N503US

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 83,764 hrs · 34,472 cycles

SEAT ROWS 23-32 EMERGENCY EXIT TRACK LIGHTS INOPERATIVE. REPLACED EMERGENCY LIGHT BATTERY PACK PER B757 M/M 33-50.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 83,003 hrs · 34,023 cycles

LT AT STA 373.2 AND STA 367.7 HAS DAMAGE TO OUTER SURFACE OF FUSELAGE SKIN AT STA 372.2 HAS 2 HOLES DRILLED THRU SKIN. FASTENER HOLE HAS DRILL START HAS 2 HOLES DRILLED THRU TRIMMED OUT SKIN AND BEAR STRAP. FABRICATED FILLERS. DOUBLER/TRIPLER INST REPAIR PARTS ON STAM TRAV T11/881990 SECT I PERM REPAIR OF ER/A 491306-14 AND SECT II REPEAT.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 83,003 hrs · 34,023 cycles

DURING HMV AT BFM, INSPECTION FOUND QTY 2 FASTENER HOLES WITH DRILL START DAMAGE ON OUTER SURFACE OF FUSELAGE SKIN AT STA 373.2 AND STA 367.1. THE SKIN AND BEAR STRAP REPAIRED. ER/A 491306-14 SECTION I. ACCOMPLISHED DURING LCK AT BFM, MAY11 SECTION II-PENDING FOR FINAL DTA EVALUATION RESULT WITHIN 24 MONTHS FROM 06MAY2011.

Part: LIGHT — BROKEN (L4 DOOR) · airframe 82,210 hrs · 33,531 cycles

DURING LAYOVER CHECK, FOUND EMERGENCY LIGHT ASSY AT DOOR L4, BROKEN. REATTACHED EMERGENCY LIGHT SIGN. OPS CK GOOD.

Part: SKIN — DENTED (BS 620) · airframe 81,249 hrs · 32,925 cycles

DURING LINE INSP, FOUND FUSELAGE SKIN DENTED AT BS 620 FWD, OF DOOR L2 AT S16L. REPAIRED IAW ERA 484616-14, REV A.

Part: STRINGER — DAMAGED (BS 620 S16L) · airframe 81,249 hrs · 32,925 cycles

DURING LINE INSP, FOUND FUSELAGE STRINGER 16L DAMAGED AFT OF BS 620. REPAIRED IAW SRM 53-00-03 FIG 201, ERA 484616-14.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 80,357 hrs · 32,593 cycles

EMERGENCY EGRESS LIGHTING INOP AT CTR AISLE EXIT SIGN BETWEEN DOOR 3R & 3L, AND OUTSIDE DOOR 3L. REPLACED POWER SUPPLY M735, OPS CKS OK.

Part: POWER SUPPLY — MALFUNCTIONED (EMERGENCY LIGHTS) · airframe 79,896 hrs · 32,434 cycles

AT PUSH TIME CREW REPORTED FLOOR PATH EMERGENCY LIGHTS AT ROW 33 TO 40 WILL NOT TURN OFF IN ARMED POSITION. REPLACED POWER SUPPLY M9004 IAW AMM.

Part: BATTERY PACK — DEFECTIVE (CABIN) · airframe 78,209 hrs · 31,838 cycles

DURING AN OVERNIGHT LINE CHECK THE EMERGENCY LIGHTS AT DOORS 1L AND 1R WOULD NOT ILLUMINATE. MAINTENANCE FOUND THE ASSOCIATED BATTERY PACKS TO BE DEFECTIVE AND REPLACED THEM. SYSTEM OPERATION CHECKED NORMAL AFTER THE BATTERY PACKS WERE REPLACED.

Part: SKIN — CORRODED (BS 889 S27L) · corrosion level 2 · airframe 77,700 hrs · 31,644 cycles

DURING "L" CHECK FOUND CORROSION ON FUSELAGE SKIN AT BS 889 S27L. REPAIRED PER EA 55-215350 SECT I SECTION II REQUIRES DTA ANALYSIS AND APPROVAL FROM BOEING NO LATER THAN MAY 9, 2010.

Part: SKIN — CRACKED (NR 2 PYLON) · airframe 77,491 hrs · 31,684 cycles

DURING "L" CHECK FOUND CRACK IN NR 2 PYLON NACELLE STRUT RT SKIN PANEL AT NAC STA 107.7-116.09. REPAIRED PER EA 55-215154 SECT I, SECTION II PERMANENT REPAIR TO BE ACCOMPLISHED NO LATER THAN MAY 10, 2009.

