N27903

Part: ELEC CONNECTOR — UNSECURE (ZONE 800) · airframe 51,471 hrs · 6,412 cycles

R4 DOOR EPAS SENSOR STATUS MSG FOLLOWING FIM 62-10-F1-T7A-421A-A. INSPECTED R4 DOOR ARM AND DISARM SENSOR. FOUND CONNECTOR LOOSE. CLEANED SENSOR. PERFORMED OPS CHECK IAW AMM DMC-B787-A-52-11-21-03A-320A-A. OPS CHECKED GOOD. SYNOPTIC PAGE SHOWS CORRECT INFO DURING CYCLING OF DOOR OPEN AND CLOSE PLUS ARM AND DISARM CYCLES.

Part: LEVER — FAULTED (ZONE 800) · airframe 51,390 hrs · 6,404 cycles

DOOR 4R WITH ARM LEVER IN DISARM POS BTH ARM/DISARM FLASH UNABLE TO DUPLICATE AND NO RECENT HISTORY OF SIMILAR FAULTS. BOTH LIGHTS FLASHING IS A NORMAL INDICATION OF THE HANDLE IN TRANSIT. OVER CENTER SPRING TENSION, IN BOTH DIRECTIONS, IS FIRM AND SIMILAR TO ADJACENT DOORS. REF AMM 52-11-00.

Part: UNKNOWN — ODOR (CABIN) · airframe 50,557 hrs · 6,308 cycles

SUDDEN STRANGE ODOR IN CABIN SMELL NOTICED WHILE APU AND PACKS RUNNING. TIMING OF SMELL COINCIDED WITH RAMP OPENING FWD CARGO PITS AND POSITIONING LOADER. VERIFIED WITH CAPTAIN AND CREW SMELL WAS SIMILIAR TO LOADER EXHAUST SMELL ENTERED FORWARD ELECTRONICS BAY TO VERIFY, NO SMELL OR LEAKS. SMELL WAS GONE AFTER RETURNING UPSTAIRS WITH PACKS STILL RUNNING. OK FOR SERVICE DMC-B787-A-05-51-99-99A-282A-A

Part: CONTROL UNIT — FAULTED (ZONE 100) · airframe 49,965 hrs · 6,232 cycles

ELEC P200 PANEL THE PRIMARY POWER DISTRIBUTION SYSTEM (PPDS) P200 PANEL IS FAULT ED SUCH THAT IT CANNOT SUPPORT AIRPLANE DISPATCH, SUCH AS DUAL C HANNEL IN-OPERATIVE. DB 24 PDHM OPS (GPM L8) DB 24 PDHM OPS (GPM R6) TS MAINTENANCE MESSAGE 24-17484 IN REF WITH FIM, 24-30-F5-61A-421A FOUND P200M3 ELCU PROTECTION CIRCUIT CARD BAD. REMOVED AND REPLACED P200M3 ELCU PROTECTION CIRCUIT CARD IN REF WITH B787-A-24-09-04 UP TO STEP 1. D. (5). REMOVED AND REPLACED P200M3 ELCU PROTECTION CIRCUIT CARD IN REF WITH B787-A-24-09-04 FROM STEP 1. D. (5) TO COMPLETION OF INSTALLATION. OPS CHECK GOOD.

Part: INTERPHONE — INOPERATIVE (ZONE 200) · airframe 49,965 hrs · 6,232 cycles

FA INTERPHONE AT DOOR 1R INOP CYCLED HANDSET BREAKERS IN CBIC REF AMM 44-14-03 DISPLAY RECOVERED.

Part: SLIDE — NO DISCREPANCY (ZONE 800) · airframe 49,447 hrs · 6,166 cycles

DOOR-MOUNTED ESCAPE SLIDE PACK ASSEMBLY REMOVAL - AT DOOR 2 RH S/N 8707, VERIFIED CORRECT SLIDE NUMBER AND EFFECTIVITY. REF IPC 25-66-01. COMPLIED WITH GMM 09-25-05 REMOVED AND REPLACED DOOR 2R ESCAPE SLIDE PER AMM 25-66-01.

Part: LIGHT — DETACHED (ZONE 200) · airframe 48,497 hrs · 6,049 cycles

FOUND AISLE EMER LIGHT AT SEAT 48F HANGING AND DAMAGED REMOVED AND REPLACED EFFECTED LIGHT IN REF TOO B/E AEROSPACE CMM 25-23-51. OPS TEST GOOD AT THIS TIME

Part: IRU — FAULTED (ZONE 100) · airframe 47,672 hrs · 5,946 cycles

IRU L LEFT IRU FAILED, PRIMARY POWER INPUT FAILED, SECONDARY (MAIN BAT TERY) POWER FAILED, PRIMARY AND SECONDARY AIR DATA INPUT NOT REC EIVED, UNIT COMPLETELY UNPOWERED OR SWITCHED OFF. FIM TASK REF : 31-90-F8-01A-421B-A CMC MSG# 3420011 FLIGHT STATUS: A INTERMITTENCE CODE: H PH: CLIMB LEFT IRU SENSOR PIC UPDATE. REMOVED AND REPLACED LEFT IRU REFERENCE: DMC-B787-A-34-21-04-00A-720A-A, ALL SOFTWARE INSTALLED AND OPS CK NORMAL AT THIS TIME.

Part: LIGHT — FALSE ACTIVATION (ZONE 800) · airframe 47,477 hrs · 5,921 cycles

SLIDE LIGHTR FLASHING DOORS 4R AND 4R CYCLED SYSTEM POWER, VERIFIED DOORS 4L & 4R SLIDE LIGHTS OPERATE NORMAL IN ARM AND DISARM MODES. UNABLE TO DUPLICATE FAULT.

Part: WIRE — ARCED (WINDOW HEAT) · airframe 46,912 hrs · 5,847 cycles

F/O FWD WINDSHIELD HEATING ELEMENT WIRE ARCING FAULT CONFIRMED. LOCALIZED ARCING IN FIRST OFFICERS FORWARD WINDOW WITH WINDOW HEAT ON. REF IMAGE. BEGAN STEPS TO REMOVE FIRST OFFICER WINDSHIELD REF. AMM DMC-B787-A-56-11-01-00A-520A-A UP TO STEP 1.B.(8) COMPLETED REMOVAL OF F/O #1 WINDOW IN REF TO AMM 56-11-01-00A-520A-A STARTED INSTALLATION OF #1 F/O SIDE WINDOW IN REF TO AMM DMC-B787-A-56-11-01-00A-720A-A, COMPLETED STEPS UP TO AND INCLUDING STEP B.3(H.3). ADD EMP:U260507 CONTINUED INSTALLATION OF F/O #1 WINDOW PER AMM DMC-B787-A-56-11-01-00A-720A-A, COMPLETED UP TO AND INCLUDING STEP C.(4)(U)6)A), PER AMM AN 8 TO 12 HOUR DWELL TIME REQUIRED BEFORE FINAL TORQUE.

Part: SKIN — DAMAGED (ZONE 100) · airframe 46,334 hrs · 5,768 cycles

WORK STAND BLEW INTO FUSELAGE WITH 30 TO 40 KTS WINDS.PREPPED A/C FOR INSP. COMPLETED STEPS 1-5 OF AVO13077. NEXT STEP IS INSP. REF AVO 13077 REV B, C/W STEPS 1-9, REF 787 NTM PT4 51-00-06, GIUDED A-SCAN, FOUND DELAMINATION 2" X 13 " LONG. C/W 787 NTM PT4 51-00-23 (RADII) INSPECTION, NO HEEL CRSCKS FOUND. VERIFIED DELAM WITH DOLPHICAM INSPECTION INFO CONTINUES INSPECTION INFO CONTINUES C/W AVO 13077 REV B STEPS 6, 7, 8, AND 9 ACCOMPLISHED STEP 9 (APPLIED SPEED TAPE) OF AVO13077 REV C. ALL OTHER STEPS OF AVO13077 REV. C. ACCOMPLISHED PREVIOUSLY. A/C OK AND READY FOR MAINT. FERRY. REF AVO 13077 REV B, C/W ALL STEPS AS REQUIRED( 1-10). C/W AVO 13077 REV C STEPS 1-10. PER ENGINEERING ECRA 5330-07322 ISSUED TO PROVIDE 2 FLIGHT CYCLES WITH NO RESTRICTIONS PER GMM 11-30-10. C/W STEP #9 APPLIED ONE LAYER OF SPEED TAPE OVER DAMAGED AREA. TOMC APPROVES 53-DIP FOR APPLICATION OF ONE LAYER OF SPEED TAPE OVER DAMAGED AREA PER STEP 9 OF ECRA 5330-0732 WITH 2 FLIGHT CYCLES FOR MAINTENANCE FERRY WITH NO RESTRICTIONS PER GMM 11-30-10.

