N605DL

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 87,141 hrs · 45,577 cycles

EMERGENCY EXIT LIGHTS EGRESS INOP. REMOVED AND REPLACED EGRESS BATTERY PACK. SYSTEMS OPERATIONAL CHECK SATISFACTORY. NO FURTHER DEFECTS NOTED. AIRCRAFT RELEASED TO SERVICE.

Part: STRINGER — CORRODED (BS 1390-1410) · airframe 86,490 hrs · 45,102 cycles

STRINGER 29L BETWEEN BS 1400 - 1410 HAS SEVERAL SPOTS OF CORROSION. REPAIRED THE STRINGER IAW SRM 53-60-12, REPAIR 1, FIGURE 201.

Part: STRINGER — CORRODED (BS 1410-1490) · airframe 86,490 hrs · 45,102 cycles

AFT EXTERNAL FUSELAGE AT BS 1455, STRINGER 29L HAS PULLED RIVETS AND EVIDENCE OF CORROSION. REMOVED AND REPLACED THE STRINGER IAW REA 47247FAB01 AND SRM 53-00-03 FIGURE 201 DETAIL 11.

Part: ATTACH BRACKET — CRACKED (BS 1660-1663) · airframe 86,490 hrs · 45,102 cycles

BRACKET CRACKED ON FORWARD SIDE OF COOLING FANS JUST AFT OF AND BELOW OUTFLOW VALVE. REMOVED AND REPLACED COOL FAN ATTACH BRACKET P/N 214N3057-3 USING 2024-T3 .080. P.O. #0089089 IN ACCORDANCE WITH BOEING DRAWING 214N3057 AND B757 SRM 51-40-02 PARAGRAPH 7.

Part: SKIN — CRACKED (FUSELAGE) · airframe 86,490 hrs · 45,102 cycles

AIRCRAFT GROUNDED FOR HEAVY MAINTENANCE. SKIN CRACKED AT STATION 1641 APPROXIMATELY 2" FROM RIVET HEAD TO FORWARD UPPER CORNER OF OUTFLOW VALVE CUTOUT. REPAIRED DAMAGED SKIN AND INTERNAL DOUBLER IN ACCORDANCE WITH ENGINEERING DOCUMENT REA 47247REA04.

Part: SHEAR TIE — CRACKED (BS 1640) · airframe 86,490 hrs · 45,102 cycles

SHEAR TIE CRACKED STATION 1640 BETWEEN STRINGER 24L - 25L. FOUND DURING EDDY CURRENT HOLE SCAN. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-40-02 PARAGRAPH 4 AND 7, DRAWING 140N7002 AND ENGINEERING DOCUMENT 7247REA04.

Part: SHEAR TIE — CORRODED (BS 1640) · corrosion level 2 · airframe 86,490 hrs · 45,102 cycles

SHEAR TIE CORRODED AT BS 1640 STRINGER 22 - 23L. REMOVED AND REPLACED SHEAR TIE IAW SRM 51-40-02 PARAGRAPH 4 AND 7, DRAWING 146N8711 AND ENGINEERING DOCUMENT 47247REA04.

Part: SHEAR TIE — CORRODED (BS 1640) · corrosion level 2 · airframe 86,490 hrs · 45,102 cycles

SHEAR TIE CORRODED AT BS 1640 STRINGER 23-24L. REMOVED AND REPLACED THE SHEAR TIE IAW SRM 51-40-02 PARAGRAPH 4 & 7, DRAWING 146N8711 AND ENGINEERING DOCUMENT REA47247REA04.

Part: SKIN — DEFORMED (BS 196) · airframe 86,490 hrs · 45,102 cycles

SKIN PANEL FORWARD OF RT WINDSCREEN JUST AFT OF RADOME HAS PREVIOUS DEFORMATION WITH INTERIM REMEDY. REPAIRED DEFORMED SKIN IAW REA 47247REA03 .

Part: BUSHING — WORN (ENTRY DOOR) · airframe 85,315 hrs · 44,395 cycles

MAIN ENTRY DOOR SAGGING AT TOP & STRIKING. NR 1 ROLLER LOCK APPEARS OUT OF ADJUSTMENT. FOUND SWING ARM BUSHING & BOLTS WORN & OUT OF RIG. R & R SWING ARM BUSHINGS & BOLTS IAW PRECISION MM 52-12-00. PERFORMED PRESS CHECK OF ACFT AMM 21-31-00. SYSTEMS CHECKED SATISFACTORY. ACFT RELEASED TO SERVICE.

