N602DL

Part: SKIN — DAMAGED (BS 378-512) · airframe 87,888 hrs · 44,617 cycles

MULTIPLE LIGHTNING STRIKES AT LAP SPLICE AT S4R. LOCATIONS APPROX STA 512, 459 AND 378. CLEANED UP AREA AT BS 378 IAW SRM 53-00-01, FIG 101.849644. CLEANED AREAS AT BS 512-459-449 IAW SRM 53-00. TREATED AND PAINTED IAW PS 900-3-6 NR 3.

Part: SKIN — DAMAGED (BS 356-540) · airframe 87,888 hrs · 44,617 cycles

LIGHTNING STRIKES ON RIVET HEADS LOCATED AT S4R APPROX BS 356 AND S4R BS 540. REMOVED FASTENERS BS 356. REMOVED FASTENER AT BS 540. COMPLIED WITH HGEC INSPECTION ON FUSELAGE SKIN AROUND REMOVED FASTENERS AT BS 356 S4R AND BS 540 S4R. NO DISCREPANCIES NOTED. REPLACED FASTENERS IAW SRM 53-00-01, FIG 201.

Part: SKIN — DAMAGED (BS 408 S3R) · airframe 87,888 hrs · 44,617 cycles

HAD LIGHTNING STRIKE AT APPROX LOCATION BS 408 S3R ON RIVET HEAD. REMOVED FASTENER. REMOVED DAMAGE, COMPLIED WITH HFEC INSPECTION ON FUSELAGE SKIN AROUND CUT OUT AREA AT BS 408 S3R. COMPLIED WITH BHEC INSPECTION ON EXISTING FASTENER HOLES IN S3R. THREE FASTENERS ON EACH SIDE OF CUTOUT. NO DISCREPANCIES. COMPLIED WITH STEPS 6 THRU 8 OF SRM 53-00. OK TO INSTALL REPAIR. INSTALLED REPAIR.

Part: SKIN — DAMAGED (BS 435 S4R) · airframe 87,888 hrs · 44,617 cycles

HAD LIGHTNING STRIKE AT APPROX LOCATION BS 435, STR 4R ON RIVET HEAD JUST FWD OF SKIN SPLICE. REMOVED FASTENER STEPPED UP HOLE TO REMOVE DAMAGE. COMPLIED WITH HFEC INSPECTION AROUND REMOVED FASTENER AT BS 435 STR 4R. NO DISCREPANCIES NOTED. REPLACED FASTENER IAW 53-00-0-2, FIG 201.

Part: SKIN — DAMAGED (BS 408 S3R) · airframe 87,888 hrs · 44,617 cycles

FOUND LIGHTNING STRIKE DAMAGE AT FS 408 S3R. INSTALLED REPAIR DOUBLER IAW SRM 53-00-01, REPAIR 2.

Part: SKIN — DAMAGED (BS 408 S3R) · airframe 87,888 hrs · 44,617 cycles

LIGHTNING STRIKE AT APPROXIMATELY BS 408 S3R ON RIVET HEAD IAW SRM 53-00, REPAIR INSTALLATION OK.

Part: SKIN — DAMAGED (BS 480 S4R) · airframe 87,888 hrs · 44,617 cycles

LIGHTNING STRIKE AT APPROX LOCATIONS BS 480, 3 INCHES ABOVE STR 4R ON RIVET HEAD. COMPLIED WITH PRI 509608-14, REV 0, STEPS 1-59917734 INSPECTED SAME. ACCOMPLISHED HFEC INSPECTION OF CUTOUT AND BHEC OF EXISTING FASTENER HOLES PRI 509608-14, REV.1 09 DEC 12 AT 0445E STEPS 4 AND 6. NO CRACKS NOTED. INSTALLED REPAIR AND COMPLETED FINAL ERA 509608-14 REV ORIG. C/W RII INSPECTION OF REPAIR IAW ERA 509608-14, REV ORIG.

Part: SKIN — PUNCTURED (BS 480) · airframe 85,364 hrs · 43,506 cycles

FUSELAGE SKIN PUNCTURED BS 480. REPAIRED PER ERA 500459-14.

