N37437

Part: WARNING MESSAGE — FALSE ACTIVATION (ZONE 800) · airframe 49,802 hrs · 17,679 cycles

DOOR WARNING ANNUNCIATOR IS ON EQUIP LIGHT ILLUMINATED INFLIGHT. PRESSURIZATION REMAINS NORMAL. PERFORMED FIM TASK 52-10 TASK 802, PERFORMED PSEU OPS CK IAW MM TASK 32-09-10-710-801.NO FAULTS DETECTED AFTER RUNNING TEST.NO FURTHER MX ACTION REQ.OK TO CONT

Part: LUG — CORRODED (ZONE 200) · corrosion level 2 · airframe 49,687 hrs · 17,641 cycles

RH MID PLUG DOOR FWD AND AFT BONDING STRAP LUGS AND HARDWARE ARE CORRODED AT WEB ATTACH POINTSREMOVED CORROSION AS PER SRM 53-60-15-1A-2 PARAGRAPH 4.D.3 REWORKED AREA REQUIRES THICKNESS CHECK. INSPECTED THE FWD AND AFT BLEND-OUTS PER NDT/NTM 00-04/ PART-4-00-04-02 ULTRASONIC INSPECTION OF THIN MATERIALS WITH OLYMPUS 35, THE THINNEST PART OF THE FWD BLEND-OUT IS 0.055 INCH AND THE THINNEST PART OF THE AFT BLEND-OUT IS 0.056 INCH. ACP GRID MAP THICKNESS MEASUREMENTS OF FWD AND AFT REPAIR AREAS REF NTM PART 4-00-04-02 . THINNEST MATERIAL WAS 0.052 INCH AT FWD REPAIR AREA AND 0.056 INCH AT AFT REPAIR AREA. GRID MAP MEASUREMENT PICTURES ATTACHED. AFTER EVALUATION FOUND ALLOWABLE DAMAGE OF 10%, MATERIAL THICKNESS IS 0.063'', ON THE AFT SIDE DEEPEST POINT IS 0.056'' WHICH IS 11.2%. ON THE FWD SIDE DEEPEST POINT IS 0.052'' WHICH IS 18%. FOUND TO BE OUT OF LIMITS AS PER SRM 53-60-15-1A-2 PARAGRAPH 4.D.(3) FIGURE 103. PART REQUIRES REPLACE. REMOVED FWD SEAL RETAINER REF SRM 51-40-02. REMOVED CENTER SEAL RETAINER REF SRM 51-40-02. REMOVED DAMAGED WEB ASSY REF SRM 51-40-02. CLEANED AREA AND PREPARED HOLES FOR HFEC. REF SRM 51-10-02-0G-0 PARAGRAPH 11. MATERIAL ID FOR WEB 7075 T6. THICKNESS 0.063" REF DWG 146A8702-1 MATERIAL ID FOR WEB 7075 T6. THICKNESS 0.063" PO: 1566166. REF DWG 146A8702-1 COMPLETED HFEC PER SRM 51019002-0G-0 PAR. 11 TO ZERO TIME THE HOLES, PER HFEC ROTARY HOLE PER NDT 6-51-00-00 P16 AND COUIINSTALLED NEW WEB AND COMPLETED ESFR