Part: STOP FITTING — MISALIGNED (L1 DOOR) · airframe 84,840 hrs · 44,121 cycles

UPPER LATCH ROLLER STOP ON L1 DOOR MISALIGNED. REALIGNED L1 DOOR UPPER LATCH ROLLER STOP IAW AMM 52-11-00. OPERATIONAL CHECKED SATISFACTORY. NO FURTHER DEFECTS NOTED. ACFT RELEASED TO SERVICE.

Part: STRINGER — CORRODED (BS 1645-1695) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO STRINGER 18L HAS CORROSION, STA 1695. REPAIRED ON FAS NR 66474, W/O N605DL-01-01.

Part: CREASE BEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN STA 1580-1622, RBL 62 CREASE BEAM HAS CORROSION. REPAIRED ON FAS NR66383, W/O N605DL-01-01.

Part: STRINGER CLIP — CORRODED (ZONE 100) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO BS 1320, STRINGER CLIP HAS CORROSION S26L. REPLACED ON FAS NR 66486, W/O N605DL.

Part: SHEAR TIE — CORRODED (BS 1300) · corrosion level 2 · airframe 44,040 hrs

AFT CARGO STA 1300, LBL8 SHEAR TIE HAS CORROSION, REPLACED ON FAS NR 66435, W/O N605DL-01-01.

Part: FRAME — CORRODED (BS 1520) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO STA 1520 FRAME HAS CORRSION BETWEEN S27R AND S27L. REPLACED ON FAS NR 66455, W/O N605DL-01-01.

Part: STRINGER CLIP — CORRODED (ZONE 100) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO STA 1340, STRINGER CLIP HAS CORROSION S26L. REPLACED ON FAS NR 66483, W/O N605DL-01-01.

Part: SHEAR TIE — CORRODED (BS 1300) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO COMPARTMENT, STA 1300, FRAME SHEAR TIE CORRODED NEAR STRINGER 28L. REPLACED ON FAS NR 66740, W/O N605DL-01-01.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO S26L HAS CORROSION STA 1370. REPAIRED ON FAS NR 66482, W/O N605DL-01-01.

Part: STRINGER — CORRODED (BS 1335) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO STA 1335 S26L HAS CORROSION. REPAIRED ON FAS NR 66485, W/O N605DL-01-01.

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

RT W/W KEEL BEAM HAS CORROSION ON CHORD IN AFT INBD CORNER STA 1140-1180 BL0. REPAIRED ON FAS NR 66172, W/O N605DL-01-01.

Part: SEAT TRACK — DAMAGED (BS 900-1080) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

SEAT TRACK, RBL 45 BS 900-1080, HAS NUMEROUS LOCATIONS OF GOUGES AND CORROSION. REPLACED.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

SEAT TRACK, LBL 45, BS 1075-1180, HAS NUMEROUS LOCATIONS OF GOUGES AND CORROSION. REPLACED.

Part: SEAT TRACK — FAILED (ZONE 200) · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN BS 1320, RBL 48 SEAT TRACK HAS CORROSION. REPAIRED ON FAS NR 66387, W/O N605DL-01-01.

Part: SEAT TRACK — FAILED (ZONE 200) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN SEAT TRACK, RBL 45, BS 1080-1180, HAS NUMEROUS LOCATIONS OF GOUGES AND CORROSION. REPLACED ON FAS NR 66736, W/O N605DL-01-01.

Part: SEAT TRACK — CORRODED (BS 1075-1180) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN SEAT TRACK, RBL 25, STA 1075-1180 HAS NUMEROUS LOCATIONS OF GOUGES AND CORROSION. REPLACED ON FAS NR 66737, W/O N605DL-01-01.

Part: SHEAR TIE — CORRODED (BS 1360) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO BS 1360, LBL8 SHEAR TIE HAS CORROSION. REPLACED ON FAS NR 66439, W/O N605DL-01-01.

Part: SEAT TRACK — CRACKED (ZONE 200) · airframe 84,686 hrs · 44,040 cycles

FOUND CRACK SEAT TRACK AT RBL 24 AND BS 640 IN FWD CARGO COMPARTMENT. VIEW LOOKING UP IN FWD CARGO, REPLACED ON FAS NR 66622, W/O N605DL-01-01.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN SEAT TRACK HAS CORROSION RBL 48, BS 1538. THE SEAT TRACK WAS REPLACED.

Part: SEAT TRACK — CORRODED (BS 1180-1280) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN SEAT TRACK HAS CORROSION BS 1180 - 1200, LBL 48. THE SEAT TRACK WAS REPLACED.

