N501TR

Part: INDICATOR — UNSERVICEABLE (NR1 EGT)

DURING CRUISE, ENG NR1 EGT OFF SCALE HIGH INDICATION. POINTER AT 6 O`CLOCK POSITION. POINTER AND DIGITAL READOUT AGREED. AMBER EGT LIGHT ON, ENGINE EGT LIGHT ON MWP, AND SSC. AC RETURNED TO FIELD, ABNORMAL PROCEDURES WERE PERFORMED AND APPROX. 8500 LBS OF FUEL WAS DUMPED TO ACCOMPLISH SAFE LANDING WT. AIRCRAFT LANDED NORMAL. C/A REMOVED AND REPLACED NR1 ENG EFT INDICATOR IAW 77-21-11 PG 401. TEST OK WIAW 77-21-11 PG 501. DURING TROUBLESHOOTING FOUND EFT BOTTOM LT THERMOCOUPLE HARNESS AND PROBE RESISTANCE OUT OF LIMITS IAW 77-21-01 PG 202. REMOVED AND REPLACED THERMOCOUPLE HARNESS AND PROBE IAW 77-21-01 PG 202. LOW PRESSURE AND HIGH PRESSURE TURBINE SECTIONS BOROSCOPED AND FOUND SATISFACTORY. MAX POWER ASSURANCE RUN ACCOMPLISHED AND FUNCTIONED SATISFACTORY, AIRCRAFT RETURNED TO SERVICE. (A)

Part: GEARBOX — CONTAMINATED (NR 2 ENG)

ON CLIMBOUT STJ FL230, OIL QTY DECREASING RAPIDLY. PERFORMED PRECAUTIONARY SHUTDOWN PROCEDURES, OIL PRESSURE WAS NOT LOST, OIL TEMP RISE TO 130 DEGREES. REPLACED GEARBOX IAW MM 72-60-01. OPS CHECK GOOD ON NR 2 ENGINE. (K)

Part: SKIN — CORRODED (FUSELAGE) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK, FOUND OUT OF LIMIT CORROSION ON FUSELAGE AT STR 6 TO FRAME 76. CUT OUT DAMAGED AREA 2.75 INCHES BY .75 INCHES AND INSTALLED FILLER FABRICATED FROM 2024 T3 0.090 AND REPAIR DOUBLER FABRICATED FROM 2024 T3 0.100 IAW A300 SRM 53-10-10.

Part: SEAT TRACK — CRACKED (FUSELAGE) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK, MAIN CABIN SEAT TRACK AT FRAME 40 RBL 54 WAS FOUND CRACKED. REPLACED SEAT TRACK AT RBL 54 FROM FRAME 40 TO FRAME 44 +12 INCHES IAW SRM 53-10-10.

Part: TRACK — CORRODED (CARGO BAY) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK WHILE ACCOMPLISHING CPCP TASK CARD ZL-150-L403-501, CORROSION WAS FOUND ON LT INBOARD ROLLER TRACK IN AFT CARGO COMPARTMENT AT FRAMES 54 TO 57. REMOVED AND REPLACED ROLLER TRACK IAW SRM 51-30-30.

Part: TRACK — CORRODED (CARGO BAY) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK WHILE ACCOMPLISHING CPCP TASK CARD ZL-150-L403-501, CORROSION WAS FOUND ON LT INBOARD ROLLER TRACK IN AFT CARGO COMPARTMENT AT FRAME 57. REMOVED AND REPLACED ROLLER TRACK IAW SRM 51-30-30.

Part: TRACK — CORRODED (CARGO BAY) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK WHILE ACCOMPLISHING CPCP TASK CARD Z:-150-L403-5-01, CORROSION WAS FOUND ON LT INBOARD ROLLER TRACK IN AFT CARGO COMPARTMENT BETWEEN FRAMES 58 TO 59. REMOVED AND REPLACED ROLLER TRACK IAW SRM 51-30-30.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK, A 8 INCH BY 2 INCH CUT WAS FOUND IN SKIN BETWEEN FRAME 51 AND 52 AT STRINGER 36R TO 39R AFT OF RMLG DOOR CUT OUT. INSTALLED SKIN REPAIR DOUBLER AT FUSELAGE FRAME 51 TO 52 AND STRINGER 36R TO 39R IAW A300 SRM 53-10-10.

