREA PER SRM 53-30-3, FIG 1 SHT 4. (M)

Part: SKIN — CRACKED (BS 756)

TPA - DURING CX-6 CHECK, FOUND 2.5 INCH CRACK IN SKIN AT BS 756 AND S17L. INSTALLED DOUBLER MADE OF 2024T3 .071 INCH THICK PER SRM 53-30-3 FIG 1. (M)

Part: SKIN — CRACKED (BS 727)

TPA - DURIGN CX-6 CHECK, FOUND .125 INCH CRACK IN SKIN AT BS 727A AND S16L. INSTALLED DOUBLER MADE FROM 2024T3 .100 INCH THICK PER SRM 53-30-3 FIG 1. (M)

Part: CSD — FAILED (NR 1 ENGINE)

CLE - FLT 1055 - ON CLIMB-OUT FROM CLE, THE NR 1 ENGINE GENERATOR DROPPED OFF LINE. CREW COULD NOT RESET THE GENERATOR. DUE TO THE APU BEING ON MEL, THE FLIGHT RETURNED TO FIELD AT CLE AND LANDED WITHOUT FURTHER INCIDENT. NO EMERGENCY WAS DECLARED. MAINTENANCE REMOVED AND REPLACED THE NR 1 ENGINE CONSTANT SPEED DRIVE, GENERATOR AND OIL COOLER. OPERATIONAL CHECK AND LEAK CHECK GOOD. (M)

Part: LIGHT — INOPERATIVE (CABIN)

GSO - MAINTENANCE FOUND THE AFT LEFT SERVICE DOOR EXTERIOR LIGHT INOP. MAINTENANCE FOUND A BAD WIRE SPLICE. REMOVED AND REPLACED WIRE SPLICE 1724. OPERATIONAL CHECK GOOD. (M)

Part: SKIN — CRACKED (BS 727)

TPA - DURING CX-5 CHECK VISUAL INSPECTION, FOUND A 2.50 INCH CRACK IN SKIN STA 727B JUST BELOW STR 15L. INSTALLED DOUBLER PER TYPICAL REPAIR NR 53-30-14. (X)

Part: SKIN — CRACKED (BS 727)

TPA - DURING CX-5 CHECK VISUAL INSPECTION, FOUND A 3.75 INCH CRACK IN THE SKIN AT STATION 727B STRIGNER 17R. INSTALLED DOUBLER PER TYPICAL REPAIR NR 53-30-14. (M)

Part: FORMER — CRACKED (WS 219)

CLT - DURING CX-5 CHECK VISUAL INSPECTION, FOUND A 10 INCH CRACK IN ANGLE FORMER RT WING L/E AT W STATION 219. INSTALLED MODIFIED PART. (M)

Part: SKIN — CRACKED (BS 1154)

INT - DURING Q-4 CHECK VISUAL INSPECTION, FOUND 3 INCH SKIN CRACK BS 1154 BETWEEN STRINGER 2R AND STRINGER 3R. INSTALLED DOUBLER, REPAIRED PER SRM 53-30-3. (M)

Part: WIRE — BROKEN (CABIN)

PHL - MAINTENANCE FOUND THE LOW LEVEL EMERGENCY LIGHTING INOP AT ROW 11ABC. MAINTENANCE REPAIRED BROKEN WIRE AT ROW 11ABC. OPS CHECK GOOD. (M)

Part: INDICATION — MALFUNCTIONED (LANDING GEAR)

CLT - FLT 1979 - ON DESCENT INTO CLT, WHEN LANDING GEAR LOWERED,CREW RECEIVED THREE GEAR RED LIGHTS AND THREE GEAR GREEN LIGHTS. THE GEARHORN SOUNDED AT FLAPS 15. CREW RECYCLED GEAR AND RECEIVED THREE GEAR GREENLIGHTS ONLY. THE FLIGHT LANDED WITH NO FURTHER INCIDENT. MAINTENANCEJACKED AIRCRAFT AND CYCLED GEAR SEVERAL TIMES. UNABLE TO DUPLICATE.CLEANED AND LUBED GEAR HANDLE. CYCLED GEAR SEVERAL MORE TIMES AND WAS STILLUNABLE TO DUPLICATE. SYSTEM OPS CHECK GOOD.(M)

Part: SKIN — CRACKED (BS 727)

BOS - DETECTED BY VISUAL AND EDDY CURRENT AND 4.25 INCH CRACK IN SKIN AT STATION 727B AT STRINGER 15R. INSTALLED DOUBLER 13.375 INCH BY 8.5 INCH PER SRM REFERENCE 53-30-3 PAGE 12B. (M)

Part: LINE — LEAKING (NLG W/W)

CLT - FLT 2188 - EN ROUTE TPA TO LGA, LOST 'A' SYSTEM HYDRUALIC QUANTITY, FOLLOWED BY LOW 'A' PRESSURE LIGHTS. FLIGHT DIVERTED TO CLT WHERE LANDING WAS WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND NOSE GEAR ACTUATOR LINE LEAKING AT 'B' NUT. REPLACED LINE, BOTH 'A' SYSTEM PRESSURE FILTERS, AND BOTH ENGINE DRIVEN PUMPS CASE DRAIN FILTERS. (W)