Part: SKIN PANEL — CRACKED (NR 2 PYLON) · airframe 77,491 hrs · 31,684 cycles

DURING "L" CHECK FOUND CRACK THE NR 2 PYLON NACELLE STRUT RT SKIN PANEL AT NAC STA 107.7-116.09. REPAIRED PER EA 55-215154 SECT I, SECTION II PERMANENT REPAIR TO BE ACCOMPLISHED NO LATER THAN MAY 08, 2011.

Part: POWER SUPPLY — FAULTY (CABIN) · airframe 76,708 hrs · 31,280 cycles

DURING AN OVERNIGHT LINE CHECK THE EMERGENCY ESCAPE PATH LIGHTING FAILED TO OPERATE FROM ROW 14 TO ROW 22. MX FOUND POWER SUPPLY M735 TO BE FAULTY AND REPLACED IT. SYSTEM OP WAS NORMAL AFTER THE POWER SUPPLY WAS REPLACED.

Part: SKIN — CRACKED (NR 2 NACELLE) · airframe 72,226 hrs · 29,628 cycles

DURING "M" CHECK, FOUND CRACK IN NR 2 PYLON SKIN PANEL AT NAC STATION 128. REPAIRED PER EA 55-194182.

Part: CREASE BEAM — CORRODED (CORRODED) · corrosion level 2 · airframe 72,226 hrs · 29,628 cycles

DURING "M" CHECK, FOUND CORROSION ON RT CREASE BEAM INNER CHORD FROM BS 760 TO 780 RBL 64. REPAIRED PER EA 55-209992.

Part: FLOORBEAM — CORRODED (BS 1717) · corrosion level 2 · airframe 72,226 hrs · 29,628 cycles

DURING "M" CHECK, FOUND CORROSION ON AFT DECK PLATE SUB FLOOR STRUCTURE AT BS 1717 LBL 60 TO RBL 60. REPAIRED PER EA 55-194183.

Part: POWER SUPPLY — MALFUNCTIONED (EMERGENCY LIGHTS) · airframe 71,958 hrs · 29,524 cycles

EMERGENCY FLOOR PROXIMITY LIGHTS IN AFT CABIN ON FLOOR ARE DIM. REMOVED AND REPLACED POWER SUPPLY (WITH BATTERY). LIGHT CHECKS NORMAL.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHT) · airframe 60,934 hrs · 25,060 cycles

AFT CABIN EMERGENCY FLOOR PROXIMITY LIGHTING INOPERATIVE. REPLACED POWER SUPPLY (M9004). OPERATIONAL CHECK GOOD.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 54,987 hrs · 22,725 cycles

DURING "H" CHECK FOUND CORROSION ON FLOORBEAM UPPER SURFACE AT BS 1280 LBL 24 TO RBL 24. REPAIRED PER EA 55-185615.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 54,987 hrs · 22,725 cycles

DURING "H" CHECK FOUND CRACK IN FLOORBEAM UPPER CAP AT BS 700 LBL 45. REPAIRED PER EA 55-185931.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 52,862 hrs · 21,918 cycles

WHILE POWERING DOWN AIRCRAFT FOR OTHER MAINTENANCE, FOUND FLOOR ROWS 23 TO 33 FLOOR EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REPLACED THE EMERGENCY LIGHT POWER SUPPLY. OPERATIONAL CHECK OK.

Part: ENGINE — FAILED (NR 1) · airframe 50,715 hrs · 21,042 cycles

DURING CLIMB, FLIGHT CREW HEARD A LOUD BANG FOLLOWED BY NR 1 ENGINE OVERTEMP. SHUT DOWN THE NR 1 ENGINE. FLIGHT CREW ELECTED TO RETURN TO DEPARTURE AIRPORT. LANDING WAS UNEVENTFUL. MAINTENANCE FOUND METAL IN THE TAILPIPE AND REMOVED AND REPLACED NBR 1 ENGINE.

Part: LINE — BROKEN (NLG STEERING)

UPON GEAR EXTENSION ON LANDING, THE LEFT HYDRAULIC SYSTEM LOST ALL PRESSURE AND SYSTEM QUANTITY DECREASED TO ZERO. ALL THREE GEAR WERE DOWN AND LOCKED. THE AIRCRAFT CONTINUED THE APPROACH AND LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS TOWED FROM THE RUNWAY TO THE GATE. MAINTENANCE FOUND THE RIGHT OUTBOARD NOSE WHEEL STEERING HYDRAULIC LINE BROKEN. REPLACED THE HYDRAULIC LINE, BOTH LEFT SYSTEM HYDRAULIC PUMPS, AND ASSOCIATED FILTERS. SYSTEM TESTS WERE SATISFACTORY.