Part: SHEAR TIE — CORRODED (ZONE 100) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

AFT CARGO BS 1460 AT S23R SHEAR TIE HAS CORROSION. THE SHEAR TIE WAS REPLACED.

Part: SEAT TRACK — CORRODED (ZONE 200) · corrosion level 2 · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN SEAT TRACK HAS CORROSION, BS 1180-1200, RBL 48. THE SEAT TRACK WAS REPLACED.

Part: SHEAR TIE — CRACKED (ZONE 200) · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN BS 1480 SHEAR TIE CRACKED AT S14L. THE SHEAR TIE WAS REPLACED.

Part: SHEAR TIE — CRACKED (ZONE 200) · airframe 84,686 hrs · 44,040 cycles

MAIN CABIN BS 1520, SHEAR TIE CRACKED AT STR 14L.

Part: UNKNOWN — UNKNOWN (CABIN PRESSURE) · airframe 82,965 hrs · 43,056 cycles

DURING CRUISE, AT FL370, CABIN ALTITUDE BEGAN TO CLIMB AT 800 FT PER MINUTE. SLOWED CLIMB RATE USING MANUAL. DESCENDED TO FL 330, CABIN ALTITUDE STABILIZED AND HELD IN AUTO. PRESSURIZED ACFT ON GROUND WITH NO LEAKS NOTED. SWAPPED POSITIONS OF THE NR 1 AND NR 2 AUTO PRESSURE CONTROLLERS IAW AMM 21-31-02. PRESSURIZED ACFT TO 7.9 PSI DIFFERENTIAL. PRESSURE WAS MAINTAINED FOR 25 MINUTES. PRESSURIZATION SYS OPS CHECKS GOOD ON THE GROUND.

Part: SEAL — LEAKING (MAIN CARGO DOOR) · airframe 82,960 hrs · 43,054 cycles

DURING CRUISE AT FL 390, MAIN DECK CARGO DOOR DEVELOPED A SQUEAL AND CABIN ALTITUDE BEGAN TO CLIMB. DESCENDED TO FL 330, DOOR STILL SQUEALED BUT CABIN ALTITUDE STABILIZED. PRESSURIZED ACFT TO 7 PSI DIFFERENTIAL AND FOUND SEAL ON MAIN CARGO DOOR LEAKING WHERE JOINED AT AFT LOWER CORNER. RESEALED JOINT IAW AMM 52-09-04. OPS CHECKED GOOD.

Part: SEAT TRACK — CRACKED (COCKPIT) · airframe 82,855 hrs · 42,960 cycles

F/O FORWARD OTBD SEAT TRACK CRACKED 0.50" AT FORWARD STOP. R & R F/O FORWARD OTBD SEAT TRACK IAW AMM 20-11-00.

Part: ANGLE — CORRODED (HORIZONTAL STAB) · airframe 82,855 hrs · 42,960 cycles

CORROSION WAS FOUND ON THE UPPER CHORD OF THE HORIZONTAL STABILIZER ON RIB NR 5 STA 128. DAMAGE WAS BLENDED TO A MAX OF .015" DEEP AND WAS BEYOND SRM LIMITS. REPAIRED DAMAGE IAW SRM 51-70-12.

Part: ATTACH ANGLE — CORRODED (HORIZTONTAL STAB) · airframe 82,855 hrs · 42,960 cycles

HORIZONTAL STABILIZER T/E PANEL ATTACHING FLANGE IS CORRODED IN SEVERAL AREAS BETWEEN THE RT STABILIZER STA 96 TO 200. REMOVED AREAS OF CORROSION FROM UPPER BEAM CAP IAW SRM 55-10-13, DETAIL II. PERFORMED HFEC INSPECTION OF THE BLENDED SURFACES IAW NDTM.

Part: ATTACH ANGLE — CORRODED (HORIZONTAL STAB) · airframe 82,855 hrs · 42,960 cycles

HORIZONTAL STABILIZER T/E PANEL ATTACHING FLANGE IS CORRODED AT THE RT STABILIZER STA 104. BLENDED, TREATED AND PAINTED CORROSION AREAS. REMOVED AND REINSTALLED T/E PANELS ON RT HORIZONTAL STABILIZER UPPER SURFACE IAW SRM 51-40-02.

Part: FRAME — CORRODED (BS 1460) · airframe 82,855 hrs · 42,960 cycles

TOP FLANGE OF FRAME IS CORRODED AT BS 1460 BETWEEN S26-27R. REPAIRED FRAME IAW SRM 53-00-07, REPAIR NR 5.