Part: SKIN — CORRODED (LT ELEVATOR) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK, WHEN ACCOMPLISHING CPCP TASK CARD 55-2007-0602-1-01 SEVERAL AREAS OF CORROSION WERE FOUND OUT OF LIMITS ON LT ELEVATOR SKIN FROM CENTER LINE RIVETS TO I/B END CAP. REPLACED ELEVATOR IAW A300 MM 27-31-24.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK, WHEN ACCOMPLISHING CPCP TASK CARD ZL-220-L403-9-01, CABIN SEAT TRACK WAS FOUND CORRODED AT FRAME 13B - 14C LBL 55. REMOVED AND REPLACED SEAT TRACK SECTION BETWEEN FRAME 13B - 14C LBL 55 IAW A300 SRM 51-30-30 WITH SEAT TRACK FABRICATED FROM EXTRUSION 60-22457.

Part: ATTACH FITTING — CORRODED (LT ELEVATOR) · airframe 49,967 hrs · 26,269 cycles

DURING M96 CHECK, CORROSION WAS FOUND OUT OF LIMITS ON NR 3 (FROM OUTBOARD END) LEFT ELEVATOR ATTACH HINGE AT BONDING WIRE ATTACH POINT. REPLACED HINGE ATTACH IAW A300 M/M 55-51-31.

Part: DAMPER — FAILED (LT MLG) · airframe 49,798 hrs · 26,220 cycles

AFTER TAKEOFF FROM IND, GEAR FAILED TO RETRACT ON BOTH SYSTEM A AND B, DIVERTED TO GSO, DUMPED APPROX 15,000 POUNDS OF FUEL AND MADE A SAFE LANDING. FOUND LEFT INBOARD PITCH DAMPER AT FAULT, REPLACED INBOARD PITCH DAMPER IAW A300 MM 32-11-15 PG 410, LEAK CHECKED IAW 12-12-32 PG 24. AIRCRAFT RELEASED FOR SERVICE.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 48,885 hrs · 25,952 cycles

DURING WALKAROUND, FOUND FUSELAGE SKIN DAMAGED AT C-1 DOOR FRAME, RIGHT SIDE AT FRAME 24B STA 1701. INSTALLED DOUBLER REPAIR ON C-1 DOOR FRAME 24B STA 1701 IAW A300 SRM 53-13-00.

Part: RUDDER — DELAMINATED · airframe 48,853 hrs · 25,931 cycles

DURING WALK AROUND POSSIBLE DELAMINATION NOTED ON TRAILING EDGE OF RUDDER. RUDDER REMOVED, REPAIRED IAW SRM 55-41-11 PG148-149, SRM 51-21-00 PG 15, 21, 22 SRM 51-40-00 PG 731-733 FIG 709, SRM 55-41-11 PG 148, 149 SRM 51-42-20 AND PCS PROCESS PROCEDURES PCS-PS0001, SRM 51-41-50. PRIMED AND PAINTED IAW SRM 51-40-12. RUDDER RETURNED SERVICEABLE TO BE RE-INSTALLED ON AIRCRAFT.

Part: RUDDER — DELAMINATED · airframe 48,853 hrs · 25,931 cycles

DURING WALK AROUND POSSIBLE DELAMINATION NOTED ON TRAILING EDGE OF RUDDER. RUDDER REMOVED, REPAIRED IAW SRM 55-41-11 PG148-149, SRM 51-21-00 PG 15, 21, 22 SRM 51-40-00 PG 731-733 FIG 709, SRM 55-41-11 PG 148, 149 SRM 51-42-20 AND PCS PROCESS PROCEDURES PCS-PS0001, SRM 51-41-50. PRIMED AND PAINTED IAW SRM 51-40-12. RUDDER RETURNED SERVICEABLE TO BE RE-INSTALLED ON AIRCRAFT.

