N534US

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 79,949 hrs · 34,148 cycles

DURING WAKEUP, FOUND EMERGENCY LIGHT AT R3 DOOR ON WITH SWITCH IN ARMED POSITION. REPLACED BATTERY PACK ASSY, OPS CHECKED GOOD.

Part: SKIN — DAMAGED (R4 DOOR) · airframe 79,803 hrs · 34,052 cycles

R4 DOOR SKIN UPPER FWD CORNER DAMAGED BELOW UPPER HINGE GATE. CUTOUT DAMAGE IAW SRM 52-10-01, REPAIR C/W HFEC OF CUTOUT IAW NDT PT. 6 51-00-19 AND BHEC IAW NDT PTG 51-00-16, NO ITEMS WERE NOTED 761595, REPAIRED IAW SRM 52-10-01, REPAIR 07.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 78,909 hrs · 33,514 cycles

EMERGENCY EXIT SIGNS INOPERATIVE. R & R EMERGENCY BATTERY PACK. OPS CHECKED GOOD.

Part: CHARGER — INOPERATIVE (EMERGENCY LIGHTS) · airframe 75,356 hrs · 31,359 cycles

FOUND RT EMERGENCY CEILING EXIT SIGN ABOVE R3 DOOR INOPERATIVE. RELAMPED EXIT SIGN NO HELP. T/S FOUND BATTERY CHARGER TO BE NOT WORKING PROPERLY. R & R BATTERY CHARGER AS REQUIRED IAW AMM 33-50. OPS CHECKED GOOD

Part: HARNESS — DETERIORATED (R4 DOOR SLIDE) · airframe 75,129 hrs · 31,198 cycles

R4 DOOR EMERGENCY ESCAPE SLIDE HARNESS DETERIORATED AND WILL NOT LATCH. R & R R-4 DOOR EMERGENCY ESCAPE SLIDE HARNESS IAW -A-25-66-01-401-926-A-A.

Part: CABLE — OUT OF TOLERANCE (DOOR ASSIST) · airframe 74,886 hrs · 31,072 cycles

DURING FLIGHT CHECK, MAINTENANCE WAS INSPECTING EMERGENCY POWER ASSIST CABLE TRAVEL. PER AMSD STEP 4C CABLE TRAVEL FAILED. MAINTENANCE LUBED AND CHECKED MOVEMENT PE AMDS 5210-01083-01E. OPERATION OF CABLE CHECKS GOOD AND RII COMPLETED.

Part: MECHANISM — LOOSE (PAX DOOR) · airframe 74,834 hrs · 31,045 cycles

L1 PAX DOOR EMERGENCY OPERATION MECHANISM HAS LOOSE AND MISSING HARDWARE (LOWER OPERATION MECHANISM) ALSO CRANK ASSY BENT, TIGHTENED LOOSE HARDWARE. NSTALLED NEW CRANK AND BUSHING PER CMM 52-11-07. OPS GOOD PER AMM 52-11 RII COMPLETE.

Part: DUCT — DAMAGED (APU BLEED) · airframe 74,298 hrs · 30,755 cycles

SMOKE IN THE BACK OF THE AIRCRAFT ACCOMPANIED BY HOT AIR AND WARM FLOOR. CLOSED APU BLEED VALVE HEAT AND DEBRIS BEGAN TO DISSIPATE FOUND APU BLEED DUCT IN AFT CARGO BIN JUST FWD OF PRESSURE BULKHEAD WITH A 3/8 INCH HOLE AT MOUNT CLAMP FWD TO MEL PER 36-11-04. REMOVED AND REPLACED APU AIR DUCT FORWARD OF 1720 BULKHEAD AND S DUCT AFT OF BULKHEAD PER 757 AMM 36-11-01. LEAK CHECK GOOD.

Part: BATTERY PACK — LOOSE (EMERGENCY LIGHT) · airframe 3,385 hrs · 1,905 cycles

DURING LINE CHECK MAINTENANCE FOUND EMERGENCY PATH LIGHTS IN ROW 26-30 INOPERATIVE. MAINTENANCE SECURED LOOSE BATTERY PACK QUICK DISCONNECT. EMERGENCY LIGHTS NOW CHECK OK.

Part: CONNECTOR — DISCONNECTED (CABIN) · airframe 2,547 hrs · 1,411 cycles

DURING LINE CHECK MAINTENANCE FOUND FIRST CLASS EMERGENCY LIGHTS INOP. MAINTENANCE RESEATED CONNECTOR ON BATTERY PACK. LIGHTS NOW CHECK OK. (LP 8490398)

Part: BOOT — BLOWN (AC BAY) · airframe 71,663 hrs · 29,221 cycles

AT FL330 GOT CABIN ALT WARNING AND CABIN AUTO INOP CAUTION. DECLARED AN EMERGENCY AND DESCENDED TO 10,000'. CABIN PRESSURE REACHED 11,000'. MASKS DID NOT DEPLOY. FLT RETURNEDTO ATL AND LANDED WITHOUT INCIDENT. REPLACED BLOWN BOOT IN RIGHT ECS BAY, OUTFLOW VALVE ACTUATOR ASSEMBLY, AND BOTH CABIN PRESSURE CONTROLLERS.

Part: SWITCH — MISWIRED (CABIN) · airframe 71,204 hrs · 28,952 cycles

DURING A LINE CHECK, MAINTENANCE FOUND THE FLIGHT ATTENDANT EMERGENCY LIGHT TEST SWITCH INOPERATIVE. MAINTENANCE CORRECTED THE SWITCH WIRING. OPERATIONAL CHECK WAS GOOD.

Part: PLATE — CORRODED (CARGO DOOR) · airframe 70,875 hrs · 28,765 cycles

FWD CARGO LOWER LT DOOR SILL PLATE STRUCTURE HAS SOME HEAVY DEFOLIATION CORROSION. REMOVED FWD CARGO DOOR SILL AND DOOR SILL PLATE REF SRM 51-40-02. LOCATED AND DRILLED REPLACEMENT DOOR SILL AND SILL PLATE REF SRM 51-40-05. INSTALLED REPLACEMENT DOOR SILL AND SILL PLATE IAW SRM 51-40-02 AND SRM 51-40-04. RII INSPECTION COMPLETED.

Part: SILL — CORRODED (BS 1673 RBL 52) · airframe 70,875 hrs · 28,765 cycles

CORROSION ON NR4 DOOR SILL RT SIDE SUPPORT FRAME AT BS 1673, RBL 52. REMOVED CORROSION AT NR4 DOOR SILL RT SIDE SUPPORT FRAME IAW REF SRM 51-10-02. FOUND OUT OF LIMITS IAW REF SRM 53-00-51, PAGE 103, FIG 101, DETAIL 6. R & R SUPPORT FRAME IAW SRM 51-40-02. COMPLETED.

Part: CHANNEL — CORRODED (BS 1683 BL 0) · airframe 70,875 hrs · 28,765 cycles

CORROSION ON CABIN COMPARTMENT HAT CHANNEL AFT GALLEY AREA AT STA 1683, BL 0. CORROSION FOUND OUT OF LIMITS IAW REF SRM 53-00-51, FIG.101, DETAIL 6. REMOVED & INSTALLED HAT CHANNEL IAW REF SRM 51-40-02 PARA 4, PAGE 2. COMPLETED.

Part: SKIN — DAMAGED (CARGO DOOR) · airframe 375 hrs · 132 cycles

DURING M CHECK. THE INSPECTION FOUND DAMAGE OUT OF LIMITS EDGE OF SKIN CARGO DOOR. REPAIR WAS ACCOMPLISHED PER ERA 488121-14.

Part: FLOOR SUPPORT — CORRODED (BS 345-377) · airframe 70,875 hrs · 28,765 cycles

FLOORBEAM CORRODED BETWEEN STA 345 AND 377. REMOVED CORROSION ON 3 EA AREAS FROM STA 345 TO STA 376 ON FLOORBEAM IAW REF SRM 51-10-02, PAGE 12. REMOVED FLOOR BEAM FROM STA 345 TO STA 418 BL 0.0 ON MAIN CABIN REF SRM 51-40-02, PAGE 7. INSTALLED NEW FLOORBEAM IAW REF SRM 51-40-02, PAGES 2, 7. FOUND OUT OF LIMITS IAW REF SRM 53-00-51, PAG 103, FIG 101 SHEET 3, COMPLETED. REQUIRED INSP COMPLETED.

Part: BOX BEAM — CORRODED (BS 1661-1681) · airframe 70,875 hrs · 28,765 cycles

CORROSION FOUND AT L4 DOOR FLOOR LEVEL AFT BOX BEAM, LBL 54 FROM STA 1661 TO STA 1681. REMOVED CORROSION AT LT DOOR, FLOOR LEVEL AFT BOX BEAM, LBL 54 FROM STA 1661 TO STA 1681 PER REF PS 900-2-4-1- NR 1. FOUND OUT OF LIMITS IAW REF SRM 53-00-51, PAGE 103, FIG 101, DETAIL U1. R & R BOX BEAM IAW REF SRM 51-40-02, PAGE 7. COMPLETED.

Part: INTERCOSTAL — CRACKED (BS 660-685) · airframe 70,875 hrs · 28,765 cycles

2 EA CRACKS AT INTERCOSTAL JUST ABOVE L2 DOOR PNUEMATIC ACTUATOR BETWEEN STA 660 AND 685. REMOVED AND INSTALLED NEW INTERCOSTAL ON L2 DOOR ABOVE PNUEMATIC ACTUATOR BETWEEN STA 660 AND 685 REF SRM 51-40-02 PG 1 AND PG 7.

Part: CUSP WEB — CORRODED (BS 1665) · airframe 70,875 hrs · 28,765 cycles

CORROSION ON NR4 RT DOOR SILL AREA CUSP WEB "J" CHANNEL AT STA 1665. REMOVED CORROSION AT NR4 RT DOOR SILL AT STA 1665. FOUND "U" CHANNEL OUT OF LIMITS, REF SRM 51-10-02, PAGE 12 AND SRM 53-00-51, PAGE 103, FIG 101. R & R "U" CHANNEL AT NR4 RT DOOR SILL AT STA 1665, REF SRM 51-4 0-02, REF SRM 51-40-02, PAGE 2 AND 3 COMPLETED.

Part: INTERCOSTAL — CRACKED (BS 660-680) · airframe 70,875 hrs · 28,765 cycles

2ND INTERCOSTAL ABOVE L2 DOOR PNUEMATIC DOOR ACTUATOR HAS A CRACK BETWEEN STA 660 TO 680. REMOVED AND INSTALLED NEW INTERCOSTAL ABOVE L-2 DOOR PNUEMATIC DOOR ACTUATOR BETWEEN STA 660 TO 680 REF SRM 51-40-02 PG 2 AND PG7 COMPLETED: A INSPECTED.

Part: FLOOR SUPPORT — CORRODED (BS 365.25) · corrosion level 2 · airframe 70,875 hrs · 28,785 cycles

DURING M-CHECK, FOUND RT DOOR SILL AT STA 365.25, FLOOR SUPPORT HAS SURFACE CORROSION OTBD OF RBL 53. R & R FLOOR SUPPORT FROM STA 348 TO 365.25 AT RBL 53 IAW REF SRM 51-40-02.

