N3322L

Part: CONTROLLER — MALFUNCTIONED (AC SYSTEM) · airframe 90,398 hrs · 92,032 cycles

DURING CLIMBOUT, A BURNING ODOR AND LIGHT HAZE PERMEATED THE CABIN. THE LT PACK VALVE WAS PEGGED FULL RT AND THE LT DUCT TEMPERATURE REACHED 120 DEGREES. FLIGHT CREW SWITCHED THE LT PACK TO MANUAL CONTROL AND ODOR DISSIPATED. FLIGHT RETURNED TO CMH AND ON DESCENT, THE BURNING ODOR RETURNED WITH LT DUCT TEMPERATURE AT 150 DEGREES. LANDING WAS UNEVENTFUL AND MAINTENANCE REPLACED THE TEMPERATURE CONTROLLER AND BOTH WATER SEPARATORS. ALSO, FOUND A LOOSE DUCT ON THE AFT SIDE OF THE WATER SEPARATOR. ALL CHECKS WERE GOOD AND THE AIRCRAFT RETURNED TO SERVICE.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 88,387 hrs · 90,556 cycles

DURING AN OVERNIGHT CHECK, A CRACK WAS FOUND IN THE AFT PRESSURE BULKHEAD DOORJAMB. THE AIRCRAFT WAS FERRIED TO ACCOMPLISH REPAIRS. THE CRACK WAS 2 INCHES LONG AT STATION X=59.8. REPAIRED IAW EA.

Part: ATTACH ANGLE — CRACKED (RT PYLON) · airframe 84,242 hrs · 87,455 cycles

DURING L-CHECK, FOUND CRACK IN RIGHT HAND PYLON UPPER ATTACH ANGLE AT BS 996. REPAIRED PER EA 99-17403 AND SRM 54-04 FIGURE 10. REF LOG PAGE 1510889.

Part: TIRE — FAILED (RT MLG)

ON TAKEOFF APROXIMATELY AT ROTATION SPEED, THE RIGHT ENGINE COMPRESSOR STALLED, EGT AND EPR INDICATIONS FLUCTUATED, AND A BURNING RUBBER SMELL WAS REPORTED IN THE CABIN. AN EMERGENCY WAS DECLARED, COM PROCEDURES FOLLOWED AND THE FLIGHT RETURNED TO DLH AND LANDED WITHOUT INCIDENT. AIRCRAFT WAS 200 LBS BELOW MAXIMUM LANDING WEIGHT. MAINTENANCE DISCOVERED THE NR 3 MAIN TIRE HAD LOST CAP DURING TAKEOFF RESULTING IN FOD DAMAGE TO THE RIGHT ENGINE AND NR 4 BRAKE FLEX HYDRAULIC LINE. MAINTENANCE REPLACED THE NR 3 AND NR 4 MAIN WHEEL AND TIRE ASSEMBLIES, NR 4 BRAKE FLEX HYDRAULIC LINE AND RIGHT ENGINE. OPERATIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND LEFT EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK, OPERATIONAL CHECK NORMAL.

Part: PROX SENSOR — BROKEN (NLG)

NOSE LANDING GEAR UNSAFE LIGHT REMAINED ON AFTER GEAR RETRACTION. CREW PERFORMED COCKPIT OPERATING MANUAL PROCEDURES AND FLIGHT CONTINUED TO DESTINATION. ON GEAR EXTENSION, NOSE UNSAFE LIGHT REMAINED ILLUMINATED. GO-AROUND PROCEDURES WERE EXECUTED AND EMERGENCY GEAR EXTENSION PROCEDURES WERE UTILIZED. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NOSE GEAR DOWNLOCK PROXIMITY SENSOR BRACKET BROKEN. REPLACED SENSOR, OPERATIONAL CHECK NORMAL.

Part: BATTERY — DISCHARGED (PAX DOOR)

DURING PERIODIC CHECK, FOUND MAIN CABIN DOOR EVACUATION SLIDE LIGHTS BATTERY LOW. REPLACED SLIDE.

Part: BATTERY — DISCHARGED (PAX DOOR)

DURING PERIODIC CHECK, FOUND MAIN CABIN DOOR EVACUATION SLIDE LIGHTS BATTERY LOW. REPLACED SLIDE.

