N519US

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 81,880 hrs · 35,061 cycles

AFT SECTION EMERGENCY LIGHTS INOPERATIVE IN AFT CABIN. TROUBLESHOT AND REPLACED GOOD BATTERY PACK. OPS CHECKED GOOD IAW AMM 33-51-07.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 81,774 hrs · 34,989 cycles

FOUND L4 DOOR EMERGENCY LIGHT INOPERATIVE DURING SERVICE CHECK. REMOVED AND REPLACED EMERGENCY LIGHT ASSY IAW AMM 33-51. OPS CHECKED GOOD.

Part: PANEL — DELAMINATED (LT WING) · airframe 81,279 hrs · 34,678 cycles

LT WING FIXED PANEL OTBD OF INBD T/E FLAP OTBD OF OTBD CARRIAGE JUST FWD OF FLAP LWR SURFACE OF WING DELAMINATED. REPLACED T/E PANEL ASSY 113N1972-9 IAW DWG 113N1620 ON N/R CARD 003.

Part: SIGN — OUT OF POSITION (CABIN) · airframe 80,568 hrs · 34,270 cycles

FOUND R3 DOOR EXIT SIGNS IMPROPER CONFIGURATION. LOCATION SWAPPED SIGNS BACK TO PROPER LOCATIONS REF IPC 33-51. CKS GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 80,520 hrs · 34,236 cycles

L4 DOOR EXTERIOR EMERGENCY LIGHT INOPERATIVE. REPLACED LAMP, REPLACED POWER SUPPLY AND BATTERY PACK. OPS NORMAL. OK FOR SERVICE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 80,520 hrs · 34,236 cycles

AFT R4 DOOR EXTERIOR EMERGENCY LIGHT INOPERATIVE. REPLACED LAMP, REPLACED BATTERY PACK. OPS NORMAL.

Part: SKIN — CRACKED (LT WING) · airframe 79,393 hrs · 33,466 cycles

SKIN CRACKED AT LT WING UPPER FIXED L/E UNDER NR 5 SLAT, 4 FT INBD OF PYLON AND 8 FT INBD OF PYLON. REPAIRED IAW ERA 401339-14MA, REV C PERMANENT REPAIR

Part: SKIN — DAMAGED (LT WING) · airframe 79,393 hrs · 33,466 cycles

COMPOSITE SKIN CRACKED LT WING FIXED L/E TWO SPOTS UNDER NR 3 SLAT, 3.5 AND 5 FT FROM INBD END, MKD REF NR65, REMOVED FASTENERS AT BOTH LOCATIONS MENTIONED ABOVE TO ALLOW FOR INSTALLATION OF COMPOSITE REPAIRS. REMOVED FASTENERS IN REPAIR AREA. REMOVED EXISTING REPAIRS TO INCORPORATE DAMAGE INTO EXISTING REPAIR AREAS. REMOVED DAMAGES AND STARTED MOISTURE REMOVAL IAW ERA 401605-14MA, REV J, DATED 8/29/12(REF SRM 51-70-17) INSTALLED PERMANENT REPAIRS IAW ERA 401605-14MA, REV J. RESEALED REPAIRS IAW ERA 401605-14MA REV J, DATED 8/29/12 (REF SRM 51/70/17, NR 3H) RE-INSTALLED FASTENERS REMOVED FOR REPAIR RESTORED FINISH IAW MM 51-24-13.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 78,574 hrs · 32,931 cycles

DURING MAINTENANCE CHECK, MAINTENANCE FOUND L1 DOOR UPPER EXIT SIGN INOPERATIVE. MAINTENANCE REPLACED BAD BATTERY PACK. OPERATION OF SIGN NOW CHECKS GOOD.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 77,954 hrs · 32,611 cycles

EMERGENCY EXIT LIGHTS WILL NOT EXTINGUISH. REMOVED AND REPLACED POWER SUPPLY AND BATTERY AT DOOR 2L. OPS CHECKED GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 4,090 hrs · 2,133 cycles

DURING LINE CHECK MAINTENANCE FOUND EMERGENCY PATH LIGHT AT SEAT 17 INOP. MAINTENANCE REPLACED FLOOR LIGHT ASSEMBLY PER SWPM 20-30-12. OPERATION OF LIGHT NOW CHECKS GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 75,981 hrs · 31,475 cycles

DURING A LINE CHECK, MAINTENANCE FOUND THE EMERGENCY PATH LIGHTS AT ROWS 16-27 INOPERATIVE. MAINTENANCE REPLACED THE POWER SUPPLY. OPERATIONAL CHECK WAS GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 75,837 hrs · 31,397 cycles

MANY EMERGENCY EGRESS LIGHTS WERE FOUND INOPERATIVE THROUGHOUT CABIN. MAINTENANCE RE-LAMPED THE FAULTY ONES AS NECESSARY. OPERATIONAL CHECK WAS GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 75,604 hrs · 31,271 cycles

FIRST CLASS ROW 5 L33 EMERGENCY LIGHT ON LEFT OVERHEAD BULLNOSE INOPERATIVE. REPLACED EMERGENCY LIGHTS POWER SUPPLY PER B757 AMM 33-51-07. OPS CHECK OK.