Part: FLOOR SUPPORT — CRACKED (BS 660-680) · airframe 70,875 hrs · 28,765 cycles

DURING M-CHECK, FOUND FWD CARGO BETWEEN STA 680 AND STA 660, 36" LT OF CTR THE FLOOR SUPPORT IS CRACKED. REMOVED FLOOR SUPPORT AND INTERCOSTAL WEB CRACKED. FABRICATED REPLACEMENT INTERCOSTAL WEB LOCATED AND DRILLED NEW INTERCOSTAL WEB. NDT VERIFIED FLOOR SUPPORT NO CRACKS. INSTALLED INTERCOSTAL WEB AND FLOOR SUPPORT IAW REF DWG NR 143N5264 AND SRM 51-40-02, PARA 4B AND 7D PG2 AND 7 AND SRM 51-40-05, PARA 2, PG 1.

Part: INTERCOSTAL — CRACKED (R2 DOOR) · airframe 70,875 hrs · 28,765 cycles

INTERCOSTAL CRACK AT NR2 R DOOR JUST ABOVE PNEUMATIC ACTUATOR BETWEEN STA 660 AND 685. R & R INTERCOSTAL AT NR2 R DOOR BETWEEN STA 660 AND STA 685, REF SRM 51-40-02, PG 2, 7.

Part: FLOORBEAM — CORRODED (BS 365 RBL 64) · airframe 70,875 hrs · 28,765 cycles

FLOORBEAM CORRODED AT STA 365 FROM BL 0.0, TO RBL 64. REMOVED CORROSION FOUND TO BE OUT OF LIMITS IAW SRM B757-20053-00-51, FIG 101. GAINED ACCESS TO REPAIR AREA, CUT OUT DAMAGE "T" ANGLE. FABRICATED & INSTALLED REPLACEMENT "T" ANGLE, 2 EA REPAIR ANGLES AND 2 EA STRAPS. RESTORED ACCESS IAW SRM 53-00-51, FIG 201, REP 3 AND SRP B757-A-53-01-07-801-663A-A, PG 1 THRU 4, AND SRM 51-40-02.

Part: SKIN — CRACKED (NR 2 PYLON) · airframe 65,090 hrs · 26,698 cycles

EA 55-212961 SECTION I ISSUED FOR NR2 PYLON, RT SIDE SKIN CRACK AT NAC STA 132. FOLLOW ON ACTION IS REQUIRED. COMPLIED WITH ER/A 488115-14 REV ORIGINAL PERMENANT REPAIR ACCOMPLISHED COMPLETED.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 62,788 hrs · 25,851 cycles

DURING OVERNIGHT LINE CHECK, FOUND ESCAPE PATH LIGHTS ON FLOOR INOP BETWEEN ROWS 23 THRU 32. MAINTENANCE REMOVED AND REPLACED 2 BATTERY PACKS AND A TEST SWITCH AT THE FORWARD FLIGHT ATTENDANT PANEL. OPERATIONAL CHECKED GOOD AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: ACM — SEIZED (A/C BAY) · airframe 58,483 hrs · 24,191 cycles

DURING CLIMB BOTH PILOTS SMELLED ELECTRICAL SMOKE, THEY IMMEDIATELY DONNED OXYGEN MASKS. THERE WAS NO SMOKE IN THE COCKPIT. FLIGHT ATTENDANTS REPORTED SOME WHITE SMOKE IN THE CABIN. THE EVENT LASTED ABOUT TWO MINUTES. THE FLIGHT CONTINUED AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE COOLING TURBINE SEIZED AND TURBINE BLADES DAMAGED. REMOVED AND REPLACED THE COOLING TURBINE, OPERATIONALLY CHECKED AND RETURNED TO SERVICE.

Part: SEAT TRACK — CORRODED (FUSELAGE) · corrosion level 2 · airframe 52,315 hrs · 21,648 cycles

DURING (H) CHECK FOUND CORROSION ON SEAT TRACK AT BS 1640 LBL 46. REPAIRED IAW EA 55-199278.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 52,314 hrs · 21,648 cycles

DURING (H) CHECK FOUND CRACK IN FLOORBEAM AT BS 700 LBL 45. REPAIRED IAW EA 55-199754.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 52,314 hrs · 21,648 cycles

DURING H-CHECK FOUND CORROSION ON FLOORBEAM AT BS 365 RBL 25. REPAIRED IAW EA 55-198961.