Part: BATTERY PACK — DISCHARGED (ZONE 200) · airframe 48,493 hrs · 17,149 cycles

EMERGENCY LIGHTING SYSTEM OPERATIONAL CHECK {B737-33-3-0235} - FOUND EMERGENCY AISLE LIGHT ABOVE ROW 9 INOP, AND AISLE LIGHT ABOVE ROW 12 TURNING ON AND OFF INTERMITTENTLY. REMOVED AND REPLACED EMERGENCY LIGHT BATTERY PACK AT POWER SUPPLY M01676, REF WDM 33-51-12-6 AND AMM 33-51-06-960-805. NO FIX. REMOVED AND REPLACED FUSES AT POWER SUPPLY M01676, REF AMM 33-51-06-960-804. NO FIX. REMOVED AND REPLACED POWER SUPPLY M01676, REF 33-51-06-960-806. NO FIX. REQUIRES FURTHER TROUBLESHOOTING.PARTS USED: 29-3351-3-0031,QTY :1 99-3351-3-0015,QTY :1 REQUESTING TO DEFER PER MEL 3315A TOMC APPROVED 2 BULLNOSE LIGHTS INOP, NOT OPPOSITE EACH OTHER INSTALLED INOPERATIVE STICKER ADJACENT TO EMER EXIT LIGHTS SWITCH ON THE FORWARD OVERHEAD PANEL AND ADJACENT TO EMER EXIT LIGHT SWITCH AT DOOR 2L FLIGHT ATTENDANT PANEL.

Part: LIGHT — NO TEST (ZONE 200) · airframe 48,217 hrs · 17,028 cycles

EMERGENCY LIGHTING SYSTEM OPERATIONAL CHECK {B737-33-3-0235} - R/H FWD OVERWING EMERGENCY LIGHT INOP. RELAMPED R/H FWD OVERWING EMERGENCY LIGHT PER MM 33-51-04. OPS CHECK GOOD.

Part: WARNING LIGHT — ILLUMINATED (E/E DOOR) · airframe 47,683 hrs · 16,798 cycles

EQUIPMENT DOOR LIGHT CAME ON CLIMBING PASSING 9500 FEETATTEMPTED TO OPEN EQUIPMENT DOOR. FOUND DOOR TO BE DIFFICULT TO OPEN FOUND NO FAULT CODE ON PSEU BITE IN REFERENCE TO FIM 32-62 TASK 801 RANG AND MEGGER WIRES FROM PSEU CONNECTORS D10986 PIN 6, D10988 PIN 6 TO DOOR SWITCH S197 & S196 & TO CONNECTOR D1406 PIN 6. WDM 52-71-12-4 PG 4 & SSM52-71-12-103 PG103. D10986 AND D10988 CONNECTORS SECURED TO PSEU & D1406P SECURED TO P5-20 ( DOOR WARNING ANNUNICATOR PANEL). PER TST REQUEST CHANGED S197 SWITCH IAW WDM 52-71-12-04. REMOVED E&E DOOR FOR CONDITIONAL INSPECTION. PRESSURE SEAL IS IN SERVICEABLE CONDITION. ALL ROLLERS, TRUCKS, & BEARINGS ARE IN GOOD CONDITION. OPS OF LOCKING MECHANISM AND PINS ARE WITHIN SERVICE LIMITS. RE-INSTALLED E&E DOOR. PERFORMED MULTIPLE OPERATIONAL CHECKS. DOOR OPENS & LOCKS IN PLACE WITH NO BINDING AND NORMAL EFFORT. E&E DOOR OPERATION IS IN SERVICEABLE CONDITION. REF AMM 52-48-41-200-801, AMM 52-48-41-200-802, AMM 52-48-41-00-801, AND AMM 52-48-41-400-801 PERFORMED CABIN PRESSURE LEAK TEST UP TO 4 PSI REF AMM 05-51-91-790-801. DOOR OPEN INDICATION LIGHT DID NOT COME ON. PERFORMED DETAILED INSPECTION OF FWD ACCESS DOOR. ALL STOPS ARE INTACT AND SAFETIED. THE DOOR HINGE BUSHINGS ARE WITHIN LIMITS AND THE DOOR SEAL IS PROPER CONDITION. OPS CHECKED DOOR MULTIPLE TIMES AND IT PASSESRECEIVED APPROVAL FROM TOM-C CONTROLLER AND SENIOR MANAGER TO CLEAR THIS DISCREPANCY.