Part: CONNECTOR — DEFECTIVE (CABIN) · airframe 85,171 hrs · 43,425 cycles

LINE MAINTENANCE FOUND EMERGENCY ESCAPE PATH LIGHT INOPERATIVE AT ROW 32 RIGHT. UNDER-SEAT CONNECTOR WAS RE-PINNED, LIGHT OPERATION NORMAL.

Part: LIGHT — DISCONNECTED (CABIN) · airframe 84,775 hrs · 43,245 cycles

DURING LINE CHECK MAINTENANCE EMERGENCY LIGHTS AT STA 670 AND EXIT SIGN DISCONNECTED. MAINTENANCE CONNECTED EMERGENCY LIGHT AND EXIT SIGN. OPERATION OF LIGHTS NOW CHECK OK.

Part: DOOR FRAME — DAMAGED (CABIN) · airframe 84,671 hrs · 43,204 cycles

ER/A 386365-14AD SECTION II PERMANENT REPAIR OF C1 DOOR STRUCTURE FS 620 AFT EDGE FRAME S-25R. C/W ER/A 386365-14AD REV ORIG ON N/R CARD 005. INSTALLATION OF REPAIR OK.

Part: DOOR FRAME — DAMAGED (CARGO DOOR) · airframe 84,671 hrs · 43,204 cycles

DURING OPN 5032AD INSPECTION CARGO DOOR FRAMES FOUND SEVERAL OVERSIZED HOLES AND INCORRECT FASTENERS INSTALLED AT C2 CARGO DOOR. REMOVED FASTENERS, PREPARED AREA FOR INSPECTION AS PER ER/A 497284-14AD, AND INSTALLED FASTENERS IN C2 DOOR FRAME.

Part: WIRE — BROKEN (CABIN) · airframe 84,618 hrs · 43,184 cycles

DURING A ROUTINE MAINTENANCE VISIT, THE EMERGENCY LIGHT AT SEAT ROW 19 WAS FOUND TO BE INOPERATIVE. FURTHER INSPECTION FOUND WIRE ON SEAT HARNESS BROKEN. WIRE WAS SPLICED PER B757 AMM CHAPTER 20. OPERATION CHECKS GOOD AFTER REPAIR.

Part: WIRE — DAMAGED (CABIN) · airframe 84,360 hrs · 43,089 cycles

DURING A LAYOVER CHECK, MAINTENANCE FOUND THE EMERGENCY PATHLIGHTS AT SEATS 31D AND 34D INOPERATIVE. MAINTENANCE REPAIRED THE WIRING AT EACH LOCATION. OPERATIONAL CHECK WAS GOOD.

Part: UNKNOWN — FUMES (GALLEY) · airframe 83,417 hrs · 42,732 cycles

ON DESCENT, FLIGHT ATTENDANTS REPORTED FUMES IN THE AFT GALLEY. THE QRH WAS ACCOMPLISHED. SMELL DISSIPATED. MAINTENANCE CHECKED THE LAVATORIES, GALLEYS, CABIN LIGHTS, AND RECIRCULATION FANS. NO FINDINGS. AIRCRAFT WAS APPROVED FOR SERVICE.

Part: SKIN — BULGED (BS 1720 S29R) · airframe 80,575 hrs · 41,430 cycles

SKIN BULGING FS 1720 S29R. REPAIRED AREA IAW ERA 483346-14 REV A.

Part: NUT — WORN (FLAP DRIVE) · airframe 73,632 hrs · 38,054 cycles

AT LANDING WHEN FLAPS LEVER PLACED TO 5, GOT TE FLAP DISAGREE CAUTION AND FLAPS LOCKED AT 1. FOUND RT INBD FLAP OUTBD JACKSCREW DISCONNECTED FROM TRANSMISSION AT U JOINT. U JOINT PARTS FOUND IN FAIRING. REPLACED TRANSMISSION, U JOINT PARTS, AND DAMAGED FAIRING. SUSPECT LOCKING FEATURE ON U JOINT ASSY NUT WORN.