Part: BULKHEAD — CRACKED (BS 108)

DURING L CHECK, FOUND CRACKS IN THE NOSE LANDING GEAR WHEEL WELL HORIZONTAL PRESSURE PANEL AT THE RIGHT OUTBOARD AND INBOARD VERTICAL SUPPORTS FS 108. REPAIRED PER EA 99-153484.

Part: BULKHEAD — CRACKED (BS 108)

DURING L CHECK, FOUND A CRACK IN THE NOSE LANDING GEAR WHEEL WELL HORIZONTAL PRESSURE PANEL AT THE LEFT OUTBOARD VERTICAL SUPPORT FS 108. REPAIRED PER EA 99-153484.

Part: RELAY — INOPERATIVE (CABIN)

DURING LINE CHECK, FOUND EXTERIOR EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE REPLACED R2-213 RELAY, OPERATIONAL CHECK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND RIGHT AFT OVERWING EMERGENCY EXIT LIGHT VERY DIM DURING TEST. REPLACED BATTERY PACK AND BATTERIES. OPERATIONAL CHECK NORMAL.

Part: UPLATCH MECH — FAILED (RT MLG DOOR)

ON DEPARTURE AT 11,000 FEET AND 310 KNOTS, A 'THUD' WAS FELT IN THE AIRFRAME ALONG WITH NOISE OF THE GEAR DOORS OPENING SUDDENLY. RIGHT HYDRAULIC SYSTEM WAS PRESSURIZED TO 3000 PSI AND RIGHT GEAR UNSAFE AND DOOR OPEN LIGHTS EXTINGUISHED. FLIGHT CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND RIGHT MAIN GEAR UPLATCH MECHANISM HAD FAILED. REPLACED UPLATCH MECHANISM. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: DOWNLOCK SW — MALFUNCTIONED (RT MLG)

DURING APPROACH, RIGHT MAIN LANDING GEAR GREEN DOWNLOCK LIGHT DID NOT ILLUMINATE AFTER GEAR EXTENSION. CREW RECYCLED GEAR AND CONFIRMED VISUALLY THROUGH PERISCOPE THAT GEAR WAS DOWN AND LOCKED. GREEN LIGHT DID FINALLY COME ON. FLIGHT LANDED WITHOUT INCIDENT. CREW DID PERFORM GO-AROUND DURING TROUBLESHOOTING OF SYSTEM. MAINTENANCE REPLACED RIGHT MAIN GEAR DOWNLOCK SWITCH AND CLEANED CONNECTOR. OPERATIONAL CHECK NORMAL ON GEAR SWING.

Part: BATTERIES — DISCHARGED (CABIN)

FLIGHT ATTENDANT REPORTED AFT EMERGENCY FLASHLIGHT NOT BLINKING. REPLACED BATTERIES, OPERATIONAL CHECK NORMAL.

Part: POWER SUPPLY — INOPERATIVE (TAIL COMPT)

DURING LINE MAINTENANCE INSPECTION, FOUND TAIL COMPARTMENT CATWALK EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REPLACED POWER SUPPLY AND BATTERIES. OPERATIONAL CHECK NORMAL.

Part: CLIP — OUT OF ADJUST (TAIL CONE)

DURING LINE CHECK, FOUND THAT EXCESSIVE FORCE WAS REQUIRED TO REMOVE INTERNAL TAIL CONE RELEASE HANDLE FROM CLIPS. ADJUSTED CLIPS, OPERATIONAL CHECK OK.

Part: PT7 LINE — WATER CONTAM (RT ENGINE)

AS TAKEOFF POWER WAS APPLIED, THE RIGHT ENGINE EPR INDICAITON DID NOT RESPOND. CREW ABORTED THE TAKEOFF AND RETURNED TO THE GATE. MAINTENANCE REMOVED MOISTURE FROM THE PT7 LINES, OPERATIONAL CHECK OK.

Part: EPR TRANSMITTER — MALFUNCTIONED (LT/RT ENGINE)

AS TAKEOFF POWER WAS APPLIED, BOTH ENGINE EPR INDICATIONS FROZE AT 1.60. CREW ABORTED THE TAKEOFF AND RETURNED TO THE GATE. MAINTENANCE REPLACED THE EPR TRANSMITTERS FOR BOTH ENGINES. OPERATIONAL CHECK OK.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND FORWARD OVERWING EXIT EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERIES, OPERATIONAL CHECK NORMAL.