Part: PROXIMITY SWITCH — FAULTED (E&E DOOR) · airframe 47,177 hrs · 16,590 cycles

PASSING 16000 FEET THE EQUIP WARNING LIGHT CAME ON FOUND DOOR CLOSED AND HANDLE STOWED. HAD TO PRY HANDLE OPEN FWD E&E DOOR HINGES ARE LOOSE AND WORN, BUSHINGS APPEAR TO BE REMOVED FWD ACCESS DOOR IAW AMM 52-48-31-000-801 TO INSPECT FOUND HANDLE TO BE LOOSE AND EXSESIVE FOR AND AFT PLAY IN WORN. DOOR BUSHINGS. NO DEFECTS NOTED IN BUSHINGS THEY ARE SLOTTED FOR HANDLE WHEN STOWING DOES NOT FEEL NORMALE. EASE OF OPENING DOOR. INSTALLED ORIGINAL FWD EQUIPMENT ACCESS DOOR IAW B737 AMM 52-48-31-400-801. REF LOGPAGES 8222470 & 8222495 FOR CORRECTIVE ACTION ON THE EQUIP DOOR WARNING LIGHT. DUE TO RETURN TO THE FIELD EVENT SUGGEST REPLACE MAIN E&E DOOR SENSOR, REF TASK 52-71-42-400-801. REF LP 8219983. REPLACED MAIN E&E DOOR SWITCH S187, OP CKS GOOD PER TASK 52-71-42-710-801.

Part: SWITCH — INOPERATIVE (CABIN PRESSURE) · airframe 47,172 hrs · 16,588 cycles

CABIN ALTITUDE WAS SLOWLY RISING BUT NEVER EXCEEDED 10000 BITE OF DCPC SHOWED NO FAULTS. PERFORMED PRESSURIZATION CHECK PHASE 1 UP TO 4 PSI IAW AMM 21-00-05-780-801. AIRPLANE PRESSURIZED NORMALLY AND NO LEAKS WERE FOUND, NO FAULTS ON PSEU BITE. OK PER TASK 52-71-42-710-801.

Part: HANDLE — OUT OF ADJUST (DOOR 2L) · airframe 43,775 hrs · 15,216 cycles

2L DOOR HANDLE HARD TO DEPRESS COMPLETELY DOOR EXTERIOR HANDLE DIFFICULT TO OPERATE HARD TO CLOSE. REF TO FIN 52-10-810. INSPECTED DOOR AND FOUND FORWARD STOP PINS OUT OF ADJUSTMENT. ADJUSTED STOP PINS IAW AMM 52-13-00-820-801. CHECKED HANDLE TORQUE IAW AMM 52-13-00-700-805. DOOR OPERATES AND LATCHES NORMAL. VERIFIED ADJUSTMENT MADE TO DOOR AND DOOR HANDLE TORQUE ARE WITHIN LIMITS REF. AMM 52-13-00-700-805 AND GMM 09-25-05.

Part: WINDOW FRAME — CRACKED (UPPER AFT CORNER) · airframe 43,727 hrs · 15,193 cycles

AFTER HFEC INSPECTION ON THE LH WINDOW FRAME AT THE UPPER AFT CORNER AND INNER CORNER RADIUS FOUND TO BE CRACK PER EA 5310-04554 REV B STEP 9.1 AND 9.2. (REF: AAR NR 99965475) SFR NO 1031988. PERFORMED CUT OUT ON LH WINDOW FRAME OF THE CRACK FOUND. (WORK ACCOMPLISHED BY V937984 AND AAR QC A-82 UPPER CORMER & INNER CORNER RADIOS IAW B737-900ER, UNITED V931568) EA 5310-04554, REV. B STEP 15.2, 15.3 FIG 7 CONF "B", NDT PERFORMED IAW B737 PART 6, 51-00-00 PROC 23, AFTER CUT OUT NO

Part: BATTERY PACK — FAILED (M1673) · airframe 43,727 hrs · 15,193 cycles

EMEGENCY POWER PACK, M1673, FAILS EMERGENCY LIGHTING FUNCTIONAL CHECK. BATTERY DISCHARGES IN LESS THAN 10 MINS (REF AAR NR 99965142) REMOVED AND INSTALLED NEW BATTERY PACK ON M1673 IAW B737 AMM 33- 51-06-960-805, OPS CHECK GOOD.