Part: FRAME — DENTED (BS 1400 S26-27L)

FOUND DENT IN UPPER CAP OF AFT PIT MAIN FRAME BS 1400 BETWEEN S-27 AND S-26 LT. REPAIRED BY FABRICATING AND INSTALLING FRAME REPAIR 9 BY 14 FROM 7075-T6 .071 IAW DELTA ERA 380490-14MA REV ORIG, DELTA PROCESS STANDARD 900-5-1 NR 4, B757 SRM 51-40-02, PG 2, 7, AND 8, 51-70-11, AND 51-20-01 PG 1. PLUGGED EXISTING HOLE IAW B757 SRM 51-40-02 AS DIRECTED BY TIMCO RFTS 291041-60024.

Part: STRINGER — CORRODED (BS 1480 S29L) · corrosion level 2

FOUND S-29L CORRODED IN AFT PIT AT BS 1480. REPAIRED CORRODED STRINGER BY REMOVING AND INSTALLING STRINGER P/N 146N3110-8201 AND SPLICE IAW B757 SRM 53-00-03.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 71,761 hrs · 37,246 cycles

FOUND LIGHTNING STRIKE BS 310 BETWEEN S-8L AND S-9L. REPAIRED BY REMOVING SHEAR TIE, CUT OUT STRIKE AREA, HFEC CUT OUT IAW B757 NTM PT6 51-00-01, 51-00-19 NO RELEVANT INDICATIONS NOTED. TRIMMED OUT AN EXTRA .040” MATERIAL. FABRICATED AND INSTALLED SHEAR TIE 10.0 BY 2.25 FROM 7075-T6 .050 AND SKIN REPAIR 11.5 BY 13.5 FROM 2024-T3 .063 IAW B757 SRM 53-00-01 FIG 201.

Part: SKIN — DAMAGED (FS 434 S17L) · airframe 71,762 hrs · 37,247 cycles

DURING CURRENT HMV, A DENT WAS FOUND ON THE EXTERIOR SKIN PANEL P/N 143N3320-3 JUST ABOVE S-17L AT FS 443. THE SUBJECT DAMAGE WAS OUTSIDE OF THE ALLOWABLE DAMAGE LIMITS OF THE SRM. THE DAMAGE WAS TRIMMED OUT AND AN EXTERNAL REPAIR DOUBLER INSTALLED PER ER/A 460840-14, WHICH WAS BOEING APPROVED.

Part: STRINGER — CORRODED (BS 750) · corrosion level 2

FOUND CORROSION ON STRINGER AND SKIN AT BS 750 S-23R. REPAIRED BY CUTTING OUT SECTION OF STRINGER. FABRICATED AND INSTALLED STRINGER REPAIR 14 BY 3.5 FROM BAC1498-204 IAW B757 SRM 51-20-01 AND 53-00-03 FIG 201.

Part: STRINGER — CORRODED (BS 1681 S29R) · corrosion level 2

FOUND STRINGER 29R AT BS 1681 CORRODED. REPAIRED CORROSION ON STRINGER S-29R AT BS 1681 BY CUTTING OUT AND REMOVING CORRODED SECTION OF STRINGER BS 1670 TO BS 1720 IAW B757 SRM 53-00-53 AND 51-40-02. FABRICATED AND INSTALLED STRINGER SECTION 50 BY 3 REPAIR FROM BAC1498-144 IAW B757 SRM 51-20-01, 51-40-02 AND 53-00-53.

Part: ATTACH ANGLE — CORRODED (BS 1680 S28-29R) · corrosion level 2

FOUND CORROSION AFT PIT MAIN FRAME FWD ATTACH ANGLE BS 1680 BETWEEN S-28 - S-29R. REPAIRED CORROSION ON FRAME ATTACH ANGLE BY FABRICATING AND INSTALLING NEW FRAME ATTACH ANGLE FROM 7075-T6 .071" CLAD IAW B757 SRM 51-40-02, 51-70-11 AND 51-20-01.