Part: PITOT LINE — BLOCKED (RUDDER)

RUDDER TRAVEL UNRESTRICTED LIGHT REMAINED ON AFTER TAKEOFF. FLIGHT DIVERTED TO DTW AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND PITOT LINE TO RUDDER LIMITER PROBE BLOCKED WITH ICE. DRAINED WATER FROM TRAP. REPLACED RUDDER TRAVEL UNRESTRICTED LIGHT SWITCH, OPERATIONAL CHECK NORMAL.

Part: WIRE — MISINSTALLED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND FLOOR PROXIMITY EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE FOUND WIRES AT CANNON PLUG RECEPTACLES R5-4009 PINS L AND M REVERSED. CORRECTED WIRING AT RECEPTACLE. OPERATIONAL CHECK NORMAL.

Part: POWER SUPPLY — INOPERATIVE (TAIL COMPT)

DURING LINE MAINTENANCE INSPECTION, FOUND TAIL COMPARTMENT CATWALK AND CONE RELEASE HANDLE EMERGENCY LIGHTS INOPERATIVE. REPLACED FLOOD LIGHT/POWER SUPPLY ASSEMBLY, OPERATIONAL CHECK NORMAL.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND BOTH LEFT AND RIGHT OVERWING EMERGENCY EXIT LIGHTS DIM. REPLACED BATTERIES, OPERATIONAL CHECK NORMAL.

Part: BATTERIES — DISCHARGED (TAIL COMPT)

DURING LINE MAINTENANCE INSPECTION, FOUND EMERGENCY EVACUATION LIGHTS IN TAIL COMPARTMENT INOPERATIVE. REPLACED BATTERIES, OPERATIONAL CHECK NORMAL.

Part: CONTROLLER — MALFUNCTIONED (CABIN)

LOSS OF CABIN PRESSURIZATION OCCURRED DURING INITIAL DESCENT AT 31,000 FEET. EMERGENCY DESCENT WAS MADE TO 10,000 FEET AND CABIN PRESSURE WAS REGAINED. FLIGHT CONTINUED TO DESTINATION WITHOUT FURTHER INCIDENT. AN UNEVENTFUL LANDING WAS ACCOMPLISHED. REPLACED CABIN PRESSURE CONTROLLER AND RESECURED LOOSE DUCT AT RIGHT ACM. OPERATIONAL CHECK NORMAL ON CABIN PRESSURE CHECK. AIRCRAFT RETURNED TO SERVICE.

Part: FITTING — CORRODED (WNG 69)

DURING M-CHECK, FOUND CORROSION ON THE FITTING LOCATED AT WING STR 15 AND THE RIGHT WS 69 FRAME. REPLACED FITTING PER SRM 51-30-5.

Part: LONGERON — CORRODED (WS 60/68)

DURING M-CHECK, FOUND CORROSION ON THE RIGHT WING STR 14 AT XRS 68 AND ON STR 19 AT XRS 60. REPAIRED STRINGERS (P/N 5919238-502, 5911279-502) PER EA 99-110820, -110876.

Part: LONGERON — CORRODED (WS 58-112)

DURING M-CHECK, FOUND CORROSION ON THE LEFT WING STR 13 TO 15, 17 BETWEEN XW 58 AND XRS 112. REPAIRED STRINGER (P/N 5919239, 5919237, 5919238) PER EA 99-110827.

Part: SPLICE — CORRODED (WS 91)

DURING M-CHECK, FOUND CORROSION ON THE LOWER FORWARD SPAR CAP SPLICE PLATE AT XRS 91, LEFT SIDE. REPAIRED SPLICE (P/N 3912208-1) PER EA 99-109071.

Part: INSULATION — OUT OF POSITION (CABIN)

AIRCRAFT FAILED TO PRESSURIZE AFTER TAKEOFF. FLIGHT RETURNED TO MEM AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND LOOSE INSULATION BLANKET STUCK IN OUTFLOW VALVE. REMOVED INSULATION. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: FRAME — CRACKED (FS 756)

DURING M-CHECK, FOUND THREE CRACKS ON THE FS 756 FRAME INBOARD FLANGE OF THE LOWER PRODUCTION SPLICE POCKET. REPAIRED FRAME (P/N 9919620-501) PER EA 99-108562.