Part: BATTERY PACK — DISCHARGED (M1670) · airframe 43,727 hrs · 15,193 cycles

EMEGENCY POWER PACK, M1670, FAILS EMERGENCY LIGHTING FUNCTIONAL CHECK. BATTERY DISCHARGES IN LESS THAN 5 MINS (REF AAR NR 99965141) REMOVED AND INSTALLED NEW BATTERY PACK (M1670) AND PERFORMED OPERATIONAL TEST GOOD IAW B737 AMM 33-51-06-960-805.

Part: BATTERY PACK — DISCHARGED (M1694) · airframe 43,727 hrs · 15,193 cycles

EMEGENCY POWER PACK, M1694, FAILS EMERGENCY LIGHTING FUNCTIONAL CHECK. BATTERY DISCHARGES IN LESS THAN 8 MINS (REF AAR NR 99965140) REMOVED AND INSTALLED NEW BATTERY PACK (M1694) AND PERFORMED OPERATIONAL TEST GOOD IAW B737 AMM 33-51-06-930-805.

Part: FRAME — CRACKED (LH WINDOW) · airframe 43,727 hrs · 15,193 cycles

AFTER HFEC INSPECTION ON THE LH WINDOW FRAME AT THE UPPER AFT CORNER AND INNER CORNER RADIUS FOUND TO BE CRACK PER EA 5310-04554 REV B STEP 9.1 AND 9.2. (REF: AAR NR 99965475)

Part: LIGHT — INOPERATIVE (R1 DOOR) · airframe 40,327 hrs · 13,954 cycles

EMERGENCY LIGHTING SYSTEM OPERATIONAL CHECK {B737-33-3-0235} - EXTERIOR EMERGENCY LIGHT AT R1 DOOR INOP. RELAMPED EMERGENCY LIGHT REF MM 33-51-04. OPS CK OK.

Part: WING — DENTED (STA 219.8) · airframe 37,593 hrs · 12,949 cycles

BIRDSTRIKE ON T/O CLIMBI NG THRU 2000 FT. 200KTS. LARGE BIRD 5FT SPAN HIT RT SIDE NOSE + WING. ACCOPLISHED BIRD STRIKE INSPECTION IAW SRM 53-00-01. FOUND DENT AT SECTION 41 STATION 219.8 W4" L380" D.085". ALLOWABLE DAMAGE 1 PARAGRAPH 4 SECTION 3 DENTS, DETAIL G TABLE 103 WITH IN LIMITS LESS THAN .125" NO REPAIR NESSESARY.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 35,190 hrs · 12,072 cycles

SUPPORT TASK: P/R (721771) MULTIPLE PASSENGER CABIN EMERGENCY LI GHTING ZONES FAIL TO ILUMINATE. REF BY PEMCO NR 2710N69 REMOVED AND REPLACED EMERNCY BATTERY PACKS AT ALL FWD, MID AND A FT LOCATIONS PER B737 AMM 33-51-06. TEST OK 12 EA. PACKS REPLICE D EQUIPMENT NO.5 M1672, M1673, M1674, M1675, M2626, M2627 TO CAPACITY CHECK FAIL.WRK PERFORMED BY P431, ENTERED, I NSP.