Part: SKIN — DENTED (BS 440)

FOUND DENT BELOW STR 17L, BS 440. REPAIRED BY CUTTING OUT DENTED SECTION OF SKIN, HFEC CUT OUT IAW B757 NTM PT6, 51-00-01, NO RELEVANT INDICATIONS NOTED. FABRICATED AND INSTALLED REPAIR DOUBLER 15-1/4 BY 13-1/2 FROM 2024-T3 .063 IAW B757 SRM 53-00-01 FIG 201, ERA NR 640840-14 REV ORIG FAA APPROVAL FAA FORM 8100-9. REPAIR APPROVAL IS LIMITED TO 12 MONTHS SERVICE ONLY. ADDITIONAL ENGINEERING AUTHORIZATION, (ER/A REVISION) IS REQUIRED FOR CONTINUED SERVICE OF THIS REPAIR LONGER THAN 12 MONTHS FROM FAA FORM 8100-9 APPROVAL DATE.

Part: LIGHT — BROKEN (ANTICOLLISION) · airframe 71,095 hrs · 36,943 cycles

ON ARRIVAL TO GATE, FOUND LOWER ANTI COLLISION BEACON LIGHT LENS BROKEN. REPLACED LIGHT ASSY.

Part: WIRE — DAMAGED (TRU) · airframe 63,145 hrs · 33,974 cycles

CIRCUIT BREAKER C-23 ON P-64 PANEL POPPED IN FLIGHT. BREAKER IS FOR TRANSFORMER RECTIFIER UNIT. REPAIRED DAMAGED WIRING OVER DRIP PAN IN E/E.

Part: SKIN — CRACKED (FUSELAGE) · airframe 61,606 hrs · 33,389 cycles

THE UPPER FWD CORNER OF THE L1 DOOR CUTOUT WAS FOUND WITH A 2 INCH CRACK IN THE SKIN AND UNDERLYING BEARSTRAP. THE CRACK WAS REMOVED WITH A CUTOUT THROUGH ALL LAYERS OF THE SKIN ASSEMBLY. THE AREA WAS REPAIRED WITH 3 EXTERNAL ALUMINUM REPAIR DOUBLERS PER ER/A 088886-14.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHT) · airframe 61,326 hrs · 33,276 cycles

F/C SEATS EMERGENCY LIGHTS INOP. REPLACED POWER SUPPLY.

Part: LINE — DAMAGED (NR 2 ENGINE) · airframe 60,752 hrs · 33,030 cycles

RIGHT HYD QTY LOSS. FOUND PRESSURE LINE IN RT PYLON DAMAGED. REPLACED SAME.

Part: CLAMP — LOOSE (A/C PACK) · airframe 59,081 hrs · 32,335 cycles

LT DUCT LEAK. EICAS MSG. WITH CORRESPONDING DUCT LEAK LT ON AIR CONDITIONING PANEL. FOUND PNEUMATIC DUCT LT WING LEAKING. RESECURED. NO FURTHER LEAKS NOTED

Part: SKIN — PUNCTURED (FS 610, S-16L) · airframe 55,236 hrs · 30,439 cycles

FUSELAGE / SKIN / FS 590-620 / STRG. 15L-18L : PUNCTURE REPAIR THE FUSELAGE SKIN WAS PUNCTURED BY GROUND EQUIPMENT AT FS 610 AND STRINGER 16L. THE DAMAGE WAS ADJACENT TO 2 EXISTING SKIN REPAIR DOUBLERS. THE EXSTING DOUBLERS WERE REMOVED AND ALL DAMAGED AREAS WERE INCORPORATED INTO ONE LARGE SKIN CUTOUT FROM FS 590-620 AND FROM STRINGERS 15L TO 18L. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 382345-14, REV B.