Part: SWITCH — MALFUNCTIONED (LANDING GEAR) · airframe 48,524 hrs · 25,823 cycles

AFTER TAKEOFF FROM GSO, GOT NOSE LANDING GEAR DOOR UNSAFE INDICATION, WHEN GEAR HANDLE WAS PLACED IN NEUTRAL POSITION ALL GEARS EXTENDED. RETURNED TO GSO AND MADE A SAFE LANDING. PERFORMED NORMAL SYSTEM LANDING GEAR RETRACTION IAW A300 MM 32-30-00 PAGE 501, 5 TIMES, NO FAULTS NOTED. AS PRECAUTION, THE LANDING GEAR CONTROL MICRO SWITCH UNIT WAS REPLACED AS MOST PROBABLE CAUSE. COMPLETED NORMAL SYSTEM LANDING GEAR RETRACTION TEST IAM 32-30-00 PAGE 501, NO DEFECTS NOTED. AIRCRAFT RETURNED TO SERVICE.

Part: LANDING GEAR — MALFUNCTIONED (NLG) · airframe 48,523 hrs · 25,822 cycles

AFTER TAKEOFF FROM IND, NOSE LANDING GEAR FAILED TO RETRACT, PERFORMED ABNORMAL CHECK LIST AND DIVERTED TO GSO AND MADE A SAFE LANDING. PERFORMED NORMAL EXTENSION AND RETRACTION OF SYSTEM 1 AND 2, NO DEFECTS NOTED, AIRCRAFT RELEASED TO SERVICE.

Part: CONNECTOR — DAMAGED (NR 1 FIRE LOOP) · airframe 47,491 hrs · 25,543 cycles

ON TAKEOFF ROLL, ENGINE NR 1 LOOP-B ON MWP AND FLIGHT ENGINEERS PANEL ILLUMINATED. ABORTED TAKEOFF, PERFORMED CHECKLIST AND RETURNED TO GATE. INSPECTED ENGINE AND FIRE LOOP, CHECKED GOOD. PLACED ON MEL 26-12-01 CAT-B, RELEASED AIRCRAFT TO SERVICE. REPAIRED NR 1 ENGINE FIRE LOOP CONNECTION PER ESPM 20-53-26, SYSTEM CHECKS NORMAL PER MM 26-12-00PAGE 501, MEL CLEARED 7-10-06.

Part: SPAR — CORRODED (RUDDER) · airframe 47,320 hrs · 25,473 cycles

DURING M72 CHECK, FOUND CORROSION ON RUDDER SPAR BOX ANGLE AT RIBS RR20 AND RR38. REMOVED CORROSION AND INSTALLED DOUBLERS PER EMTEQ REPAIR ORDER 2-41054-801

Part: FITTING — CORRODED (VERTICAL STAB) · airframe 47,320 hrs · 25,473 cycles

DURING M72 CHECK, FOUND CORROSION ON EMPENNAGE FORWARD RIGHT FITTING ATTACHED TO VERTICAL STABILIZER. CLEANED, PRIMED AND APPLIED TOP COAT PER A300 SRM 51-40-12 AND REPLACED EMPENNAGE FORWARD RIGHT LONGITUDINAL BRACE FITTING PER A300 DRAWING 19R53870348 SHEET 2.

Part: SUPPORT — CORRODED (VERTICAL STAB) · airframe 47,320 hrs · 25,473 cycles

DURING M72 CHECK, FOUND CORROSION AND LOOSE FASTENERS ON HORIZONTAL SUPPORT OF VERTICAL STABILIZER TRAILING EDGE STRUCTURE ABOVE RUDDER FITTING NR 1. FABRICATED FITTING FROM EXTRUSION BAC1505100797 PER A300 ACCORDING SRM 51-41-00, TREATED, PRIMED AND APPLIED TOP COAT ACCORDING SRM 51-40-12 PAGE'S 1; 26; 30 AND 31, INSTALLED AS PER A300, ACCORDING SRM 51-30-30.

Part: JACKSCREW — LOCKED (LE SLATS) · airframe 47,283 hrs · 25,457 cycles

ON TAXI OUT, SELECTED SLATS TO 0/16, SLATS FAILED TO EXTEND. RETURNED TO BLOCK. FOUND LT NR 3 JACKSCREW LOCKED OUT. FREED JACKSCREW IAW 27-81-00 PG 511, FUNCTIONAL CHECK ACCOMPLISHED IAW 27-81-00 PG 501. AIRCRAFT RETURNED TO SERVICE.