Part: O2 GENERATOR — DISCHARGED (CABIN) · airframe 35,190 hrs · 12,072 cycles

B737-35-3-0149 (ORANGE PARTS RACKS 11 SHELF C): O2 GEN 24LH FOUN D EXPENDED UPON. REF BY PEMCO NR 2710N359

Part: SKIN — CRACKED (HORIZONTAL STAB) · airframe 35,190 hrs · 12,072 cycles

(EA 5510-01843 REV H) R/H HORZ STAB, RIB STA 92.70 VERTICAL VERT ICAL STIFFENER NO.1 CRACKED.REF BY PEMCO NR 2710N315. REPAIRED RIB 92.70 ON R/H HORZ STAB IAW B737-900 ER SRM 55-10-09 4 PLACES PER NON-ROUTINE 2710N316 N317 AND N318 WRK PERFORMED B Y V915737, ENTERED Y V928371, INSP BY Q995 REPAIRED RIB 92.70 ON R/H HORZ STAB IAW B737-900 ER SRM 55-10-09 4 PLACES PER NON-ROUTINE 2710N316 N317 AND N318 WRK PERFORMED B Y V915737, ENTERED Y V928371, INSP BY Q995

Part: OVEN — ODOR (FWD GALLEY) · airframe 34,448 hrs · 11,813 cycles

RETURNED TO AIRPORT DUE TO STRONG ODOR ONCE A/C WAS AIRBORNE WIT H TAKEOFF THRUST PER FLT CREW DEBRIEF A/C UNDER MAX LANDING WEIGHT SMOOTH LANDING NORMAL SPEED. NO ABNORMAL INDICATIONS,"SMOKE SMELL"AND "LIGHT HAZE" DISSAPATED IN FLIGHT WITH NO REOCCURENCE PRIOR TO LANDING CREW COMPLETED SMOKE/ODOR QUESTIONAIRE. DUE TO WORK ON #2 ENG, OPENED COWLING AND CHECKED, NOTHING ABNORMAL FOUND, PERFORMED HIGH POWER RUN ON BOTH ENGS AND PACKS, NO ODOR, FOUND OVEN 204 WITH ODOR, REPLACED OVEN 204. ADD EMP:U54382 ROTABLE PARTS CHANGE WAS INDICATED - TT # 1013868 SN OFF 4359 OVEN, SMALL, ST OFF 99-2532-9-0001 4359 ON 99-2532-9-0001 8014

Part: CHECK VALVE — INOPERATIVE (NR 2 ENGINE) · airframe 31,139 hrs · 10,552 cycles

CREW REPORTS LOUD BANG FOLLOWED BY UNCOMMANDED SHUTDOWN OF THE RIGHT ENGINE, ENGINE WAS SUCCESFULLY RESTARTED AFTER APPROX 10 MIN, POSITIVE OIL PRESS MAINTAINED DURING WINDMILL. ENGINE OPERATED NORMALLY AFTER RESTART AND RESPONDED TO THRUST COMMANDS. CREW REPORTS NORMAL LANDING UNDER MAX LIMIT.ACP EEC BITE CK AND POWER ASSURANCE CK. ALL NORMAL.

Part: LENS — MISSING (EMERGENCY LIGHT) · airframe 27,562 hrs · 9,158 cycles

L2 DOOR EMERGENCY EXIT SIGN LENS MISSING. REPLACED THE LENS.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 26,992 hrs · 8,937 cycles

EMERGENCY AISLE AREA LIGHTS AT 24DEF AND 27DEF ARE INOPERATIVE. REPLACED CHARGER AND BATTERY PACK. OPS CHECKED GOOD IAW AMM 33 -51-06.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 25,617 hrs · 8,470 cycles

RT FWD EMERGENCY EXIT EXTERIOR LIGHT INOP. RELAMPED OPS CHECK OK. OK TO CONTINUE.

Part: LIGHT — INOPERATIVE (OVERWING EXIT) · airframe 25,128 hrs · 8,285 cycles

RIGHT WING FWD OVERWING EMERGENCY LIGHT NOT WORKING. RELAMPED IAW AMM 33-51-04. OPS CHECKS GOOD.