Part: SPAR — DAMAGED (L/E SLAT) · airframe 54,852 hrs · 30,249 cycles

NR 9 SLAT NOSE BEAM SPAR WAS FOUND WITH SEVERAL DAMAGED FASTENER HOLES. REPAIR PER ER/A 410486-14.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 53,432 hrs · 29,577 cycles

THE FUSELAGE SKIN WAS FOUND CREASED JUST FWD OF THE E&E COMPARTMENT DOOR CUTOUT AT RBL 2.3 BETWEEN FS 223 & 239. THE DAMAGE WAS CUTOUT OF THE SKIN AND REPAIRED WITH TWO EXTERNAL ALUMINUM DOUBLERS PER ER/A 380763-14, REV A.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 53,432 hrs · 29,577 cycles

THE LOWER DOOR SILL CHORD OF THE C2 DOOR CUTOUT WAS CORRODED AND REQUIRED REPLACEMENT. TO ALLOW REMOVAL AND INSTALLATION OF A NEW CHORD, THE OUTER CHORD OF THE FS 1440 DOOR OPENING FRAME WAS CUT NEAR STRINGER 27R AND THE LOWER SECTION REMOVED. A NEW SECTION WAS LATER INSTALLED AND SPLICED IN WITH TWO ALUMINUM REPAIR ANGLES INSTALLED PER ER/A 380664-14, REV A.

Part: SKIN — GOUGED (FUSELAGE) · airframe 53,432 hrs · 29,577 cycles

THE FUSELAGE SKIN BETWEEN FS 590-660 AND BETWEEN STRINGES 16L & 18L WAS FOUND WITH SEVERAL DENTS AND GOUGES. THE DAMAGES WERE REMOVED WITH THREE SEPARATE CUTOUTS. EACH CUTOUT WAS REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER. THE REPAIR WAS ACCOMPLISHED PER ER/A 380592-14, REV A.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 53,432 hrs · 29,577 cycles

THE UPPER CAP OF THE FS 1681 PASSENGER FLOORBEAM WAS FOUND WITH SEVERAL AREAS OF CORROSION ALONG ITS LENGTH. THE UPPER CAP WAS TRIMMED OFF ALONG THE ENTIRE BEAM LENGTH TO REMOVE ALL CORROSION. A NEW UPPER CAP WAS FABRICATED FROM AN ALUMINUM EXTRUSION AND INSTALLED PER ER/A 380597-14, REV A.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 53,432 hrs · 29,577 cycles

THE C1 DOOR OPENING LOWER SILL WAS FOUND BADLY CORRODED AND REQUIRES REPLACEMENT BETWEEN STRINGERS 25R & 26R. THE LOWER SECTIONS WERE TEMPORARILY REMOVED TO ALLOW INSTALLATION OF A NEW SILL CHORD. THE CHORD WAS SPLICED BACK WITH TWO ALUMINUM ANGLES AND THE WEB WITH AN ALUM DOUBLER PER ER/A 380663-14.

Part: SKIN — CRACKED (FUSLEAGE) · airframe 53,432 hrs · 29,577 cycles

WHILE ACCOMPLISHING A SKIN REINFORCEMENT MODIFICATION TO THE LOWER AFT VHF ANTENNA CUTOUT, AN EXISTING REPAIR DOUBLER WAS FOUND. THE EXISTING REPAIR WAS REMOVED AND THE CUTOUT AREA INCREASED TO 18 X 5.25 INCHES. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER AND TRIPLER PER ER/A 380619-14, REV A.

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 52,939 hrs · 29,350 cycles

AT 41000 FT LEFT OIL QTY DROPPED TO 0 WITH INCREASING OIL TEMP. OIL TEMP REACH YELLOW BAND, MAX TEMP 171.ENG WAS OPERATED AT IDLE AND DESCENDED TO 29000. OIL QTY AND TEMP RETURNED TO NORMAL AT 41000 FT. SCAVANGE PUMP PRES WAS 2 PSI. REPLACED GEARBOX SCAVANGE PUMP AND MAIN ENG LUBE/SCAVANGE PUMP. LEAK CKS GOOD. ALSO REPLACED SCAVANGE OIL PRES XMITTER AND NR 4 BEARING SCAVANGE VLV. RAN ENG PER M/M ALL INDICATIONS GOOD.

Part: ACTUATOR — MALFUNCTIONED (LE FLAP)

L/E SLAT DISAGREE LIGHT ILLUMINATED ON TAKEOFF. PERFORMED PROC PER POM. LIGHT REMAINED ILLUMINATED. FLAPS INDICATED A LITTLE LESS THAN 1 DEG. REPLACED NR 6 I/B AND O/B SLAT ACTUATORS.