Part: SILL — CORRODED (BS 365-377) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK, FOUND L1 DOOR SILL WEB TOP SURFACE SKIN CORRODED INCLUDING ADJACENT FLOORBEAM AT STA 365 & 377. CORROSION WAS ON FLOOR SUPPORTS NOT ON WEB. REMOVED CORROSION AREA IAW SRM 51-10-02 OUT OF LIMITS. RECEIVED NEW MATERIAL SUPPORT LOCATED AND DRILLED AND INSTALLED FLOOR SUPPORT IAW SRM 51-40-02.

Part: SKIN — DAMAGED (LT WING TE FLAP) · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK FOUND LT WING INBD FLAP UPPER INBD SECTION PUNCTURED. REMOVED DAMAGED SKIN, POTTED HOLE, FABRICATED REPAIR DOUBLER, BONDED DOUBLER, SEALED AND PRIMED. WORK PERFORMED IAW SRM 51-70-10.

Part: CHANNEL — CORRODED (BS 1500 S28-29L) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK, FOUND AFT CARGO BS 1500, S28L TO S29L 2 EA CHANNELS ATTACHED TO FLOOR SUPPORT HAS CORROSION. REMOVED CHANNEL SUPPORT IAW SRM 51-42-02. LOCATED AND DRILLED CHANNEL SUPPORT IAW SRM 51-40-05. TREATED AND PRIMED IAW SRM 51-20-01. INSTALLED CHANNEL SUPPORT IAW SRM 51-40-02.

Part: SEAT TRACK — CORRODED (BS 1320) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK, FOUND AFT CABIN, STA 1320, RBL 24.75 SEAT TRACK CORRODED. BLENDED SEAT TRACK AT STA 1320, RBL 24.75 IAW SRM 51-10-02. FOUND TO BE OUT OF LIMITS IAW SRM 53-00-52, FIG 101. REMOVED SEAT TRACK SEGMENT FROM STA 1320-1370 IAW SRM 51-40-02. FABRICATED NEW SEAT TRACK, REPAIR ANGLES (2EA) IAW SRM 53-00-52, FIG 201, OPTION 1. TREATED & PRIMED IAW SRM 51-20-01. TOP COATED IAW AMM 51-24-03 AND INSTALLED REPAIR PARTS IAW SRM 53-00-52, FIG 201 & SRM 51-40-02.

Part: STRINGER — CORRODED (BS 1440-1480 S30) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK, FOUND AFT CARGO COMPARTMENT BETWEEN STA 1440 TO 1480 SEVERAL AREAS AROUND RIVETS STR 30 CORRODED. REMOVED SPLICE AND FASTENERS IAW SRM 51-40-02 TO BLENDED AREA ON STR 30, STA 1440 TO 1480 MATERIAL LOSS .003 REMAINING THICKNESS .097" WITH IN LIMITS IAW SRM 53-00-03 FIG 101, DETAIL II. BLENDED SPLICE ORIGINAL THICKNESS .105 MATERIAL LOSS .045" REMAINING THICKNESS .060" OUT OF LIMITS IAW SRM 53-00-03, FIG 101, DETAIL II, LOCATED AND DRILLED NEW SPLICE IAW SRM 51-40-05 WHICH WAS FABRICATED IAW DWG 146N3820 FROM 7075-0 .100B BATCH 0001679661 HEAT TREATED TO T6 ON TRAVELER T10/863023, TREATED AND PRIMED IAW SRM 51-20-02, INSTALLED SPLICE IAW SRM 51-40-02, APPLIED TOP COAT IAW AMM 51-21-10.