Part: AIRSPEED IND — FAILED (LT COCKPIT)

LOST CAPTAIN'S AIRSPEED INDICATION ON TAKEOFF ROLL. TAKEOFF WAS ABORTED AND THE AIRCRAFT RETURNED TO THE GATE. MAINTENANCE REPLACED THE CAPTAIN'S AIRSPEED INDICATOR WITH A SERVICEABLE UNIT.

Part: CONTROL UNIT — MALFUNCTIONED (NR 1 LE FLAP)

WHILE EXTENDING FLAPS TO FLAP 1 POSITION, LEADING EDGE FLAP DISAGREE LIGHT ANNUNCIATED. AIRCRAFT DIVERTED TO LAX AND PERFORMED AN UNEVENTFUL LANDING. MAINTENANCE REPLACED THE FLAP SLAT ELECTRONIC UNIT.

Part: SKIN — CRACKED (NR 2 PYLON)

DURING L-CHECK, FOUND CRACK IN NR 2 PYLON INNER SKIN AT AFT UPPER EDGE OF ACCESS 443AL. REPAIRED PER EA 55-150272.

Part: WEB — CRACKED (NR 2 PYLON)

DURING L-CHECK, FOUND CRACK IN NR 2 PYLON SIDE WEB AT CUTOUT FOR CROSS BRACE APPROXIMATELY NACELLE STA 125. REPAIRED PER EA 55-150276.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING PREFLIGHT, FOUND EMERGENCY LIGHTS AT DOOR 3R AND OVERHEAD LIGHTS AFT RIGHT SIDE OF AIRCRAFT INOPERATIVE. REPLACED BATTERY PACK AT DOOR 3R, SYSTEM CHECKED OK.

Part: FUEL PRESS SW — FAILED (NR 2 ENGINE)

DURING TAKEOFF ROLL, NR 2 ENGINE FUEL FILTER MESSAGE APPEARED. TAKEOFF WAS ABORTED AND AIRCRAFT RETURNED TO GATE. MAINTENANCE PERSONNEL REPLACED FUEL FILTER PRESSURE DIFFERENTIAL SWITCH AND OPERATIONAL CHECK OK.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING MAINTENANCE, FOUND AFT RIGHT SECTION OF CABIN EMERGENCY LIGHTS ARE INOPERATIVE. REPLACED POWER SUPPLY M736 AND BATTERY, OPERATIONAL CHECK NORMAL.

Part: SKIN — DELAMINATION (RUDDER)

DURING T-CHECK, FOUND DELAMINATION IN THE RUDDER TRAILING EDGE SKIN, LEFT SIDE STATION 153. REPAIRED SKIN (P/N 173N2102-33) PER EA 55-103371.

Part: SEAT TRACK — CRACKED (FS 898)

DURING T-CHECK, FOUND A CRACK IN THE RBL 45 LONGITUDINAL FLOOR BEAM SEAT TRACK UPPER CHORD AT BS 898. REPAIRED CHORD (P/N 111N5207-5) PER EA 55-105062.

Part: CHORD — CRACKED (FS 1380-1440)

DURING T-CHECK, FOUND CORROSION ON THE AFT CARGO DOOR LOWER SILL INNER CHORD, BS 1380-1440. REPAIRED SILL (P/N 146N8522-51) PER EA 55-105061.

Part: SILL FITTING — CORRODED (CARGO DOOR)

DURING T-CHECK, FOUND CORROSION IN THE AFT CARGO FORWARD DOOR SILL FITTING. REPLACED FITTING.

Part: EEL WIRE — BROKEN (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS AT ROWS 23 THROUGH 32 INOPERATIVE. REPAIRED BROKEN WIRE.

Part: FUEL CONTROL — MALFUNCTIONED (LT ENGINE)

DURING TAXI AND AFTER BOTH ENGINES STABILIZED, THE LEFT ENGINE SHUTDOWN BY ITSELF. RECEIVED LOW OIL PRESSURE WARNING AND LEFT ENGINE PIRMARY CONT MESSAGE. THE FUEL CONTROL WAS THEN SHUTOFF AND THERE WAS A TAILPIPE FIRE. AIRCRAFT WAS RETURNED TO GATE WHERE THE ENGINE FUEL CONTROL AND EEC WERE REPLACED.