Part: SEAT TRACK — MECHANIC ERROR (FUSELAGE) · airframe 16,313 hrs · 5,310 cycles

STATION 727B LBL 24.72 SEAT TRACK FASTENERS HOLES DON'T HAVE EDGE MARGIN. TRIMMED, PERFORMED HFEC, FABRICATED REPAIR PARTS & INSTALLED ON SEAT TRACK FLANGE IAW ECRA 5320-02289.

Part: SEAT TRACK — MECHANIC ERROR (FUSELAGE) · airframe 16,313 hrs · 5,310 cycles

STATION 727B LBL 45.5 SEAT TRACK FASTENERS HOLES DON`T HAVE EDGE MARGIN. TRIMMED, PERFORMED HFEC, FABRICATED REPAIR PARTS & INSTALLED ON SEAT TRACK FLANGE IAW ECRA 5320-02289.

Part: SEAT TRACK — CRACKED (FUSELAGE) · airframe 16,313 hrs · 5,310 cycles

SEAT TRACK STATION 727B AT LBL 45.50 CRACKED AT HOLE COMMON TO SPLICE PLATE IAW EA 5320-02076 OP 3 STEP 4.1 C. TRIMMED, PERFORMED HFEC, FABRICATED REPAIR PARTS & INSTALLED ON SEAT TRACK FLANGE IAW ECRA 5320-02289.

Part: SEAT TRACK — MECHANIC ERROR (FUSELAGE) · airframe 16,313 hrs · 5,310 cycles

SEAT TRACK FLANGE AT STATION 727B, RBL 45.50 INBD & OTBD HAVE NO ED IAW EA 5320-02076 & OP 3 - 4. TRIMMED, PERFORM HFEC, FABRICATED REPAIR PARTS & INSTALLED ON SEAT TRACK FLANGE AT STATION 727B RBL 45.50 IAW ECRA 5320-02289.

Part: SKIN — CRACKED (RT HORIZ STAB) · airframe 16,313 hrs · 5,310 cycles

WHEN PERFORMING A C SCAN INSPECTION ON RT HORIZ LOWER IN SPAR SKIN FOUND CRACK INDICATION AT SS 101.9 & 10 INCHES FROM AFT SPAR. SEE WIPS FOR DETAILS OF WORK ACCOMPLISHED. TRIMMED OUT CRACK & INSTALLED REPAIR DOUBLER IAW SRM 55-10-01 REPAIR 11. INITIATED DIP 28557 TO DO INSPECTION AS GIVEN IN TABLE 204 REPAIR 11 & FIG 206 AT 56000 FLIGHT CYCLES AFTER INSTALLATION & 9000 FLIGHT CYCLES INTERVALS THEREAFTER IAW SRM 55-10-01 REPAIR 11

Part: SCREW — MISSING (UPPER GUIDE ARM) · airframe 4,412 hrs · 1,338 cycles

MAIN CABIN FORWARD ENTRY DOOR (1L) JAMMED WILL NOT OPEN ON ARRIVING IN SJU REF PREV/WRITEUP 8503603 INSTALLED SCREW & WASHER IAW AMM52-11-21-410-802. ENSURE DOOR IS ADJUSTED PROPERLY IAW AMM52-11-00-820-801. ENSURE LATCH TORQUE TUBES, ADJ PROP IAW AMM52-11-00-820-802. PERFORM DOOR SYS TEST IA AMM52-11-00-200-809. INITIATE DIP IAW ECRA 5211-01163 TO PERF PERM REPAIR PER PART 3 WITHIN 1 FLT CYCLE. INSTALLED PROPER HARDWARE AS PER IPC 52-11-21-01, ECRA 5211-01163 AND AMM 52-11-21. OPS CHECKED DOOR 1L, NO DEFECTS NOTED. DIP CLOSED. "Q/C" ACCOMPLISH A PERMANENT REPAIR WITHIN 1 FLT CYCLE FROM DATE 10/02/2010 PER PART 3 OF ECRA 5211-01163. REMOVED INTERIM SCREW AND INSTALL SCREW P/N BACS12ER06K6. DIP C/N 07276 ISSUED.