Part: SEAT TRACK — CORRODED (BS 1409-1411) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK, FOUND AFT CABIN, STA 1409-1411 RBL 45.5 SEAT TRACK CORRODED. BLENDED SEAT TRACK AT STA 1409-1411, RBL 45.5 IAW SRM 51-10-02. FOUND TO BE OUT OF LIMITS IAW SRM 53-00-52, FIG 101. REMOVED SEAT TRACK SECTION FROM 1320-1450 IAW SRM 51-40-02. FABRICATED NEW SEAT TRACK SECTION IAW SRM 53-60-52, FIG 1, LOCATED AND DRILLED IAW SRM 51-40-05. TREATED AND PRIMED IAW SRM 51-20-01, TOP COATED IAW AMM 51-24-03 AND INSTALLED NEW SEAT TRACK SECTION TO BS 1320-1450, RBL 45.5 IAW SRM 51-40-02.

Part: FLOORBEAM — CORRODED (BS 377) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK FOUND FWD CABIN FLOORBEAM PREVIOUS REPAIR FROM LBL 64 TO RBL 38 CORRODED AT 7 LOCATIONS AS MARKED AT BS 377.7. REMOVED CORROSION AREA BEAM FOUND TO BE OUT OF LIMITS IAW SRM 53-00-51, ORIG MATERIAL .125 MAX ALLOWABLE 10 PERCENT. REMOVED (2 EA) UPPER CHORDS, (2EA) STRAPS AND (1) ANGLE AT BS 377.7 LBL 64.0 AND 45.0 IAW SRM 51-40-02. FABRICATED UPPER CHORD REPAIR IAW SRM 53-00-51, FIG 201, REPAIR 3. TREATED AND PRIMED UPPER CHORDS IAW SRM 51-20-01. PAINTED AREA IAW AMM 51-20-00. INSTALLED FLOORBEAM REPAIR AT STA 377 FROM LBL 64-45.5 201 REPAIR 3.

Part: FLOORBEAM — CORRODED (BS 365) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK FOUND FWD CABIN FLOORBEAM, STN 365 PREVIOUS REPAIR FROM LBL 15 TO RBL 64 CORRODED AT SEVERAL LOCATIONS AS MARKED. BLENDED AREA ON FLOORBEAM FOUND TO BE OUT OF LIMITS IAW SRM 53-00-51, FIG 101. FABRICATED NEW UPPER CHORD TREATED AND PRIMED NEW UPPER CHORD IAW SRM 51-20-01. APPLIED TOPCOAT TO UPPER CHORD IAW SRM 51-21-00. INSTALLED FRAME SPLICE IAW SRM 51-40-02. INSTALLED SUPPORT ANGLE AT RBL 60, STA 365 IAW SRM 51-40-02. INSTALLED SUPPORT ANGLE RBL 24.75, STA 365 IAW SRM 51-40-02. INSTALLED (2EA) SUPPORT BRACKETS AT RBL 45.5 STA 365 IAW SRM 51-40-02. INSTALLED SUPPORT CHANNEL STA 345-365, RBL 24. INSTALLED UPPER FLOORBEAM CAP IAW SRM 53-00-51.

Part: FLOORBEAM — CORRODED (BS 1640) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK, FOUND AFT CABIN, STA 1640 FLOORBEAM CORRODED AS MARKED BETWEEN LBL 51-5 AND RBL 51.5. BLENDED SEVERAL AREAS IAW SRM 51-10-02. FOUND 2 PLACES OF CORROSION OUT OF LIMITS BETWEEN RT BL 51.5 TO BL 0 IAW SRM 53-00-51, FIG 101. REMOVED UPPER CHORD IAW SRM 51-40-02, FABRICATED UPPER CHORD IAW SRM 53-00-51, REPAIR 3. LOCATED AND DRILLED UPPER CHORD IAW SRM 51-40-05, TREATED AND PRIMED UPPER CHORD IAW SRM 51-20-01 AND TOP COATED UPPER CHORD IAW SRM 51-21-02, INSTALLED UPPER CHORD IAW SRM 51-40-02.

Part: FLOOR SUPPORT — CORRODED (BS 430-450) · corrosion level 2 · airframe 74,471 hrs · 30,609 cycles

DURING M-CHECK FOUND FWD CABIN FLOOR SUPPORT AT LBL 67 PREVIOUS REPAIR BETWEEN STN 430 TO STN 450 CORRODED AT 3 LOCATIONS. FOUND TO BE OUT OF LIMITS IAW SRM 53-30-13 FIG 101, DET 8, REMOVED FLOOR SUPPORT IAW SRM 51-40-02, FABRICATED NEW PART LOCATED & DRILLED IAW SRM 51-40-05, TREATED & PRIMED IAW SRM 51-20-01, PAINTED IAW AMM 51-21-00, INSTALLED NEW FLOOR SUPPORT IAW SRM 51-40-02.