Part: RETRACT MECH — MALFUNCTIONED (NLG DOOR)

ON GEAR RETRACTION HAD DOOR DISAGREE AND DOOR LIGHT REMAINED ON ACCOMPANIED BY WIND NOISE. ALSO HAD EICAS MESSAGE.

Part: CONTL MODULE — FAILED (LANDING GEAR)

GEAR FAILED TO RETRACT, GEAR HANDLE RAISED TO OFF POSITION AND WOULD NOT MOVE FURTHER. GEAR LIGHT AND GEAR DISAGREE MSG ILLUMINATED. FOLLWED POM PROCEDURE. RETURNED TO JFK. ON LANDING AIRCRAFT PULLED TO RIGHT. FOUND NR 3 BRAKE DRAGING REPLACED SAME. HAD FAULT CODES 421/422/423/424 ON PSEU. REPLACING LANDING GEAR CONTROL MODULE PER FIM PRIOR TO MTC, FERRY TO ATL.

Part: EEC — FAILED (NR 2 ENGINE)

ON DESCENT RT ENGINE ROLLED BACK TO IDLE AND STABILIZED, THEN ENGINE ROLLED BELOW IDG ONLINE SPEED. CREW ELECTED TO SHUTDOWN ENGINE. RT ENG PRI CONTROL STATUS MSG ON AND THE EPCS MESSAGE EEC P/EEC 275-16 275-19 PRESENT.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHT IN FIRST CLASS (SIDES OF SEATS) DO NOT ILLUMINATE. REPLACED BATTERY MODULE BASE.

Part: WIRE — FAILED (COCKPIT)

STRONG SMELL/FUMES LIKE ELECTRIC INSULATION BURNING DETECTED DURING APPROACH IN COCKPIT AND BY FLT ATTENDANT IN FWD GALLEY. REPLACED NOSE GEAR GREEN LIGHT IN COCKPIT AND REPAIRED ASSOCIATED WIRING.

Part: BULB — FAILED (CABIN)

RT FWD OVERWING EMERG EXT LT INOP. RELAMPE, OPN NORMAL.

Part: BULB — FAILED (CABIN)

RIGHT OVERWING ESCAPE PATH LIGHT FORWARD POSITION INOP. RELAMPED, OP CK GOOD.

Part: LIGHT — INOPERATIVE (CABIN)

THE 4L DOOR EXTERIOR EMERGENCY LIGHT INOP. RELAMPED AND REPLACED POWER SUPPLY, BOTH NO HELP. NEEDS NEW LIGHT ASSY. PLACED ON MAINTENANCE CARRY OVER.

Part: GUST LOCK COLLAR — BROKEN (L4 DOOR)

L-4 DOOR GUST LOCK COLLAR BROKEN. REPLACED GUST LOCK COLLAR, OPS CKS OK.

Part: LIGHT — DAMAGED (COCKPIT)

FROM CDL FIRST BULB CAPT SIDE EMERGENCY TRACK LIGHTING INOP. REPLACED PIGTAIL LIGHT, CKS GOOD.

Part: INDICATOR LIGHT — INOPERATIVE (3L DOOR SLIDE)

3L DOOR SLIDE INDICATOR LIGHT INOP. RELAMPED, OPS CK GOOD.

Part: FAN — FAILED (CARGO COMPT)

ELECT SMELL IN AIRCRAFT AND SHORTLY AFTER AN EQUIPMENT COOLING MESSAGE. REPLACED FAN, OPS CHECK GOOD.

Part: BULB — FAILED (CABIN)

LEFT AFT EXTERIOR EMERGENCY LIGHT FAILS TO LIGHT. RELAMPED LIGHT, CKS GOOD.

Part: SKIN — DELAMINATED (LT LE FLAP)

DURING INSPECTION, LEFT WING SLAT PANEL WAS FOUND WITH SKIN DELAMINATED AT THE INBOARD EDGE UNDER DOUBLER. REPAIRED PER SRM 51-70-10.