Part: FITTING — CORRODED (FS 598-617)

DURING M-CHECK, FOUND CORROSION ON THE FRONT SPAR FITTING AT FS 598 TO 617 LBL 66. REPLACED FITTING PER SRM 51-30-0.

Part: SILL — CORRODED (FS 389-408)

DURING M-CHECK, FOUND CORROSION ON THE LEFT HAND WINDOW FRAME SILL, UPPER SIDE, BETWEEN FS 389 TO 408. REPAIRED SILL PER EA 99-108554.

Part: FRAME — CRACKED (FS 612)

DURING M-CHECK, FOUND A CRACK IN THE FS 612 FRAME ATTACH FITTING AT LONGERON 17L. REPLACED FITTING PER SRM 51-10-2.

Part: OXY REGULATOR — MALFUNCTIONED (LT COCKPIT)

CREW OXYGEN DROPPED TO ZERO PRESSURE, FLIGHT DIVERTED TO ATL AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE CAPTAIN'S AND FIRST OFFICER'S OXYGEN REGULATORS, LEAK AND OPERATIONAL CHECK NORMAL.

Part: BATTERY — MALFUNCTIONED (BATTERY COMPT)

A STEADY BATTERY CHARGE RATE OF 15 TO 18 AMPS WAS OBSERVED DURING CLIMBOUT. FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. REPLACED THE BATTERY CHARGER, MAIN BATTERY, AND SENSOR. OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND AFT CEILING EMERGENCY LIGHTS DIM. REPLACED BATTERIES AND OPERATIONAL CHECK NORMAL.

Part: EEL POWER SUPPLY — INOPERATIVE (CABIN)

DURING LINE CHECK, FOUND EMERGENCY FLOOR TRACK LIGHTS FORWARD OF ROW 6 AND THE TWO EMERGENCY EXIT SIGNS BY THE MAIN CABIN DOOR AND SERVICE DOOR INOPERATIVE. REPLACED THE POWER SUPPLY AND BATTERIES, OPERATIONAL CHECK GOOD.

Part: FITTING — CRACKED (WS 164)

DURING MAINTENANCE CHECK, FOUND A CRACK IN THE LEFT WING FITTING STA 164 AT STR 20, OUTBOARD SIDE. REPLACED FITTING PER EA 99-10239.

Part: YAW DAMPER — MALFUNCTIONED (AUTO PILOT)

DURING CLIMB THROUGH 26,000 FEET WITH AUTO-PILOT ENGAGED, THE AIRCRAFT SUDDENTLY YAWED TO ONE SIDE THEN THE OTHER. DISCONNECTED AUTO-PILOT AND PROBLEM CONTINUED. SWITCHED RUDDER CONTROL MANUAL; YAWING CEASED. CAPTAIN DECLARED AN EMERGENCY AND FLIGHT DIVERTED TO TYS. NOTE: NUMEROUS RUDDER TRIM CHANGES WERE REQUIRED DURING CONTINUATION OF FLIGHT TO MAINTAIN CENTERED POSITION. AIRCRAFT LANDED WITHOUT INCIDENT. REPLACED THE YAW DAMPER ACTUATOR. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE.

Part: SEALS — FAILED (ANTI-ICE DUCT)

ON APPROACH INTO MEM, PASSENGER AT ROW 16 REPORTED EXCESSIVE HEAT COMING FROM FLOOR AREA. BOTH FLOOR AND SIDEWALL WERE HOT TO TOUCH. ENGINE AND WING ANTI-ICE WERE ACTIVATED. CAPTAIN DECLARED AN EMERGENCY AND EQUIPMENT WAS CALLED AS A PRECAUTION. AIRCRAFT LANDED WITHOUT INCIDENT. REPLACED BLOWN SEALS AT ANTI-ICE DUCT. AIRCRAFT RETURNED TO SERVICE.

Part: WIRE — CHAFED (AFT FUSELAGE)

TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ILLUMINATED DURING CRUISE FLIGHT AT 33,000 FEET. FLIGHT DIVERTED TO BIS AND LANDED WITHOUT INCIDENT. FOUND WIRING TO RIGHT TEMPERATURE SENSOR CHAFED AND GROUNDING ON TUBING. REPLACED THE RIGHT TEMPERATURE SENSOR AND INSTALLED HEAT SHRINK ON WIRING. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE.