N27958

Part: UNKNOWN — SMOKE (ZONE 100) · airframe 47,746 hrs · 4,569 cycles

SMOKE REPORTED FROM WHEEL WELL AREA BY AIRCRAFT BEHIND AND OPS INSPCT ALL LANDING GEARS AND CACS INLETS OUTLETS AND SURROUNDING AREA. NO SIGNS OF OVERHEAT OR FIRE. NO INDICATIONS OF OVERHEAT IN CABIN. NO FLUCUTATIONA OF PACKS APU OR ANY OTHER SYSTEMS. COULD NOT FIND ANY DEFECTS. OK TO CONTINUE

Part: INITIATOR — EXPIRED (ZONE 200) · airframe 44,383 hrs · 4,265 cycles

GENERATE LOG PAGE FOR SDR REPORTING. REF LOG PAGE 4381952. FOUND FOLLOWING INITIATOR ASSY EXPIRED. MFD 01/2015: 43ABC. MFD 02/2015: DR3 GLY, 2DF, 31 ABC, 34 ABC,42 ABC,45 ABC,50 ABC, 51 ABC AND 53 ABC. ABOVE MENTIONED INITIATOR ASSY REPLACED PER EC/RA #3520-01777. TO CARRY OUT INSTALLATION TEST FOR AMM: B787-A-35-21-00- 01B-320A-A. INSTALLATION TEST FOR INITIATOR ASSY AS PER AMM 35-21-00-01B-320A-A C/OUT. TEST PASSED. PERFORMED BY V941780 IN SIAEC SIN HGR. NRC ELE0013/ 39584845 TOTAL OF 10 INITIATORS WERE REPLACED. LOCATION: 43 ABC, DR3 GLY, 2DF, 31 ABC, 34 ABC,42 ABC,45 ABC,50 ABC, 51 ABC & 53 ABC SDR SUBMITTED AS REQUIRED. OK TO CLEAR LOG PAGE.

Part: DISPLAY — INOPERATIVE (FLIGHT DECK) · airframe 41,780 hrs · 4,016 cycles

INFORMATION ONLY-CREW DEBRIEF- CREW REPORTED BOTH CAPTAINS DISPLAYS BANK, BOTH CAPT AND FO HUD DISPLAY BLANK, THEY COULD NOT ENTER ANY INFO TO AIRCRAFT USING THE CDU KEYS CORRECTION TO ABOVE INFO- DUE TO MISUNDERSTANDING,THERE WAS NO DISCREPANCIES WITH THE CAPTS OR FO HUDS CAPT SIDE SCREENS WERE BLANK BEFORE REMOVING GGM 1L . RPL GGM 1L REF MM 31-61-31-00A-720A S/W CONFIG CHECKED OK. OPS TEST OK NO MSG. PARTS USED: 78-3161-9-9001,QTY :1 ROTABLE PARTS CHANGE WAS INDICATED - TT # 1718018 SN OFF 5924 MODULE, GRAPHIC OFF 78-3161-9-9001 5924 ON 78-3161-9-9001 1642

Part: WARNING MESSAGE — FALSE ACTIVATION (MLG DOORS) · airframe 40,747 hrs · 3,920 cycles

GEAR DOOR ADVISORY ONE OR MORE GEAR DOORS ARE NOT CLOSED. FIM TASK REF : 31-90-F8-01A-421B-A CMC MSG# 3251001 FLIGHT STATUS: A INTERMITTENCE CODE: H PH: INITIAL CLIMB NARRATIVE: 32 LGA NWS HM OPS PERFORMED:FIM TASK 32-30-F1-05A-421A,NOSE L/G DOOR CONTROL VALVE MODULE INSTALLATION TEST I.A.W AMM 32-34-03-00A-720A,NOSE GEAR DOOR CLOSED INDICATION PROXIMITY SENSOR FUNCTIONAL TEST I.A.W AMM 32-61-03-00A-340A,NOSE LANDING GEAR HYDRAULIC PRESSURE TRANSDUCER INSTALLATION TEST I.A.W AMM 32-31-19-00A-720A.FAULT REMAINS ''NOT ACTIVE''. NO ADDITIONAL ACTION PERF AC RETURNED TO THE FIELD (JNB) DUE TO GEAR DOOR ADVISORY MESSAGE. THE FIM TASK 32-30-F1-05A-421A WAS ACCOMPLISHED WITH NO FAULTS.

Part: CONTROL VALVE — FAULTED (MLG DOORS)

AFTER TAKE OFF, NLG DOORS FAILED TO CLOSE AFTER L/G RETRACTION, RESULTING IN AIR TURNBACK. TROUBLESHOOTING REVEALED NO ISSUES, HOWEVER, DUE TO HISTORY, AIRLINE (TOMC) ELECETD TO FERRY FLIGHT BACK TO HOME BASE. PERFORMED FIM TASK 32-30-F1-05A-421A, NOSE L/G DOOR CONTROL VALVE MODULE INSTALLATION TEST I.A.W AMM 32-34-03-00A-720A, NOSE GEAR DOOR CLOSED INDICATION PROXIMITY SENSOR FUNCTIONAL TEST I.A.W AMM 32-61-03-00A-340A, NOSE LANDING GEAR HYDRAULICPRESSURE TRANSDUCER INSTALLATION TEST I.A.W AMM 32-31-19-00A-720A. FAULT REMAINS ''NOT ACTIVE''.

Part: LANDING GEAR — WARNING MESSAGE (NOSE) · airframe 40,747 hrs · 3,920 cycles

UPON GEAR RETRACTION AFTER TAKEOFF NOSE GEAR DOOR DISAGREE PERFORMED: FIM TASK 32-30-F1-05A-421A, NOSE L/G DOOR CONTROL HYDRAULIC.PRESSURE TRANSDUCER INSTALLATION TEST I.A.W AMM VALVE MODULE INSTALLATION TEST I.A.W AMM 32-34-03-00A-720A, NOSE 32-31-19-00A-720A. FAULT REMAINS NOT ACTIVE. GEAR DOOR CLOSED INDICATION PROXIMITY SENSOR FUNCTIONAL TEST I.A.W AMM 32-61-03-00A-340A, NOSE LANDING GEAR

Part: WARNING MESSAGE — ILLUMINATED (DOORS) · airframe 40,047 hrs · 3,849 cycles

GEAR DOOR ADVISORY ONE OR MORE GEAR DOORS ARE NOT CLOSED. FIM TASK REF : 31-90-F8-01A-421B-A CMC MSG# 3251001 FLIGHT STATUS: A INTERMITTENCE CODE: H PH: CLIMB NARRATIVE: 32 LGA NWS HM OPS ON ARRIVAL FLIGHT CREW WAS DEBRIEFED AND THE FOLLOWING INFO WAS ASCERTAINED. CAPT INFORMED THE FOLLOWING. AFTER 10 MIN ELAPSED GEAR UP SELECTED, IND SHOWED ALL THREE IND FOLLOWED BY MAIN GEAR UP AND CLOSED BUT THE NOSE GEAR IND CHANGED AND BECAME HATCHED FOLLOWED BY EICAS STATUS MSG. CAPT BELIEVES GEAR WAS DOWN, AFTER FUEL JETTISON AND ON DESCENT NOSE GEAR RETRACTED UNCOMMANDED CAPT NOTED ONLY LOWER ALT AND SPEED WAS DIFFERENT. ON ARRIVAL TO AIRCRAFT NIL STATUS MESSAGES DISPLAYED. ALL LANDING GEAR AND LANDING GEAR DOOR INDICATIONS FOUND CORRECT WITH ALL DOORS CLOSED DOWNSTAIRS. CMCF SHOWED MM 32-51001 AS NOT ACTIVE. IAW FIM B787-A-32-30-F1-05A-421A-A CMCF SPECIAL ADD EMP:U407130 FUNCTION: 32 LANDING GEAR ACTUATION SYSTEM, LANDING GEAR ACTUATION ALLOW DOOR NORMAL CLOSE TEST PERFORMED. LANDING GEAR LEVER CYCLED WITH GEAR DOORS OPENING AND CLOSING CORRECTLY BOTH DOWNSTAIRS AND WITH CORRECT COCKPIT INDICATIONS. SPECIAL FUNCTION STOPPED PER FIM B787-A-32-30-F1-05A-421A-A AND HYDRAULIC PRESSURE REMOVED. MM 32-51001 REMAINED NOT ACTIVE WITH NO OTHER STATUS OR MAINTENANCE MESSAGES DISPLAYED DURING TEST. VIA CMCF EXISTING FLIGHT DECK EFFECTS, PRESENT LEG FAULTS AND EXISTING FAULTS CHECKED WITH NIL REPORTS OR FINDINGS.

Part: SPRING — DAMAGED (NLG) · airframe 40,047 hrs · 3,849 cycles

REF LOGPAGE 8031938 DUE TO GEAR DOOR FAULT AND SUBSEQUENT AIR RETURN, AT TOMC REQUEST AIRCRAFT TO BE JACKED AND GEAR SWING CARRIED OUT. NOSE LANDING GEAR JACKED IAW AMM B787-A-07-11-02-00A-912A-A. AC THE CORRECT TIME AS PER THE AMM FOR THE POWER SUPPLY AVAILABLE REMOVED. AC PLACED BACK IN USUAL CONDITION. PLACED IN AIR MODE IAW AMM B787-A-32-09-00-08A-950A-A. NOSE WITH ALL INDICATIONS OK. NO FAULT MESSAGES RECORDED. NLG RETRACT LANDING GEAR EXTENSION AND RETRACTION CARRIED OUT 5 TIMES IAW ACTUATOR CHECKED FOR FLUID BYPASS. NO FAULT FOUND. AC LOWERED AMM B787-32-30-01-00C-340A. GEAR RETRACTION AND EXTENSION OK IN OFF JACKS, RETURNED TO GROUND MODE AND CB''S RESET. JACKING PAD REMOVED.AIRCRAFT PLACE BACK IN USUAL CONDITION.

Part: LIGHT — DAMAGED (OFCR) · airframe 33,061 hrs · 3,202 cycles

FOUND OFCR 4EA FLOOR PROXIMITY LIGHTS DAMAGED REF HEACO NON-ROUT INE NO:9496668 - ORIGINATED BY EMP V903214,EA 2500-09808 REV A O P 028. PERFORMED BY EMP V903214,REPLACED OFCR 4EA FLOOR PROXIMITY LIGHT S AND PERFORMED OPERATIONAL TEST OF THE EMERGENCY LIGHTS FOUND NORMAL REF TO AMM 33-51-06-00A-520/720A & AMM 33-51-00-00C-320A- A REV 166.IDT BY TA399.

Part: LIGHT — FAILED (GALLEY G2F-1C L/) · airframe 33,061 hrs · 3,202 cycles

THE CONNECT DL0401P2 FOR GALLEY G2F-1C L/H FWD FLOOR PROXIMITY LIGHT DL0401 WAS FOUND WIRE DETACHED REF HAECO NON-ROUTINE NO: 9497158 - ORIGINATED BY EMP V903214,EA 2500-09808 REV A OP 045. PERFORMED BY EMP V903214,REPLACED THE TERMINAL OF CONNECTOR DE04 AMM33-51-00-00A-320A-A REV 166,IDT BY TA399. 01P2 FOR GALLEY G2F-1C L/H FWD FLOOR PROXIMITY LIGHT DL0401 AND PERFORMED OPERATIONAL TEST OF THE EMER LIGHT FOUND NORMAL REF TO SWPM 20-30-15 REV 81&AMM 33-51-06-00A-720A-A REV 166 &

Part: LIGHT — FAILED (G5 GALLEY) · airframe 33,061 hrs · 3,202 cycles

FOUND G5 GALLEY 4EA FLOOR PROXIMITY LIGHTS DAMAGED REF HAECO NON -ROUTINE NO:9496670 - ORIGINATED BY EMP V903214,EA 2500-09808 REV A OP 045. PERFORMED BY EMP V903214,REPLACED G5 GALLEY 4EA FLOOR PROXIMITY LIGHTS AND PERFORMED OPERATIONAL TEST OF THE EMERGENCY LIGHTS FO UND NORMAL REF TO AMM 33-51-06-00A-520A/720A-A & AMM 33-51-00-00 C-320A-A REV 166.IDT BY TA399.

Part: LIGHT — FAILED (G4 GALLEY) · airframe 33,061 hrs · 3,202 cycles

FOUND G4 GALLEY 4EA FLOOR PROXIMITY LIGHTS DAMAGED REF HAECO NON-ROUTINE NO:9496669 - ORIGINATED BY EMP V903214,EA 2500-09808 REV A OP045. PERFORMED BY EMP V903214,REPLACED G4 GALLEY 4EA FLOOR PROXIMITY LIGHTS AND PERFORMED OPERATIONAL TEST OF THE EMERGENCY LIGHTS FOUND NORMAL REF TO AMM 33-51-06-00A-520A/720-A AND AMM 33-51-00 -00C-320A-A REV 166.IDT BY TA399.

Part: CHECK VALVE — FAILED (LT A/C PACK) · airframe 26,126 hrs · 2,470 cycles

REF LOG 6188005 CPCS REPORTS HI LEAK RATE. FOUND SUPPLY DUCT DISCONNECTED AT RECIRC FAN ON LEFT PACK LEFT RECIRC FAN REPLACED DUE TO FAILED CHECK VALVE, PER AMM DMC-B787-A-21-25-17-03B-720A-A, CONNECTING DUCT SEAL AND SLIP JOINT SEAL REPLACED BETWEEN FAN AND HEAT EXCHANGER. LEAK CHECK OF SYSTEM OK AND GROUND TEST PASSED. ROTABLE PARTS CHANGE WAS INDICATED - TT # 1999557 SN OFF 0406 FAN, ASSY, MIXE OFF 78-2125-9-9001 0406 ON 79-2125-9-9001 8077

Part: BEAM — CORRODED (LAV THRESHOLD) · airframe 25,469 hrs · 2,400 cycles

CAB LAV M THRESHOLD BEAM FOUND CORROSION REF NON-ROUTINE NO:9426 589,ORIGINATED BY EMP:V906647,SPEC NO.B787-25-3-0035. PERFORMED BY EMP:V906647,CAB LAVM THRESHOLD BEAM REPAIRED AS PER ECRA 2541-01549 REV.-.RII BY EMP V902604.

Part: BEAM — CORRODED (LAV THRESHOLD) · airframe 25,469 hrs · 2,400 cycles

CAB LAV L THRESHOLD BEAM FOUND CORROSION REF NON-ROUTINE NO:9426 588,ORIGINATED BY EMP:V906647,SPEC NO.B787-25-3-0035. PERFORMED BY EMP:V906647,CAB LAV L THRESHOLD BEAM REPAIRED AS PE R ECRA2541-01548 REV.-. RII BY EMP:V902604.

Part: LIGHT — CRACKED (AFT GALLEY) · airframe 25,469 hrs · 2,400 cycles

FOUND G5 GALLEY RIGHT SIDE AFT WALL MOUNTED EMERGENCY LIGHT ASSY CRACKED REFER NON-ROUTINE NO:9427777, ORIGINATED BY EMP:V903214, SPEC NO.B787-33-3-0002. PERFORMED BY EMP:V903214, REPLACED G5 GALLEY RIGHT SIDE AFT WALL MOUNTED EMERGENCY LIGHT ASSY AND PERFORMED INSTALLATION TEST FOUND NORMAL REF TO AMM 33-51-06-00A-520A/720A REV.144.

Part: LENS — MISSING (EMERGENCY LIGHT) · airframe 25,469 hrs · 2,400 cycles

SEAT 16F EMERGENCY LT LENS FND MISSING REF TO NON-ROUTINE NR 9427051, SPEC NR B787-33-3-0002. PERFORMED REPLACED SEAT 16F EMER LT AND INSTALLATION TEST NORMAL PER AMM 33-51-06-00A-520A & -720A REV.144. IDT BY TA627 V905344.

Part: LIGHT — CRACKED (LH FWD WALL) · airframe 25,469 hrs · 2,400 cycles

OFAR LT FWD WALL MOUNTED EMER LT FND CRACKED REF TO NON-ROUTINE NR 9427055, SPEC NO.B787-33-3-0002. PERFORMED BY V903214 REPLACED OFAR LT FWD WALL MOUNTED EMER LT, AND INSTL TEST NORMAL PER AMM 33-51-06-00A-520A &-720A REV.144.

Part: CONNECTOR — BROKEN · airframe 23,203 hrs · 2,132 cycles

CAPT REPORTED AFTER T/O AND UPON RETRACTION, GOT SLAT DRIVE EICAS MSG - REPEAT DMC-B787-A27-80-F1-29A-421A-A ACCOMPLISHED.DURING WIRING CHECK FOUND PLUG D1284P OUT OF PLACE AND LOCK BROKEN. CONNECTOR, ELECTRICAL PLUG SHELL P/N BACC65BJ-F REMOVED & REPLACED IN POSITION D1284P IAW SWPM 20-74-14. NO WIRES DISCONNECTED DURING REPLACEMENT.HIGH LIFT SYSTEM TEST, SLAT PRIMARY FCM L/R/C ACCOMPLISHED IAW DMC-B787-A-27-80-F1-29A-421A-A OK.FLAPS/SLATS OPERATIONAL TEST ACCOMPLISHED, ALL SATISFACTORY.

Part: WARNING MESSAGE — FALSE ACTIVATION (SLAT SYSTEM) · airframe 23,190 hrs · 2,129 cycles

SLAT DRIVE EICAS MSG SHOWS 27-22321. TRIED TO TEST (SLAT PRIMARY FCM L )SYSTEM TEST. PASSED. ALL SLATS FUNCTION WAS NORMAL. NO FOUND FAULT ABOUT THIS PROBLEM DURING TEST AND AFTER DONE.ALSO CHECKED ACTUAL SLAT NR 5 ASSY AND THE SKEW HARNESS ( WIRE ) ALL ROUTE. NO FOUND DAMEGE. THE CONDITION WAS OK. REF FIM 27-80-F1-29A-421A-A,AMM 05-41-05-22B-311A-A.

Part: SENSOR — MALFUNCTIONED (SLAT SYSTEM) · airframe 23,182 hrs · 2,128 cycles

CREW REPORTED, "SLATS DRIVE" MESSAGE DISPLAYED DURING CLIMB FOUND MSG 27-22321. FOLLOWED FIM . REPLACED SLAT SKEW DETECTION MECHANISM ASSY. ALL OPERATION NORMAL AND SLATS PRIMARY FCM L GND TEST PASS , NO MSG FOUND. ALSO SLAT BRAKAWAY CONNECTOR FUNCTION TEST NORMAL. FLAP AND SLATS OPERATION ALL NORMAL. REF FIM DMC-B787-A-27-80-F1-29A-421A-A, IAW DMC-B787-A-27-89-05-00B-340A-A. DMC-B787-A-27-89-03-00A-520A-A,AMM OBSERVED OUTBOARD LEADING EDGE SLAT SKEW DETECTION MECHSNISM INS TALLATION NO DEFECTS NOTED.

Part: BATTERY — FAULTY (EMERGENCY LIGHTS) · airframe 11,817 hrs · 1,120 cycles

DURING AN EMERGENCY LIGHTS OPERATIONAL CHECK, EMERGENCY LIGHT INOPERATIVE. REPLACED THE CONTROL UNIT M3351033 AND BATTERY IAW AMM 33-51-07. EMERGENCY LIGHTS OPS CHECKED GOOD.

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT) · airframe 11,817 hrs · 1,120 cycles

THE EMERGENCY LIGHT EXIT SIGN AT THE RT ENTRY DOOR FOUND INOPERATIVE. REPLACED THE BATTERY IAW AMM 33-51-07, OPS CHECKED OK.

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 8,287 hrs · 824 cycles

EMERGENCY FLASHLIGHT AT 4R DOOR INOP. RPLD FLASHLIGHT BATTERY REF AMM 25-64-00-00B-921A. OPS CK GOOD.

Part: BATTERY — FAULTED (FLASHLIGHT) · airframe 7,939 hrs · 792 cycles

R2 DOOR EMERGENCY FLASHLIGHT BLINKING RED. REMOVED AND REPLACED THE FLASHLIGHT BATTERY. OPS CHECKED GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 6,662 hrs · 676 cycles

DOOR 4L EMERGENCY LIGHTS INOP. REPLACED EMERGENCY LIGHT SYS CONTROL UNIT AND BATT PACK. SYSTEM CHK OK REF DMCB787-A-33-51--07-02B-520A-A AND DMC-B787-A-33-51- 00-00C-320A-A.