Part: ACCESS PANEL — DEPARTED (ECS L 195DL) · airframe 43,385 hrs · 5,395 cycles

PDA 2 REFERENCE L/P 6056036. L ECS GROUND AIR CONDITIONING ACCESS PANEL DEPARTED AIRCRAFT ON LANDING. PANEL HAS BEEN RETRIEVED BY AIRPORT AUTHORITY. ENGINEERING NOTIFIED. GROUND CONNECT ACCESS PANEL FOR ECS AIR SUPPLY MISSING. FOUND BY AIRPORT AUTHORITY ON RUNWAY PHOTO UPLOADED PICTURE UPDATE DIP LIMIT Y QC UPDATE RECORDS UPDATE INSPECTED IN AND AROUND ECS AIR SUPPLY DOOR, NO FURTHER DAMAGE FOUND. RESECURED PER ECRA ESTIMATED GROUND TIME AND LABOR HOUR UPDATE. PHOT UPLOADED ADDING PARTS QC RECORDS UPDATE BUT BEFORE 2 FLIGHT CYCLES. SPEED TAPE APPLIED TO PANEL AS PER EC/RA 5240-02069 PART 1. ACCOMPLISH TERMINATING ACTION PER PART 3 AFTER 1 FLIGHT CYCLE UPON LANDING GROUND AIR CONDITIONING SERVICE DOOR ECS L 195DL DEPARTED AIRCRAFT. PANEL RETRIEVED. PER ECRA 5240-02069 COMPLY WITH INTERIM REPAIR PER PART 1. INITIATE DIP TO ACCOMPLISH TERMINATING ACTION PER PART 3 AFTER 1 FLIGHT CYCLE BUT BEFORE 2 FLIGHT CYCLES. CURRENT TAFC IS 5395. TOMC-APPROVAL FROM SC1ELBYC COMMENT QC REVIEWED. <<< QC UPDATE >>> REF. ECRA 5240-02069 REV. B REVISES DIP TO:"AC COMPLISH INSPECTION REQUIREMENTS PER PART 2 EACH FLIGHT CYCLE AN D ACCOMPLISH TERMINATING ACTION PER PART 3 WITHIN 5 FLIGHT CYCLE S." ****PER MRB DIP REV DTD 18OCT23.LIMIT CHANGE AS FOLLOWS**** INSPECTIONS CREATED BY AUTODIP PENDING AIRCRAFT RECORDS AUDIT & T/A: >1<2 FC...NC/U342507 UPDATE. RIR: M-METER EACH FLIGHT CYCLE (NO M&E REQUIRED) T/A: WITHIN 5 FC...LN/U253409.

Part: ACTUATOR — FAILED (SPOILER #5) · airframe 38,222 hrs · 4,764 cycles

ONE SPOILER PANEL FAILED ON LEFT WING DEACTIVATED SPOILER #5 PER AMM 27-61-02 DUE TO HISTORY. REQUEST PLACED #5 SPOILER ON MEL. MEL 2761AR. ADD EMP:123432 DISPATCH DESK: 22 NAME: JV DATE: 09-JUL-22- NOC DESK: 787 NAME: DW DATE: 09-JUL-22- TOMC APPROVED; MM 27-12752 SPOILER MOTOR HAS AN INTERNAL FAULT LOCKED FOR DISPOSITION OF REPEAT FAULT FOR #5 SPOILER. UNLOCKED DISPOSITION MAINTENANCE MESSAGE 27-12752 DUE TO PRIOR ACTUATOR REPLACEMENT, TO DEACTIVED POSITION REF. MEL 2761AR. RECOMMEND CHANGING EMCU. ITEM REMAINS ON MEL, RETURNED SPOILER REACTIVATED SPOILER REF. DDG 27-61-02-01, RAN SYSTEM TEST TWICE. NO FIX (SPOILER ACTUATED BUT FAILED TEST). REFERENCING FIM FOR ADD EMP:U114836 SHOOTING. RAR #5 EMCU IAW AMM 27-61-18. PERFORMED INSTALLATION UPTO AND #5 EMCU FAILED SPOILER RIG TEST, REF AMM 27-61-18-00A-720A, STEP ACCOMPLISHED WIRE CHECKS PER FIM 27-60-F1-P1A-42A-A. WIRES SUSPECT BAD M2761005 ACTUATOR-SPOILER ELECTRIC-5, ORDLM MARTINE INCLUDING 27-61-18-00A-720A-A STEP D 2. 1. D. (6). WITH MAINT MSG 27-12472. NEEDS FURTHER TROUBLE CHECKED GOOD AND MEGGERED GOOD. Z ADD EMP:181291 ADD EMP:U008906 ROTABLE PARTS CHANGE WAS INDICATED - TT # 1950351 SN OFF 1068 UNIT, CONTROL, OFF 78-2741-9-9003 1068 ON 78-2741-9-9005 0798 REMOVED AND REPLACED #5 SPOILER ACTUATOR IN REFERENCE TO DMC 27-61-16. RAN RIG TEST AND SYSTEM TEST. OPS CHECK GOOD AT THIS TIME. NO FAULTS NOTED AT THIS TIME MEL CLEARED. ADD EMP:U375583,U377350 ROTABLE PARTS CHANGE