Part: POWER SUPPLY — DEFECTIVE (MID CABIN) · airframe 47,414 hrs · 19,640 cycles

DURING EMERGENCY LIGHT TEST, MID CABIN AFT SECTION OF EMERGENCY FLOOR TRACK LIGHTS INOPERATIVE. MAINTENANCE REPLACED THE POWER SUPPLY. OPERATIONAL CHECK GOOD.

Part: SMOKE — DETECTED (CABIN) · airframe 44,471 hrs · 18,502 cycles

DURING CRUISE AT 41,000 FT, A BURNING SMELL WAS NOTICED IN THE FLIGHT DECK. LEAD FLIGHT ATTENDANT REPORTED SMOKE IN THE CABIN. SMOKE IN THE AIRCRAFT DISSIPATED AFTER SMOKE CHECK LIST WAS COMPLIED WITH BUT RETURNED DURING APPROACH. MAINTENANCE CHECKED OPERATION OF OVENS, COFFEEMAKERS, HOT PLATES, INTERIOR LIGHTS, LAV HOT WATER HEATERS, LAV FLUSH MOTORS, AND RECIRCULATION FANS. CHECKED E/E COMPARTMENTS, AND CB PANELS. PERFORMED ENGINE HIGH POWER RUNUP AND OPERATED PACKS. APU CHECKED OK. NO TROUBLE FOUND. AIRCRAFT RETURNED TO SERVICE.

Part: FIRE DETECTOR — MALFUNCTIONED (LT ENGINE) · airframe 42,763 hrs · 17,873 cycles

ON ENGINE START, THE LEFT ENGINE FIRE WARNING OCCURRED. WARNINGS STOPPED AFTER FIRE SWITCH WAS PULLED AND ONE BOTTLE DISCHARGED. MAINTENANCE CHECKED ENGINE, DUCTING, AND FUEL AND OIL LINES FOR EVIDENCE OF FIRE WITH NONE FOUND. REPLACED THE NR 1, 2, 3, AND 4 LEFT ENGINE FIRE DETECTORS. ALSO REPLACED THE LEFT ENGINE LOOP 2 DETECTOR CARD M681, THE NR 1 AFOLTS FIRE DETECTION SYSTEM CARD M10224, AND THE NR 1 FIRE EXTINGUISHER BOTTLE. OPERATIONAL CHECK NORMAL.

Part: ENGINE — FAILED (NR 2)

DURING FINAL APPROACH AT 1000 FEET, NR 2 ENGINE EXPERIENCED A COMPRESSOR STALL AND FLAMED OUT. AN UNEVENTFUL SINGLE ENGINE LANDING WAS PERFORMED. MAINTENANCE FOUND TRACE OF METAL IN THE TAILPIPE AND REPLACED THE ENGINE.

Part: FLOORBEAM — CORRODED (BS 1640)

DURING PERIODIC CHECK, FOUND CORROSION ON THE BS 1640 FLOORBEAM UPPER CHORD FROM LBL 6 TO RBL 60. REPAIRED CHORD (P/N 146N5089) PER EA 55-106273.

Part: FLOOR SUPPORT — CORRODED (FS 1445 1500)

DURING PERIODIC CHECK, THE AFT CARGO FLOOR SUPPORT STRINGERS WERE FOUND CORRODED AROUND NUTPLATES BETWEEN FS 1445 AND 1500, LBL 11 AND RBL 3. REMOVED CORROSION AND INSTALLED REPAIR PER NWA EA 55-97818.

Part: SKIN — DAMAGED (SPOILERS)

DURING PERIODIC CHECK, THE NR 1, NR 2, NR 10, NR 11, AND NR 12 SPOILER UPPER SKIN PANELS WERE FOUND WITH NUMEROUS AREAS OF DAMAGE AND DELAMINATION (2 INCH DIAMETER TYPICAL). INSTALLED REPAIRS PER SRM 57-70-01, FIG. 201 AND NWA EA 55-97817.