N501US

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 86,500 hrs · 36,519 cycles

FIRST CLASS AND FWD COACH EMERGENCY LIGHTING STRIPS ARE VERY DIM INOPERATIVE. REPLACED FWD AND MID BATTERY PACK M9001 AND M9002. REPAIRED WIRE AT 16D ALL OP CKS GOOD REF AMM 33-51 AND SWPM CH 20-00.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHT) · airframe 86,073 hrs · 36,207 cycles

EMERGENCY EXIT PATH LIGHTS INOPERATIVE. FOUND EMERGENCY LIGHT POWER SUPPLY BAD, REP SAME. OPS CHECKED NORMAL. OK FOR SERVICE.

Part: FUSE — FAILED (EMERGENCY LIGHTS) · airframe 86,031 hrs · 36,189 cycles

FOUND FWD CABIN EMERGENCY PATH LIGHTS INOPERATIVE. REPLACED FUSES AT PB M9001 IAW AMM 20-00. EMERGENCY LIGHT TEST OK.

Part: CONTROL PANEL — MALFUNCTIONED (EMERGENCY LIGHTS) · airframe 86,039 hrs · 36,192 cycles

EMERGENCY LIGHTS STAY ON, DIM WITH SWITCH IN OFF POSITION. REPLACED PANEL.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 84,981 hrs · 35,615 cycles

EMERGENCY LIGHT ON "DIM" IN OFF POSITION-EXT POWER APU AND GROUND SERVICE ALL LIGHTS ON DIM WITH SWITCH IN OFF POSITION-AIRCRAFT LEFT WITH EXTERNAL POWER FULLY ON, EMERGENCY LIGHT SWITCH IN ARM POSITION ONLY POSITION LIGHTS ARE EXTINGUISHED. REPLACED COCKPIT LIGHT SWITCH PANEL AND BATTERY CHARGER AND BATTERY PACK ABOVE L3 DOOR PER AMM 33-5. LIGHTS EXTINGUISH AND ILLUMINATE PROPERLY. FOUND FLOOR TRACK LIGHTS IN AFT CABIN INOPERATIVE. CONFIRMED POWER SUPPLY M9004 IN AFT LEFT CABIN AT FAULT. REPLACED AFT EMERGENCY POWER SUPPLY OPS CHECKED GOOD PER AMM 33-51-07

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 4,310 hrs · 2,349 cycles

DURING LINE CHECK MAINTENANCE PERFORMED EMERGENCY LIGHT TEST AFT RIGHT BIN LIGHT WAS DIM DURING TEST. MAINTENANCE REPLACED BATTERY PACK PER AMM 33-51. LIGHTS NOW TEST GOOD.

Part: BATTERY — DISCHARGED (CABIN) · airframe 83,159 hrs · 34,533 cycles

DURING LINE CHECK FOUND R2 AND R3 EXTERIOR EMERGENCY LIGHTS INOPERATIVE. REPLACED R2 M732 AND ASSOCIATED BATTERY AND L-47 AND L-50 LIGHT ASSEMBLIES. OPS CHECK NORMAL.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 82,947 hrs · 34,426 cycles

EMERGENCY EGRESS EXIT LIGHTS INOPERATIVE AT DOORS 1L & 4L. MAINTENANCE RE-LAMPED AS NECESSARY AND THE OPERATIONAL CHECKS ARE GOOD.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 82,613 hrs · 34,270 cycles

ER/A 493213-14 SECTION I ISSUED FOR SKIN AND BEAR STRAP REPAIR AT THE NR 4 LT PASSENGER DOOR CUTOUT, LOWER FWD CORNER. FOLLOW ON ACTION IS REQUIRED. STA MSP 31MAY11 ACCOMPLISH SECTION II INSPECTION WITHIN 24 MONTHS OF SECTION I. SECTION II IS PENDING A DAMAGE TOLERANCE ANALYSIS. IF THE LOGPAGE AND ER/A HAVE NOT BEEN REVISED WITHIN 23 MONTHS CONTACT ENGINEERING.

Part: OVEN — MALFUNCTIONED (GALLEY) · airframe 82,491 hrs · 34,198 cycles

FORWARD GALLEY OVENS HAD FUMES AND SOME SMOKE 5 MINUTES AFTER TAKEOFF. OVENS WERE TURNED OFF AND LEFT, CTR, AND RIGHT OVEN CIRCUIT BREAKERS WERE PULLED. NO FURTHER FUMES OR SMOKE PRESENT FOR REMAINDER OF FLIGHT. RESET CIRCUIT BREAKERS AND TURNED OVENS ON HIGH FOR 15 MINUTES. NO SMOKE OR FUMES NOTICED.

Part: SKATE ANGLE — CRACKED (RT PYLON) · airframe 82,376 hrs · 34,138 cycles

RT WING OUTBD OF RT PYLON T/E SKATE ANGLE CRACKED. PERFORMED HFEC INSP IAW NTM 51-00-19 PT 6. STOP DRILLED CRACK IAW SRM 54-52-01-801. REMOVED PNL 455BR IAW SRM 51-40-02. REMOVED SKATE ANGLE IAW SRM 51-40-02. RECEIVED FABBED SKATE ANGLE WITH TRAVELER T11/878413 IAW DWG 112N4601-13 LOCATED AND DRILLED IAW SRM 51-40-05. TREATED AND PRIMED IAW SRM 51-20-01. APPLIED TOPCOAT IAW SRM 51-20-01. INSTALLED SKATE ANGLE IAW SRM 54-52-01.

Part: WEDGE — DAMAGED (LE SLAT) · airframe 82,376 hrs · 34,138 cycles

RT WING SLAT NR 8 LOWER T/E WEDGE PUNCTURED AS MARKED. REMOVED DAMAGE AREA AND FABRICATED DOUBLER REPAIR IAW SRM 51-70-10 PER WORKCARD 5742-01022-02H. DOUBLER FABBED FROM 2024T3-.020. AREA PAINTED IAW MM 51-21-10.

Part: SEAT TRACK — CRACKED (COCKPIT) · airframe 82,376 hrs · 34,138 cycles

COCKPIT AREA, CAPTAINS SEAT, OTBD AFT SEAT TRACK CRACKED AT AFT POSITION, AS MARKED. CONFIRMED CRACK L=0.5" NOT PERMITTED PER SRM 53-00-52, FIG 1, PAGE 101. R & R SEAT TRACK IAW SRM 51-40-02 AND AMM 25-11-01-201-925A-A.

Part: FUSE — BLOWN (POWER SUPPLY) · airframe 79,061 hrs · 32,525 cycles

THE 1R EMERGENCY SLIDE LIGHT INOPERATIVE. RELAMPED 1R EMERGENCY EVAC SLIDE EXTERIOR LIGHT ASSY WITH NO HELP. DEFERRED LIGHT PER MEL 33-51-2 (DAY OPS ONLY). MSP MAINTENANCE REPLACED THE FUSE IN POWER SUPPLY M730 PER FIM 33-51-00. OPS CHECK GOOD.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 78,169 hrs · 32,227 cycles

DURING AN OVERNIGHT LINE CHECK THE EMERGENCY LIGHTS FROM ROW 33 AFT INCLUDING THE DOOR FOUR RIGHT EXIT SIGN TO BE INOPERATIVE. MAINTENANCE FOUND POWER SUPPLY M736 TO BE DEFECTIVE AND REPLACED IT. THE SYSTEM OPERATED NORMALLY AFTER THE POWER SUPPLY WAS REPLACED.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 78,169 hrs · 32,227 cycles

DURING AN OVERNIGHT LINE CHECK THE EMERGENCY EXIT SIGNS AT DOORS ONE LEFT AND FOUR LEFT WOULD NOT ILLUMINATE. MAINTENANCE FOUND POWER SUPPLY AND BATTERY PACK M731 TO BE DEFECTIVE AND REPLACED IT. SYSTEM OPERATION WAS NORMAL AFTER THE POWER SUPPLY AND BATTERY PACK WERE REPLACED.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 75,922 hrs · 31,369 cycles

DURING AN OVERNIGHT LINE CHECK, THE EMERGENCY EXIT LIGHTS AND EXTERIOR SLIDE ILLUMINATION AT DOOR 3L WERE FOUND TO BE INOPERATIVE. MX FOUND THE ASSOCIATED POWER SUPPLY TO BE DEFECTIVE AND IT WAS REPLACED. THE SYSTEM OPERATED NORMALLY AFTER THE DEFECTIVE POWER SUPPLY WAS REPLACED.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 75,922 hrs · 31,369 cycles

DURING AN OVERNIGHT LINE CHECK THE EMERGENCY ESCAPE PATH LIGHTING IN THE FORWARD CABIN WAS INOPERATIVE. MX FOUND THE ASSOCIATED POWER SUPPLY TO BE DEFECTIVE. THE POWER SUPPLY WAS REPLACED AND THE SYSTEM OPERATED NORMALLY AFTER THE POWER SUPPLY WAS REPLACED.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 74,121 hrs · 30,698 cycles

DURING OVERNIGHT MAINTENANCE, OPERATIONAL CHECK OF THE FLOOR TRACK EMERGENCY EXIT LIGHTS REVEALED THAT THE FIRST CLASS SECTION INCLUDING THE FLOOR LEVEL EXIT LIGHTS AT DOORS 1 LEFT AND 1 RIGHT WERE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE BATTERY PACK AND OPERATION RETURNED TO NORMAL.

Part: UNKNOWN — MALFUNCTIONED (CABIN PRESSURE) · airframe 71,586 hrs · 29,751 cycles

DURING CLIMB, LOST PRESSURIZATION CONTROL AT 35,000 FT, CABIN PRESSURE AT 10,000 FT AND CLIMBING, AND AURAL WARNING SOUNDED. NEITHER AUTO 1 OR AUTO 2 WOULD WORK, TO MANUAL-CLOSED OUTFLOW VALVE, CABIN STILL CLIMBING. CONDUCTED RAPID DESCENT TO 10,000 FT, AND AUTO CONTROL BEGAN WORKING. ACCOMPLISHED COM RED BORDERED CHECK LIST AND RETURNED TO DTW. LANDING WAS UNEVENTFUL. MAINTENANCE IS STILL WORKING ON PRESSURIZATION PROBLEM.

Part: SWITCH — FAILED (MLG SELECTOR) · airframe 70,972 hrs · 29,524 cycles

ON CLIMB-OUT PASSING FL 250 AT APPROXIMATELY 290 KNOTS, UNCOMMANDED GEAR EXTENSION OCCURRED WITH THE GEAR HANDLE IN THE OFF POSITION. GEAR GREEN (NOSE, LEFT, RIGHT) AND DOORS AND GEAR AMBER LIGHTS ILLUMINATED UNTIL GEAR HANDLE WAS PUT IN DOWN POSITION THEN GEAR LIGHT EXTINGUISHED. CREW RETURNED TO SFO AND ATC DECLARED AN EMERGENCY. AN OVERWEIGHT LANDING WAS MADE AND THE FLIGHT LANDED WITHOUT INCIDENT. AIRCRAFT FERRIED TO SEA FOR MAINTENANCE, FOUND SWITCH S10191 BAD, REPLACED SWITCH. REPLACED RELAYS K10369 AND K10370. FOUND ELECTRICAL SHORT ON WIRE W2516-1025-20 AND SHORT IN CONNECTOR D403700P. REPLACED CONNECTOR. JACKED AIRCRAFT AND SWUNG GEAR, OPS CHECKED NORMAL PER AMM 32-32-00 PAGE 501. AIRCRAFT OK

Part: SWITCH — FAILED (MLG SELECTOR) · airframe 70,972 hrs · 29,524 cycles

ON CLIMB OUT PASSING FL 250 AT APPROXIMATELY 290 KNOTS, UNCOMMANDED GEAR EXTENSION OCCURRED WITH THE GEAR HANDLE IN THE OFF POSITION. GEAR GREEN (NOSE, LEFT, RIGHT) AND DOORS AND GEAR AMBER LIGHTS ILLUMINATED UNTIL GEAR HANDLE WAS PUT IN DOWN POSITION THEN GEAR LIGHT EXTINGUISHED. CREW RETURNED TO SFO AND ATC DECLARED AN EMERGENCY. AN OVERWEIGHT LANDING WAS MADE AND THE FLIGHT LANDED WITHOUT INCIDENT. AIRCRAFT FERRIED TO SEA FOR MAINTENANCE, FOUND SWITCH S10191 BAD, REPLACED SWITCH. REPLACED RELAYS K10369 AND K10370. FOUND ELECTRICAL SHORT ON WIRE W2516-1025-20 AND SHORT IN CONNECTOR D403700P. REPLACED CONNECTOR. JACKED AIRCRAFT AND SWUNG GEAR, OPS CHECKED NORMAL PER AMM 32-32-00 PAGE 501. AIRCRAFT OK F

Part: SKIN PANEL — CRACKED (NR 2 PYLON) · airframe 70,948 hrs · 29,512 cycles

DURING "M" CHECK, FOUND CRACK IN 2 PYLON RT SKIN PANEL LIGHTING HOLE AT NAC STA 133. REPAIRED PER EA 55-208817.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 54,286 hrs · 22,828 cycles

DURING H-CHECK FOUND CRACK IN FLOORBEAM UPPER CAP. REPAIRED PER EA 55-183746.

Part: HYDRAULIC LINE — RUPTURED (NLG STEERING) · airframe 53,597 hrs · 22,574 cycles

DURING APPROACH AFTER GEAR EXTENSION, THE LEFT HYDRAULIC SYSTEM LOST ALL FLUID. AN EMERGENCY WAS DECLARED WITH DFR EQUIPMENT CALLED OUT. LANDING WAS UNEVENTFUL. MAINTENANCE REPLACED THE RUPTURED NOSE GEAR STEERING HYDRAULIC LINE AND SERVICED THE LEFT HYDRAULIC SYSTEM. OPERATIONAL CHECK GOOD.

Part: INDICATOR — MALFUNCTIONED (LT MLG)

UPON GEAR EXTENSION ON APPROACH INTO DTW, THE LEFT MAIN GEAR DOWN AND LOCKED INDICATOR FAILED TO ILLUMINATE. THE APPROACH WAS ABORTED AND THE GEAR WAS RECYCLED. SUBSEQUENT APPROACH AND LANDING OCCURRED WITHOUT INCIDENT. MAINTENANCE REPLACED THE LEFT MAIN GEAR INDICATOR WITH A NEW UNIT. SYSTEM TESTS WERE SATISFACTORY.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING PREFLIGHT, FOUND DOOR 1R AND SEVERAL EMERGENCY LIGHTS IN FIRST CLASS ONLY STAY ON FOR ABOUT 5 SECONDS. REPLACED BATTERY PACK IN POWER SUPPLY M730, OPERATIONAL CHECK OK.

Part: ACTUATOR — MALFUNCTIONED (NR 8 SPOILER)

AIRCRAFT REQUIRED EXCESSIVE AILERON AND RUDDER TRIM TO FLY STRAIGHT AND LEVEL. CREW OBSERVED THE NR 8 SPOILER FLOAT. AIRCRAFT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE NR 8 SPOILER ACTUATOR WITH A SERVICEABLE UNIT, OPERATIONAL CHECK SATISFACTORY.

Part: SWITCH — OUT OF ADJUST (DOOR 4R)

DURING TAKEOFF ROLL AT 110 KIAS, THE RIGHT AFT ENTRY DOOR WARNING LIGHT ILLUMINATED. ABORTED TAKEOFF AND RETURNED TO THE GATE. ADJUSTED DOOR 4R DOOR SWITCH AND CLEANED DEBRIS FROM SWITCH. PSEU BITE TEST DOES NOT SHOW ANY FAULTS. FUNCTIONAL TEST OK.

Part: DOOR SEAL — CONTAMINATED (PAX DOOR)

DURING TAKEOFF, THE RIGHT AFT ENTRY DOOR OPEN LIGHT FLICKERED ON AND OFF. TAKEOFF WAS ABORTED AT 110 KNOTS. MAINTENANCE FOUND PLASTIC TABS JAMMED UNDER DOOR. REMOVED PLASTIC TABS, INSPECTED DOOR, LOCKS, LATCHES, AND CHECKED SWITCH ADJUSTMENT. DOOR OPERATION CHECKED GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING PREFLIGHT, FOUND DOOR 4L EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY POWER SUPPLY, OPERATIONAL CHECK OK.

Part: SWITCH — OUT OF ADJUST (DOOR 4L)

ABORTED TAKEOFF AT 120 KNOTS DUE TO A LEFT AFT ENTRY DOOR WARNING INDICATION. FOUND THE DOOR CLOSED AND LOCKED. ADJUSTED THE SWITCH PER MM 52-71-00, OPERATIONAL CHECK OK.

Part: ENGINE — FAILED (NR 2)

DURING TAKEOFF, THE NR 2 ENGINE EGT INDICATION REACHED 880 DEGREES FOR TWO SECONDS. TAKEOFF WAS ABORTED AT 90 KTS. AIRCRAFT RETURNED TO THE GATE. GROUND MAINTENANCE REPLACED THE NR 2 ENGINE. GROUND RUN AND LEAK CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: CONNECTOR — LOOSE (RT IDG)

DURING TAKEOFF ROLL, THE RIGHT IDG FELL OFF LINE. TAKEOFF WAS ABORTED WITHOUT INCIDENT. MSP MAINTENANCE FOUND CANNON PLUG BACK SHELL LOOSE. TIGHTENED BACK SHELL. ALSO, FOUND IDG LOW ON OIL. SERVICED PER MAINTENANCE MANUAL. OPERATIONAL CHECK OK.

Part: PITOT TUBE — FAILED (RIGHT)

DURING FLIGHT, THE RIGHT AUXILIARY PITOT CAUTION MESSAGE APPEARED. AIRCRAFT DIVERTED TO DEN AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE RIGHT AUXILIARY PITOT TUBE. SYSTEM OPERATIONAL CHECK OK.

Part: POSITION TRANS — FAILED (HORIZ STAB)

DURING APPLICATION OF TAKEOFF POWER, STABILIZER WARNING MESSAGE ILLUMINATED AND TAKEOFF WAS ABORTED. VERIFIED STABILIZER TRIM SETTING WAS WITHIN GREEN BAND AND MESSAGE REMAINED. MAINTENANCE REPLACED THE CENTER STABILIZER TRIM POSITION TRANSMITTER AND OPERATIONAL CHECK WAS NORMAL.

Part: FLOORBEAM — CORRODED (FS 365)

DURING T-CHECK, FOUND CORROSION ON THE FS 365 FLOORBEAM UPPER CHORD FROM RBL 1 TO 62. REPAIRED BEAM (P/N 141N5112), PER EA 55-99005.

Part: FITTING — CORRODED (FS 336)

DURING T-CHECK, FOUND CORROSION ON THE LAVATORY MOUNT FITTING BS 336 AT LBL 20. REPLACED FITTING.

Part: DOOR SILL — CORRODED (FS 1380 1440)

DURING T-CHECK, FOUND CORROSION ON THE AFT CARGO DOOR LOWER SILL INNER CHORD FS 1380 TO 1440. REPAIRED CHORD (P/N 146N8522-51), PER EA 55-99002.