Part: SIGN — LOOSE (EMERGENCY LIGHT) · airframe 33,535 hrs · 4,153 cycles

L4 DOOR EMERGENCY SIGN ASSY LOOSEN DURING EMERGENCY LIGHT OPERAT IONAL TEST. REF HAECO NON-ROUTINE NO.9436292 . EA4400-01089 OP002 L4 DOOR EXIT LOCATOR SIGN REPLACED, INSTALLATION TEST NORMAL REF AMM 33-51-01-00A-720A/520A REV.148. I

Part: TERMINAL — LOOSE (EMERGENCY LIGHT) · airframe 33,535 hrs · 4,153 cycles

OFAR RESTORATION FOUND FLOOR PROXIMITY LIGHT TERMINAL LOOSEN, RE FER HAECO NON-ROUTINE NO.9439905, ORIGINATED BY EMP V905344, EA2 500-09201 REV B OP042. FLOOR PROXIMITY LIGHT ON OFAR UNDER ATTENDANT SEAT REPLACED, INS TALLATION TEST NORMAL REF AMM 33-51-06-00A-520A/720A REV.148, PE RFORMED BY EMP V905344, IDT BY EMP V907748.

Part: BEZEL — CRACKED (EMERGENCY LIGHT) · airframe 33,535 hrs · 4,153 cycles

OFCR EMERGENCY LIGHT REMOVAL FOUND 3EA BEZELS CRACKED EXCEPT AT RH AFT CORNER, REFER HAECO NON-ROUTINE NO.9437200, ORIGINATED BY EMP V905344, EA2500-09201 REV B OP040. OFCR 3EA EMERGENCY FLOOR PROXIMITY LIGH BEZELS REPLACED, LIGHT I NSTALLATION TEST NORMAL AS PER AMM 33-51-06-00A-520A/720A REV.14 8, PERFORMED BY EMP V905344, IDT BY EMP V907748.

Part: BEZEL — CRACKED (EMERGENCY LIGHT) · airframe 33,535 hrs · 4,153 cycles

OFAR EMERGENCY LIGHT REMOVAL FOUND 3EA BEZELS CRACKED, REFER HAE CO NON-ROUTIEN NO.9437199, ORIGINATED BY EMP V905344, EA2590-092 01 REV B OP042. OFAR 3EA EMERGENCY FLOOR PROXIMITY LIGHT BEZELS REPLACED, LIGHT INSTALLATION TEST NORMAL REF AMM 33-51-06-00A-520A/720A REV.148, PERFORMED BY EMP V905344, IDT BY EMP V907748

Part: TUBE — CRACKED (LEFT FUEL TANK) · airframe 28,812 hrs · 3,496 cycles

LEFT FUEL TANK INCREASE OVER 1000 LBS ABOVE WITH FUEL IN CENTER TANK ACPTEST PER MM 28-21-00-12A-364A-A NO FAULTS NOTED. RUNNING ALL 6 PUMPS FOUNND THAT WITHIN 6 MINUTES 100 LBS XFERED TO LEFT TANK AFTER 60 MINUTES 500 LBS XFERED TO LEFT TANK. CHECKING FLEET TEAM DIGEST ATA 2822-21 (787 FTD 28-18001) POSSIBLE MANIFOLD CRACKS REPLACED FUEL MANIFOLD ITEM 235 REF LOG PAGE 7357969 FOR WORK PERFORMED. REQUIRES OPS AND LEAK CHECK. OPERATED ALL PUMPS WITH CROSSFEED OPEN WITH NO FUEL MOVMENT FRO M CENTER OR RT TANK TO LT IN 30 MIN.