Part: INDICATOR — UNSERVICEABLE (MLG) · airframe 47,264 hrs · 25,451 cycles

DURING START OF TAKEOFF ROLL, PILOTS LANDING GEAR LIGHT INDICATOR RT MAIN UNLOCK LIGHT CAME ON. F/E PANEL OK. ABORTED TAKEOFF, MAX BRAKE TEMP IND 400. RETURNED TO GATE. ITEM DMI"D PER 32-31-01 CAT B EXPIRES 2-12-06 OK TO CONTINUE SERVICE. REMOVED AND REPLACED CAPT LANDING GEAR INDICATOR. OP'S CHECK SATISFACTORY IAW 32-61-00. DMI CLEARED, AIRCRAFT RELEASED FOR SERVICE.

Part: ENGINE — UNSERVICEABLE (NR 2)

DURING CLIMBOUT NR 2 ENGINE EXCEEDED EGT LIMITS. WHEN LIMITS WERE IN NORM OPERATING RANGE NO RESPONSE WAS SEEN WHEN THROTTLES WERE ADVANCED. FUEL DUMP PROCEDURES FOLLOWED, AIRCRAFT RETURNED TO AIRPORT, LANDING NORMAL. REMOVED AND REPLACED NR 2 ENGINE IAW A300-71-007. RUN UP CHECKS AND LEAK CHECKS ALL SATISFACTORY. AIRCRAFT RETURNED TO SERVICE.

Part: VALVE — MALFUNCTIONED (FUEL SYSTEM) · airframe 45,308 hrs · 24,897 cycles

UPON PERFORMING EMERGENCY PROCEDURES FOR A LOW SPEED AILERON FAULT, WHEN STARTING TO DUMP FUEL FOR A RETURN TO BASE LANDING, RT FUEL JETTISON VALVE MI CROSSHATCHED DURING FUEL JETTISON. DEFERRED JETTISON RT VALVE MI IAW MEL 28-31-01 CAT "C" EXPIRES 3-15-05. PLACARD INSTALLED UPDATE. 3-8-05 REMOVED AND REPLACED RT VLVE FUEL JETTISON MI INDICATOR, OPS CHECK GOOD I/A/W 28-00-00. CLEAR MEL, PLACARD REMOVED. A/C RETURNED TO SERVICE.

Part: ACTUATOR — UNSERVICEABLE (LWSPD AILERON) · airframe 45,308 hrs · 24,897 cycles

LT LOW SPEED AILERON FAILED TO DISCONNECT UPON SLAT RETRACTION. FUEL DUMP PROCEDURES FOLLOWED, AIRCRAFT RETURNED TO AIR FIELD, LANDING NORMAL. MANUALLY DISCONNECT LOW SPEED AILERON. LOCK OUT ACTUATOR I/A/W 27-00-00, VERIFIED ROD IS RETRACTED AND IN DISCONNECT MODE MEL 27-11-01 CAT "C" EXP 3-15-05 PLACARD INSTALLED. AIRCRAFT RETURNED TO SERVICE. FOUND LT LOW SPEED AILERON ACTUATOR AT FAULT. REMOVED AND REPLACED LT LOW SPEED AILERON ACTUATOR. SYSTEMS OP'S CHECK GOOD I/A/W 27-11-43, PLACARED REMOVED MEL CLEARED. AIRCRAFT OK FOR SERVICE.

Part: DUMP VALVE — FAILED (FUEL SYSTEM) · airframe 44,157 hrs · 24,593 cycles

WHEN ATTEMPTING TO DUMP FUEL, RT DUMP VALVE WOULD NOT OPEN WITH PRIMARY OR SECONDARY SELECTED. CLEANED C/P AT RT FUEL JETTISON VALVE ACTUATOR. SECONDARY SYS CHECK'S OK IAW 28-31-00. PRIMARY DEFERRED IAW MEL 28-31-02 CAT-C.