Part: FLOORBEAM — CORRODED (BS 1020) · airframe 82,855 hrs · 42,960 cycles

FLOORBEAM HAS CORROSION AROUND MULTIPLE FASTENER HOLES AT BS 1020 LBL 24.5 TO 45.5. REMOVED CORROSION FROM UPPER FLANGE AND FOUND TO BE OUT OF LIMITS. FABRICATED TWO REPAIR DOUBLERS IAW SRM 51-70-11, FIG 1 & DWG 114N5080. FABRICATED TWO FILLERS IAW SRM 51-70-11. PERFORMED DYE PENETRANT INSPECTION IAW SOPM 20-20-02. INSTALLED FILLERS AND DOUBLERS IAW SRM 51-40-02.

Part: COVER PLATE — CORRODED (BS 1020) · airframe 82,855 hrs · 42,960 cycles

CORROSION WAS DISCOVERED ON THE COVER PLATE COMMON TO A HAT SECTION INTERCOSTAL MEMBER AT BS 1020, LBL 0 TO LBL 24.5. CORROSION REMOVAL RENDERED THE COVER PLATE UNSERVICEABLE. FABRICATED COVER PLATE. CORROSION PROTECT AND APPLY SURFACE FINISH TO FABRICATED COVER PLATE IAW SRM 51-20-01. REINSTALLED IAW SRM 51-40-02.

Part: ANGLE — CRACKED (DOOR FRAME) · airframe 82,855 hrs · 42,960 cycles

TWO CRACKS IN THE INNER ANGLE OF THE AFT LOWER CARGO DOOR JAMB AT BS 1440 BY THE NR 6 DOOR STOP. FABRICATED THE CHORD SPLICE SECTION FROM 7075-T6511 EXTRUSION. ANNEAL AND FORM THE REPAIR SPLICE TO CONTOUR AND HEAT TREAT TO T-6. FABRICATED REPAIR WEB FROM 7075-T6 X .071" ALUMINUM CLAD. FINISH ALL BARE ALUMINUM PARTS WITH ALODINE AND PRIMER. HFEC INSPECT ALL OPEN HOLES IAW NDTM PART 6, 51-00-16. INSTALLED REPLACEMENT PARTS IAW AMES REPAIR DOCUMENT 47059 REA04 APPROVED BY FAA FORM 8100-9 DATED 16 JUL 2013.

Part: SAFETY VALVE — INOPERATIVE (RT MLG) · airframe 82,827 hrs · 42,951 cycles

EICAS MESSAGE "GEAR DOOR" AND RT MLG DOOR OPEN UPON TAXI IN. DURING TROUBLESHOOTING THE RT GEAR DOOR WILL NOT FULLY CLOSE USING THE COCKPIT GEAR HANDLE OR THE SECONDARY SWITCH ON THE FUSELAGE. THE LT MLG DOOR AND THE NLG DOOR BOTH FUNCTION CORRECTLY. R & R RT MAIN GEAR DOOR SAFETY VALVE IAW AMM 32-35-05. OPS AND LEAK CHECKS NORMAL IAW AMM 32-35-05. EICAS MESSAGE CLEARED.

Part: ACTUATOR — MALFUNCTIONED (MLG DOOR) · airframe 82,795 hrs · 42,929 cycles

EICAS MESSAGE GEAR DOOR DISPLAYED AND DOORS AMBER LIGHT ON WITH LANDING GEAR INDICATING DOWN. ACCOMPLISHED FIM PROCEDURE 32-30 FAULT TREE 803. R & R THE RT MLG DOOR ACTUATOR IAW AMM 32-32-12. THE RT MLG DOOR SEQUENCE VALVE IAW AMM 32-32-05, AND THE RT MLG INTERLOCK ACTUATOR IAW AMM 32-35-06. OPS CHECKED GOOD IAW AMM 32-35-06. JACKED ACFT IAW AMM 07-11-01 AND PERFORMED GEAR EXTENSION AND RETRACTION IAW AMM 32-32-00. NO DEFECTS NOTED. ACFT OK FOR CONTINUED SERVICE.

Part: WARNING LIGHT — FALSE ACTIVATION (MLG) · airframe 82,780 hrs · 42,917 cycles

EXTENSION AND RETRACTION: EICAS MESSAGE GEAR DOOR DISPLAYED AND DOORS AMBER LIGHT ON WITH LANDING GEAR INDICATING DOWN. CYCLED MAIN GEAR DOORS IAW AMM 32-12-00. NO EICAS MESSAGE PRESENT. MAIN GEAR DOORS OPERATE NORMALLY. NO DEFECTS NOTED.