Part: ACM — ODOR (LEFT) · airframe 73,904 hrs · 30,374 cycles

ONE HOUR INTO THE FLIGHT, CREW NOTED BURNING ODOR IN THE COCKPIT. ACFT RETURNED. MX CHECKED MULTIPLE SYSTEMS AND REPLACED THE LT ACM.

Part: POWER SUPPLY — DISCHARGED (CABIN) · airframe 72,219 hrs · 29,818 cycles

DOOR R2 SLIDE ILLUMINATION LIGHT INOPERATIVE. REPLACED THE POWER SUPPLY AT DOOR R2. OPERATIONAL CHECK GOOD.

Part: FAN — SMOKE (CABIN) · airframe 70,961 hrs · 29,383 cycles

IN CRUISE, THE CREW NOTICED ELECTRICAL SMOKE IN THE PASSENGER CABIN. THE FLIGHT CREW PERFORMED THE SMOKE IN CABIN COM PROCEDURE AND DIVERTED TO ALO WHERE THEY MADE AN UNEVENTFUL LANDING. MAINTENANCE FOUND THE SOURCE OF THE SMOKE TO BE THE RIGHT RECIRCULATION FAN, THE RECIRCULATION FAN WAS REPLACED AND THE SYSTEM OPERATED NORMALLY ALLOWING THE AIRCRAFT TO BE RETURNED TO SERVICE.

Part: OVEN — SMOKE (GALLEY) · airframe 70,769 hrs · 29,293 cycles

THE NUMBER ONE OVEN IN THE AFT GALLEY WAS EMITTING SMOKE WHEN THE CABIN CREW WAS HEATING UP FOOD FOR THEIR CREW MEALS. THE CABIN CREW IDENTIFIED THAT THE SMOKE WAS COMING FROM THE FAN/HEATING ELEMENT AREA. THE FLIGHT CONTINUED ON TO DTW AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE AFFECTED OVEN WHICH, OPERATED NORMALLY AFTER IT WAS REPLACED.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 69,411 hrs · 28,775 cycles

DURING AN OVERNIGHT LINE CHECK THE EMERGENCY ESCAPE PATH LIGHTING FROM ROWS 33 TO 41 WERE INOPERATIVE. MX FOUND THE ASSOCIATED BATTERY PACK TO BE DEFECTIVE AND REPLACED IT. SYSTEM OPS WERE NORMAL AFTER THE BATTERY PACK WAS REPLACED.

Part: BATTERY PACK — FAULTY (CABIN) · airframe 69,214 hrs · 28,701 cycles

DURING AN OVERNIGHT LINE CHECK THE EMERGENCY EXIT SIGNS IN THE CEILING AT DOORS 2 AND 3 WOULD NOT ILLUMINATE. THE BATTERY PACKS WERE FOUND TO BE FAULTY AND THEY WERE REPLACED. OPS WERE NORMAL AFTER THE BATTERY PACKS WERE REPLACED.

Part: SKIN — CRACKED (NR 2 NACELLE) · airframe 65,111 hrs · 27,189 cycles

DURING SCHEDULED NR 2 ENGINE CHANGE FOUND CRACK IN PYLON SIDE SKIN AT NAC STA 128. REPAIRED PER EA 55-210070 SECTION I, SECTION II TO BE ACCOMPLISHED WITHIN 24 MONTHS OF SECTION I.

Part: UNKNOWN — SMOKE (COCKPIT) · airframe 62,841 hrs · 26,293 cycles

DURING TAKEOFF AND CLIMB, HEAVY SMOKE ENTERED THE COCKPIT AND CABIN. FLIGHT CREW TURNED OFF BOTH PACKS AND SMOKE BEGAN TO DISSIPATE. FLIGHT CREW RETURNED TO DEPARTURE AIRPORT MAKING AN UNEVENTFUL LANDING. MAINTENANCE REPLACED ENGINE NR 2 AND PERFORMED PACK BURNOUT PROCEDURES.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 61,532 hrs · 25,775 cycles

DURING LINE CHECK, FOUND AFT CABIN EMERGENCY FLOOR LIGHTS, DO NOT ILLUMINATE. REPLACED EMERGENCY LIGHT BATTERY PACK ASSEMBLY. OPERATIONALLY CHECKED AND RETURNED TO SERVICE.

Part: FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 57,687 hrs · 24,230 cycles

DURING "H" CHECK, FOUND CORROSION ON FRAME AT BS 1400 BETWEEN S27L AND S28L. REPAIRED PER EA 55-201126.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 49,650 hrs · 20,998 cycles

DURING L CHECK, FOUND CRACK IN FLOORBEAM. REPAIRED PER EA55-184811.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 49,650 hrs · 20,998 cycles

IN L CHECK, FOUND CRACKED FLOORBEAM. REPAIRED PER EA55-184810.

Part: SPOILER — MALFUNCTIONED (WING) · airframe 49,283 hrs · 20,870 cycles

DURING FLIGHT LAS TO LAX TO DTW, CREW REPORTED TWO FLIGHT CONTROL ABNORMALITIES. ON APPROACH TO LAX, CREW REPORTED WITH FLAPS 15, CONTROL WHEEL TURNED TWO DEGREES LEFT WITH DEPLOYMENT OF SPOILERS. MAINTENANCE PERFORMED FUNCTIONAL AND BITE CHECK OF SPOILER SYSTEM WITH NO FAULTS FOUND. FROM LAX TO DTW, CREW REPORTED GREATER THAN NORMAL PULL ON THE YOLK ON ROTATION AT TAKEOFF. DURING APPROACH TO DTW, THE CONTROL WHEEL TURNED TWO DEGREES LEFT WITH FLAPS 15 AND SPOILERS DEPLOYED. MAINTENANCED PERFORMED FUNCTIONAL CHECK OF SPOILER SYSTEM, NO FAULTS FOUND.

Part: COOLING FAN — FAILED (E/E BAY) · airframe 46,076 hrs · 19,581 cycles

DURING CRUISE, FLIGHT CREW NOTICED AN ELECTRICAL ODOR ON THE AIRCRAFT WHICH PRECEDED AN EICAS MESSAGE EQUIPMENT OVERHEAT. FLIGHT CREW PERFORMED COM PROCEDURE AND DECLARED AN EMERGENCY. FLIGHT DIVERTED TO DTW FOR AN UNEVENTFUL LANDING. MAINTENANCE REPLACED THE NR 1 EQUIPMENT COOLING FAN, OPERATIONAL CHECK OK.

Part: COMPRESSOR — STALLED (NR 2 ENGINE)

DURING TAKEOFF, THE NR 2 ENGINE EXPERIENCED A COMPRESSOR STALL AND SHUTDOWN. TAKEOFF WAS ABORTED AT 120 KNOTS. MAINTENANCE FOUND THAT THE PMA, ROTOR, AND STATOR HAD FAILED. THE PMA WAS REPLACED. OPERATIONAL CHECK NORMAL.

Part: OVEN — MALFUNCTIONED (FORWARD GALLEY)

IN CRUISE FLIGHT, THE CREW DETECTED A BURNING ODOR THAT SEEMED TO ORIGINATE FROM THE FORWARD GALLEY OVEN AREA. THE OVENS WERE TURNED OFF BUT THE ODOR DID NOT DISSIPATE. THE FLIGHT DIVERTED TO ORD AND LANDED WITHOUT INCIDENT. MAINTENANCE DEACTIVATED THE OVEN UNIT AND RELEASED THE AIRCRAFT FOR SERVICE. THE OVEN WAS REPLACED DURING SUBSEQUENT OVERNIGHT MAINTENANCE.

Part: SO VALVE — FAILED (LT ENGINE)

DURING CRUISE FLIGHT, UNABLE TO MAINTAIN CABIN PRESSURIZATION. AIRCRAFT DIVERTED TO MSP AND LANDED WITHOUT INCIDENT. REPLACED LEFT ENGINE PRSOVS. OPERATIONAL CHECK OK.

Part: GEN CONTL UNIT — MALFUNCTIONED (LT ENGINE)

DURING APPLICATION OF TAKEOFF THRUST, THE LEFT IDG DRIVE LIGHT CAME ON. AIRCRAFT ABORTED TAKEOFF WITHOUT INCIDENT. REPLACED GENERATOR CONTROL UNIT AND SERVICED LEFT IDG. PERFORMED IDG CHECK OUT. SYSTEM CHECKED OK.

Part: ENGINE — FAILED (RIGHT)

ON TAKEOFF, THE RIGHT ENGINE SPOOLED UP SLOWER THAN THE LEFT ENGINE. A POP WAS HEARD AND THE TAKEOFF WAS ABORTED. EGT STAYED AT APPROXIMATELY 535, OTHER PARAMETERS WERE NORMAL. AIRCRAFT RETURNED TO THE GATE. ENGINE CHANGE IS IN PROGRESS.