Part: ACTUATOR — UNSERVICEABLE (FUEL JET VALVE) · airframe 44,157 hrs · 24,593 cycles

AFTER TAKE OFF AC REQUIRED A LOT OF AILERON TO KEEP LEVEL, 35 DEGREES. RETURNED TO AIRFIELD, WHEN ATTEMPTING TO DUMP FUEL, RT DUMP VALVE WOULD NOT OPEN WITH PRIMARY OR SECONDARY. OVERWEIGHT LANDING ACCOMPLISHED. LANDING NORMAL. FOUND NR 3 LT SPOILER SERVO BAD, REMOVED AND REPLACED SERVO CONTROL IAW 27-62-14, OP'S CHECKED SATISFACTORY. PERFORMED OVERWEIGHT LANDING INSPECTION AND FOUND AIRCRAFT IN AIRWORTHY CONDITION, NO DISCREPANCIES NOTED. CLEANED C/P AT RT FUEL JETTISON VALVE ACTUATOR. SECONDARY SYS CKS OK IAW 28-31-00. DEFERRED PRIMARY IAW MEL 28-31-02 CAT-C. AIRCRAFT RETURNED TO SERVICE.

Part: NUT — LOOSE (MANIFOLLD) · airframe 44,143 hrs · 24,589 cycles

COMPLETE LOSS OF GREEN SYSTEM HYD QUANTITY. PERFORMED ABNORMAL CHECKLIST. RETURNED TO AIRPORT, PERFORMED MANUAL GEAR EXTENSION. LANDING NORMAL. MAINTENANCE FOUND JAMNUT LOOSE ON GREEN PRESSURE MANIFOLD. TORQUED NUT AND LEAK CHECK GOOD I/A/W A300 MM 20-21-12. SERVICED HYD SYSTEM IAW A300 MM 12-12-21. RESTORED LANDING GEAR ACTUATING SYSTEM TO NORMAL IAW A300 MM 32-30-00. AIRCRAFT RETURNED TO SERVICE.

Part: CLAMP — LOOSE (ENGINE)

NR 1 ENG NACELLE TEMP READ 300+ ON CLIMB OUT. TEMP. REACTED TO THROTTLE MOVEMENT. DUMPED APPROX. 30K LBS. RETURNED TO FIELD, LANDING NORMAL. MAINTENANCE FOUND IP CHECK VALVE CLAMP OFF DUCT. REINSTALLED CLAMP IAW PROCESS MATERIAL SPEC. MANUAL 01-05-42. ENGINE RUN UP LEAK AND OP'S CK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: LANDING LIGHT — UNDERSERVICED · airframe 42,420 hrs · 24,072 cycles

L/H taxi/take off circuit breaker on pnl #9 trips Corrective Action: Originally MEL assigned MEL 33-46-01 3-7-03 to be cleared by 3-17-03. Closing action: R&R'd L/H taxi light assy, ops check good I/A/W 33-46-12, MEL cleared. Closing date 3-10-03.

Part: STALL WARNING — ACTIVATED (COCKPIT) · airframe 41,528 hrs · 23,770 cycles

IN CLIMBOUT, CLEAN CONFIGURATION ABOVE 250 KTS VIOLENT SHUDDER WITH STALL WARNING AND STICK SHAKER. A/C WT 335 ALT FL 200, ENGINE PARAMETERS AND FLT CONTROL INDICATION NORMAL. SYS PARAMETERS NORMAL. AIRCRAFT RETURNED TO AIRPORT. PERFORM OP'S CK OF AOA SENSOR'S, NO FAULT FOUND. INSP AOA SENSORS, NO FAULT FOUND. RAN ENGINES AT PART PWR, NO VIBRATIONS NOTED. INSP ENGINE FAN BLADES, NO FAULT FOUND. CHECKED FLAP, SLAT AND FLT CONTROL MOVEMENT AND INSP FLAP, SLATS, AND FLT CONTROLS, NO DEFECTS NOTED ALL IAW 27-10-00, 27-20-00 AND 27-50-00. AIRCRAFT RETURNED TO SERVICE. TEST FLT PERFORMED AND OPERATED SATISFACTORY.

Part: STRINGER — CORRODED · corrosion level 2 · airframe 40,242 hrs · 23,383 cycles

DURING WALK AROUND FOUND CORROSION ON FUSELAGE AT BULK CARGO DOOR AREA. LOCATED AFT, L/H LOWER CORNER. STA. 365 STRINGER 47RCORRECTIVE ACTION: REPAIR CARRIED OUT I/A/W SRM 53-10-20 FIG. 701 SHEET 3 LAP JOINT REPAIR