Part: WARNING LIGHT — FALSE ACTIVATION (MLG) · airframe 82,747 hrs · 42,892 cycles

EXTENSION AND RETRACTION EICAS MESSAGE GEAR DOOR DISPLAYED AND DOORS AMBER LIGHT ON WITH LANDING GEAR INDICATING DOWN. RT GEAR DOOR ONLY. CYCLED MAIN GEAR DOORS IAW AMM 32-12-00. NO EICAS MESSAGE PRESENT. MAIN GEAR DOORS OPERATE NORMALLY ON THE GROUND. NO DEFECTS NOTED.

Part: SENSOR — LOOSE (CARGO DOOR) · airframe 82,556 hrs · 42,749 cycles

MAIN CARGO DOOR INDICATOR LIGHT ILLUMINATED ABOVE FLIGHT LEVEL 390. COMPLETED QRH CHECKLIST AND DESCENDED TO FL350. LIGHT WENT OUT. FOUND AFT LOCK SENSOR LOOSE. SECURED SENSOR AND OPS CHECK OF DOOR INDICATION IAW PRECISION CONTROLS MM 52-50-00. CYCLED DOOR 5 TIMES WITH NO DEFECTS FOUND.

Part: STRUCTURE — DAMAGED (NLG DOOR) · airframe 82,019 hrs · 42,367 cycles

TWO POSSIBLE LIGHTNING STRIKES IN DESCENT. COMPLIED WITH LIGHTNING STRIKE INSPECTION, FOUND DAMAGE TO RT FOWARD NLG DOOR. R & R RT FOWARD NLG DOOR.

Part: ADC — FAILED (E&E BAY) · airframe 81,583 hrs · 42,041 cycles

NO AIRSPEED INDICATION ON CAPTAINS SIDE. REJECTED TAKEOFF AT 85 KTS, RTO ENGAGED. FOUND LEFT ADC FAILED. REMOVED AND REPLACED AIR DATA COMPUTER (LEFT SIDE) IAW B757 AMM 34-12-01. PERFORMED OPS CHECK IAW AMM 34-12-00, SYSTEM CHECKS GOOD.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 81,037 hrs · 41,747 cycles

CORROSION ON MAIN CABIN SEAT TRACK FROM BS 900-1020 LBL 45. REPAIRED ON WO 22010, NR 37366.

Part: FLOORBEAM — CORRODED (ZONE 200) · corrosion level 2 · airframe 81,037 hrs · 41,747 cycles

AFT PIT CORROSION ON MAIN CABIN FLOORBEAM LOWER FLANGE BS 1560 FROM BL0 TO LBL25. REPAIRED ON WO 22020, NR 37688.

Part: WARNING LIGHT — FALSE ACTIVATION · airframe 80,615 hrs · 41,563 cycles

DURING TAKEOFF ROLL AT 70 KNOTS THE TAKEOFF WAS ABORTED DUE TO THE A TAKEOFF CONFIGURATION WARNING LIGHT ON EICAS. ACFT RETURNED TO THE BLOCKS WITHOUT INCIDENT. POST FLIGHT INSPECTION PERFORMED, RECYCLED SPOILERS AND PERFORMED TAKEOFF CONFIGURATION TEST. NO DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: STATIC PORT — OBSTRUCTED (AIRSPEED) · airframe 80,466 hrs · 41,420 cycles

DURING TAKEOFF ROLL THE CREW NOTED A NEGATIVE AIRSPEED INDICATION. THE TAKEOFF WAS ABORTED AND THE ACFT RETURNED TO BLOCKS WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED NOTING DEBRIS IN THE F/O'S STATIC PORT. REMOVED DEBRIS AND PERFORMED PITOT STATIC OPS CHECK GOOD. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: ADC — INOPERATIVE (ZONE 100) · airframe 80,466 hrs · 41,420 cycles

DURING TAKEOFF ROLL, THE F/O NOTED A NEGATIVE AIRSPEED INDICATION. AN ABORTED TAKEOFF WAS PERFORMED AND THE ACFT RETURNED TO THE BLOCKS WITHOUT INCIDENT. POST FLIGHT INSPECTION WAS PERFORMED NOTING THAT THE AIR DATA COMPUTER WAS AT FAULT. R & R THE AIR DATA COMPUTER AND PERFORMED OPS CHECKS. ACFT WAS RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 80,175 hrs · 41,208 cycles

WHILE PERFORMING A SCHEDULED INSPECTION OF THE AIRCRAFT, CORROSION WAS IDENTIFIED AT STRINGER 29R, STATION 1400. CORROSION WAS DETERMINED TO BE OUT OF LIMITS. REMOVED AND REPLACED STRINGER 29R AT STATION 1400 TO 1460. NO OTHER DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (HYD PUMP) · airframe 79,504 hrs · 40,674 cycles