Part: RIB — CRACKED (RT WING) · airframe 24,663 hrs · 3,014 cycles

RT WING APPROX WS 480 SPOILER SUPPORT BEAM TO BACKUP RIB SUPPORT ASSY FOUND CRACKED. PERFORMED INTERIM REPAIR PER ECRA 5751-01314. PLACING ON DIP TO ACCOMPLISH A PERMANENT REPAIR ON OR BEFORE NOVEMBER 29, 2020. PL ANNING TO CONTACT ENGINEERING AFTER SEPTEMBER 29, 2020 BUT BEFORE OCTOBER 29, 2020 FOR THE PERMANENT REPAIR. REF HAECO LP 9130362 FOR WORK ACCOMPLISED. OK TO DIP PER ECRA ,PERM REPAIR ON OR BEFORE NOV. 29 2020 OK TO PLACE ON DIP ACCOMP/PERM REPAIR ON OR BEFORE NOV.29 2020 PLANNING TO CONTACT ENGINEERING AFTER SEPT.2020 BUT BEFORE OCT 29 2020 TOMC-APPROVAL FROM SC1ELBYC COMMENT QC QC REVIEWED. RECORDS UDPATE....JQ RECORDS UPDATE...JQ INIT:>9/29/20<10/29/20 T/A: 11/29/20......JQ

Part: SUPPORT BEAM — CRACKED (RT WING) · airframe 24,663 hrs · 3,014 cycles

RT WING APPROX WS 480 SPOILER SUPPORT BEAM TO BACKUP RIB SUPPORT ASSY FOUND CRACKED. PERFORMED INTERIM REPAIR PER ECRA 5751-01314. PLACING ON DIP TO ACCOMPLISH A PERMANENT REPAIR ON OR BEFORE NOVEMBER 29, 2020. PL ANNING TO CONTACT ENGINEERING AFTER SEPTEMBER 29, 2020 BUT BEFORE OCTOBER 29, 2020 FOR THE PERMANENT REPAIR. REF HAECO LP 9130362 FOR WORK ACCOMPLISED. OK TO DIP PER ECRA ,PERM REPAIR ON OR BEFORE NOV. 29 2020 OK TO PLACE ON DIP ACCOMP/PERM REPAIR ON OR BEFORE NOV.29 2020 PLANNING TO CONTACT ENGINEERING AFTER SEPT.2020 BUT BEFORE OCT 29 2020 TOMC-APPROVAL FROM SC1ELBYC COMMENT QC QC REVIEWED. RECORDS UDPATE.... RECORDS UPDATE...:>9/29/20<10/29/20 T/A: 11/29/20......

Part: RIB — CRACKED (LT WING) · airframe 24,663 hrs · 3,014 cycles

LT WING APPROX WS 480 SPOILER SUPPORT BEAM TO BACK-UP RIB SUPPOR T ASSY FOUND CRACKED. REF HAECO LP 9130364. PERFORMED INTERIM REPAIR PER ECRA 5751-01314. PLACING ON DIP TO ACCOMPLISH A PERMANENT REPAIR ON OR BEFORE NOVEMBER 29, 2020. PL ANNING TO CONTACT ENGINEERING AFTER SEPTEMBER 29, 2020 BUT BEFORE OCTOBER 29, 2020 FOR PERMANENT REPAIR. REF HAECO LP 9130364 FOR WORK ACCOMPLISED. OK TO PLACE ON DIP ACCOMP/PERM REPAIR ON OR BEFORE NOV.29 2020 PLANNING TO CONTACT ENGINEERING AFTER SEPT.2020 BUT BEFORE OCT 29 2020 TOMC-APPROVAL FROM SC1ELBYC COMMENT QC QC REVIEWED. RECORDS UPDATE....TW INIT: PLN/ENG >9/29/20<10/29/20 T/A: 11/29/20....TW

Part: OVEN — SMOKE (GALLEY) · airframe 21,206 hrs · 2,622 cycles

AFT GALLEY OVEN 710 WHEN OPERATING RED FAIL LIGHT ON WITH SOME SMOKE REPLACED STEAM OVEN 710 PER AMM B787-A-25-32-00-10A-520A-A @ 720 A-A, OPS NORMAL.

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 16,276 hrs · 2,079 cycles

EMERGENCY FLASHLIGHT AT 2L AFT TEST RED. REPLACED FLASHLIGHT BATTERY AT POSITION 2L AFT. TEST NORMAL.

Part: ELT — NO TEST (FORWARD) · airframe 6,411 hrs · 915 cycles

FORWARD PORTABLE ELT WILL NOT TEST. REPLACED FWD PORTABLE ELT IAW WC 78-2560-1-7800 & MM 25-63-01.