DURING CRUISE OPERATION THE LT EDP HYD LOW PRESSURE LIGHT ON, EICAS MESSAGE DISPLAYED LT HYD ENG PUMP EICAS MESSAGE HYD SYS MAINT NOT DISPLAYED. THE ACFT RETURNED & LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED, REPAIRED WIRES W3586-3501-20, W33286-1029-20, W3386-2525-20 FROM PUMP LOW PRESSURE SWITCH CONNECTOR D-6240 OPS CHECK GOOD. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: ACTUATOR — FAULTY (MLG) · airframe 79,149 hrs · 40,528 cycles

DURING TAKEOFF UPON GEAR RETRACTION THE "GEAR DISAGREE" AND "GEAR DOORS" EICAS MESSAGE DISPLAYED AND THE "GEAR" AND "DOORS" LIGHT ILLUMINATED. THE ACFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED, THE RT MLG RETRACT ACTUATOR WAS DETERMINED TO BE AT FAULT. R & R ACTUATOR, PERFORMED OPS AND LEAK CHECKS GOOD. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: CONTROL MODULE — MALFUNCTIONED (SPOILERS) · airframe 78,804 hrs · 40,347 cycles

DURING CLIMB OPERATION THE SPOILER LIGHT ILLUMINATED , EICAS MSG "SPOILERS" DISPLAYED WITH SPOILERS SELECTED DOWN. ACFT RETURNED TO DEPARTURE WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED, PCA FAULT BALL ON MODULE 1L IN VIEW AND FAULT BALL ON MODULE 3R IN VIEW. PERFORMED FIM PROCEDURES, RESET SPOILER CONTROL MODULE, PERFORMED OPS CHECK GOOD. NO OTHER DEFECTS NOTED. ACFT WAS RETURNED TO SERVICE.

Part: EEC — MALFUNCTIONED (LT ENGINE) · airframe 78,691 hrs · 40,290 cycles

DURING TAKEOFF AT APPROX 700 FT A STATUS MESSAGES WAS DISPLAYED "PRIMARY (L) ENGINE CONTROL". THE ACFT RETURNED TO DEPARTUE, WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED. R & R THE NR 1 ENGINE EEC AND SWA. PERFORMED OPS CHECKS ALL CHECKS NORMAL. ACFT WAS RETURNED TO SERVICE.

Part: STRUCTURE — CRACKED (LT AILERON) · airframe 78,691 hrs · 40,290 cycles

DURING A HEAVY MX INSP EVENT THE LT AILERON LOWER T/E WAS FOUND CRACKED AND GOUGED BETWEEN THE PCA'S. REPAIRED DAMAGE WITH A COMPOSITE LAY UP. ITEM WAS RETURNED TO SERVICE.

Part: KEELBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 78,691 hrs · 40,289 cycles

DURING A HEAVY MX INSP EVENT FOUND CORROSION ON THE KEELBEAM ANGLE IN THE RT WHEEL WELL. REMOVED CORROSION AND WAS OUT OF LIMITS. FABRICATED REPAIR DOUBLERS AND INSTALLED. ITEM WAS RETURNED TO SERVICE.

Part: FITTING — CORRODED (ZONE 100) · corrosion level 2 · airframe 78,691 hrs · 40,290 cycles

DURING A HEAVY MX INSP EVENT FOUND A CORRODED FITTING AT THE FLC DOOR THRESHOLD LOWER/AFT CORNER BEHIND SEAL RETAINER. R & R FITTING, ITEM RETURNED TO SERVICE.

Part: SUPPORT BRACKET — CRACKED (NR 10 SLAT) · airframe 78,691 hrs · 40,289 cycles

DURING A HEAVY MX INSP EVENT FOUND NR10 SLAT TRACK DOOR OTBD SUPPORT BRACKET CRACKED. R & R SLAT SUPPORT BRACKET AND ADJUSTED FOR CLEARANCE. ITEM RETURNED TO SERVICE.

Part: STRINGER — CORRODED (ZONE 200) · airframe 78,691 hrs · 40,289 cycles

DURING A HEAVY MAINTENANCE INSPECTION EVENT,FOUND FUSELAGE SKIN BULGING. FOUND TO BE STRINGER 28L AT STA. 1495 APPROX 1 INCH CORRODED. REPLACED STRINGER FROM STATION 1450 TO 1510. FUSELAGE SKIN WAS FOUND TO HAVE NO CORROSION. ITEM RETURNED TO SERVICE

Part: DOUBLER — CORRODED (ZONE 100) · corrosion level 2 · airframe 78,691 hrs · 40,290 cycles

DURING A HEAVY MX INSP EVENT FOUND ANTENNA DOUBLER BULGING FWD RT CORNER AT FS 720. FOUND ANTENNA DOUBLER TO BE CORRODED. R & R SKIN DOUBLER IAW REA. ITEM WAS RETURNED TO SERVICE.

Part: FAN BLADE — DAMAGED (NR 1 ENGINE) · airframe 78,141 hrs · 40,029 cycles

DURING TAKEOFF, ACFT ENCOUNTERED A BIRD STRIKE, TAKEOFF WAS ABORTED. POST FLIGHT INSP WAS PERFORMED NOTING THAT THE NR 1 ENGINE HAD DAMAGED FAN BLADES. R & R (5) EA SETS OF FAN BLADES. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: FUEL SYS — OUT OF BALANCE · airframe 78,013 hrs · 39,960 cycles

FLT 201 FROM MIA TO CCS, DURING CRUISE OPERATION THE FUEL CONFIGURATION LIGHT ILLUMINATED NOTING A FUEL IMBALANCE BETWEEN THE LEFT AND RIGHT FUEL TANKS. THE AIRCRAFT DIVERTED TO SDQ WHERE AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. THE RIGHT FUEL QTY WAS PREVIOUSLY PLACED ON MEL. POST FLIGHT INSPECTION WAS PERFORMED, NO EXTERNAL LEAKS WERE NOTED AND FUEL DISTRIBUTION SYSTEM OPS CHECKED NORMAL. AIRCRAFT WAS FUELED TO KNOWN QTY. NO OTHER DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: EEC — MALFUNCTIONED (ZONE 500) · airframe 76,854 hrs · 39,367 cycles

DURING CRUISE OPERATION AT FL390 THE LT ENG SHUTDOWN ON ITS OWN. THE ACFT DECLARED AN EMERGENCY AND DIVERTED WHERE IT LANDED WITHOUT INCIDENT. POST FLIGHT INSP WAS PERFORMED, INSPECTED CONNECTOR AT RVA D5536, TLR D4734, FCU 4860, SVA 4868, EEC D502, D4554, NO DEFECTS FOUND IAW EICAS MSG 5273-22, REMOVED AND REPLACED EEC, OPS CHECK GOOD. NO OTHER DEFECTS WERE NOTED. ACFT WAS RETURNED TO SERVICE.

Part: WINDOW — FAILED (ZONE 200) · airframe 76,078 hrs · 38,957 cycles

FLT 5001 FROM MIA TO PTY - DURING CRUISE OPERATION THE L1 WINDOW SHATTERED. THE AIRCRAFT LANDED WITHOUT INCIDENT IN PTY. THE L1 WINDOW WAS REMOVED AND REPLACED, OPS CHECK GOOD. NO OTHER DEFECTS WERE NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNKNOWN — UNKNOWN (NR 1 ENGINE) · airframe 74,374 hrs · 38,206 cycles

PER THE CREW, AT CRUISE ALTITUDE, 380 LEFT ENGINE ROLLED BACK AND QUIT. CREW TRIED TO IN-FLIGHT START WITH NO JOY. REPLACED FUEL CONTROL AND FUEL PUMP PER MM. REPLACED EEC PE MM. INSPECTED PMG WIRING AND CONNECTORS. INSPECTED AND BLEW OUT PB SENSE LINE. NO PROBLEMS NOTED. LEAK CK GOOD. RAN ENG PER MM.

Part: A/C PACK — MALFUNCTIONED (RIGHT) · airframe 72,721 hrs · 37,469 cycles

IN FLIGHT, THE RIGHT PACK WAS UNABLE TO PRESSURIZE A/C. THE LT PACK WAS ON MCO. CHECKED NR 1 AND NR 2 CABIN PRESSURE CONTROLLER BOTH CK GOOD. CHECKED ALL DOOR SEALS AND OUTFLOW VALVE. AFTER LT ACM CHANGE PRESSURIZED A/C TO 5 PSID WITH APU NO LEAKS NOTED.

Part: FLOORBEAM — CORRODED (BS 1681) · airframe 71,238 hrs · 36,794 cycles

THE STA 1681.8 FLOORBEAM WAS FOUND CORRODED BEYOND SRM LIMITS AT SEVERAL LOCATIONS ON THE UPPER CAP. CUT OFF THE DAMAGED UPPER CAP AND REPLACED IT WITH A NEW TEECAP SECTION.

Part: SKIN — CRACKED (FUSELAGE) · airframe 63,181 hrs · 33,710 cycles

INSPECTION OF THE FWD UPPER CORNER OF THE L1 DOOR CUTOUT PER AD 2004-09-32, REVEALED A SMALL CRACK IN THE SKIN. THE CRACK WAS REMOVED WITH A 1 INCH CUTOUT AND REPAIRED WITH TWO EXTERNAL ALUMINUM REPAIR DOUBLERS PER ER/A 091537-14AD, REV A.

Part: WEDGE — DENTED (NR 1 SLAT) · airframe 61,855 hrs · 33,202 cycles

NR 1 SLAT TRAILING EDGE WEDGE DENTED 50 INCHES FROM I/B END. REPAIRED PER SRM 51-70-10.

Part: SKIN — DENTED (FUSELAGE) · airframe 57,314 hrs · 31,199 cycles

THE FUSELAGE SKIN WAS FOUND DENTED AT FS 1624 ABOVE STRINGER 18L. THE DENT WAS REMOVED WITH A CUTOUT AND REPAIRED WITH AN EXTERNAL DOUBLER PER ER/A 383531 -14, REV A.

Part: SILL — CORRODED (FUSELAGE) · airframe 57,314 hrs · 31,199 cycles

CORROSION FOUND ON THE C2 DOOR LOWER SILL WHICH REQUIRES REPLACEMENT OF OUTER CHORD. REPLACEMENT OF CHORD REQUIRES SPLICE OF THE STA 1440 FRAME OUTER CHORD AND WEB. CORRECTIVE ACTION, ER/A 383444-14 R.B.

Part: SKIN — CORRODED (FUSELAGE) · airframe 57,151 hrs · 31,109 cycles

WHILE ACCOMPLISHING A REINFORCEMENT MODIFICATION TO THE AFT VHF ANTENNA CUTOUT AT FS 1473 AND RBL 3.2 AND EXISTING REPAIR DOUBLER WAS REMOVED. THE NEW CUTOUT WAS REPAIRED WITH 2 EXTERNAL DOUBLERS PER ER/A 383467-14, REV A.

Part: TIRE — SEPARATED (RT NLG) · airframe 56,726 hrs · 30,929 cycles

ON L/O, FOUND RT NLG TREAD SEPARATED. REPLACED RT NLG WHEEL ASSY PER M/M.

Part: IDG — FAULTY (NR 2 ENGINE) · airframe 53,386 hrs · 29,359 cycles

AT ROTATION LOST RT GEN AND ASSOCIATED HYD. T/S PER FIM. RPLCD RT GCU & RT IDG PER M/M. IDG LK CKS OK RAN RT ENG, GEN WILL NOT PICK UP BUS. BITE CKD BPCU, FAULT OPEN PHASE TRIP MAIN BUS. IDG NEEDS DISCONNECT TEST. RPLCD BUS PWR CTL UNIT, RAN ENG, CONNECTED & RAN GEN. LOAD CKS OK.DISCONNECTED GEN & RECONNECTED SAME & LOAD CKS OK.

Part: SWITCH — SHORTED (COCKPIT)

WHEN FWD LAV OCCUPIED LIGHT ON PILOT OVRHD PANEL IS PRESS TO TEST, IT CREATES SPARKS. REPLACED LAV OCCUPIED SWITCH LIGHT, CK'S GOOD.

Part: DOOR STRAP — OUT OF POSITION (3R DOOR)

AFTER T/O, F/A ADVISED A LOUD NOISE AT 3R DOOR. FOUND DOOR OPEN SAFETY STRAP OUTSIDE OF DOOR SEAL. REPOSITIONED SAFETY STRAP, CKED OUTSIDE OF DOOR AND FOUND PAINT WORN ON DOOR. FWD PAINT TO MCO.

Part: HOSE — CRACKED (LT MLG GEAR)

ON TAKEOFF, GEAR HANDLE WOULD NOT GO TO THE UP POSITION, USED LOCK OVERIDE TO GET GEAR UP AND FLIGHT RETURNED ATL. FOUND LEFT TRUCK POS HYD HOSE CRACKED. REPLACED HOSE AND OPERATION NORMAL.

Part: TE WEDGE — DELAMINATED (NR 3 LE SLAT)

DURING A SHOP INSPECTION, THE TRAILING EDGE WEDGE WAS FOUND TO BE DELAMINATED. A NEW WEDGE WAS INSTALLED PER SRM 57-42-02, ON NR 3 L/E SLAP PANEL.