N615US

Part: SLIDE — RUPTURED (SERVICE DOOR) · airframe 94,403 hrs · 20,870 cycles

DURING ''L'' CHECK, DOOR 2R SLIDE SCHEDULED FOR CHANGE WAS DEPLOYED FOR NORMAL DEPLOYMENT TEST. SLIDE DEPLOYED AND OPERATED NORMALLY. AFTER AN ADDITIONAL (APPROXIMATELY) 30 MINUTES SLIDE RUPTURED AT UPPER TUBE SEAM AND PARTIALLY DEFLATED. REPLACED SLIDE.

Part: SLIDE — RUPTURED (PAX DOOR) · airframe 94,403 hrs · 20,870 cycles

DURING ''L'' CHECK, DOOR 1R SLIDE SCHEDULED FOR CHANGE WAS DEPLOYED FOR NORMAL DEPLOYMENT TEST. SLIDE DEPLOYED AND OPERATED NORMALLY. AFTER AN ADDITIONAL (APPROXIMATELY) 30 MINUTES SLIDE RUPTURED AT UPPER TUBE SEAM AND PARTIALLY DEFLATED. REPLACED SLIDE.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING CHECK, E ZONE FLOOR PATH EMERGENCY LIGHTS WOULD NOT TEST. REPLACED BATTERY PACK, OPERATIONAL CHECK GOOD.

Part: RETRACT MECH — MALFUNTIONED (NLG)

WHILE CHECKING FOR A HYDRAULIC LEAK, THE NOSE LANDING GEAR RETRACTED RESULTING IN DOOR 1L BECOMING DETACHED FROM THE FUSELAGE BY THE JETWAY. THE BOEING AOG TEAM WILL BEGIN THE REPAIR PROCESS ON 26AUG99. EXACT CAUSE OF EVENT TO BE DETERMINED.

Part: VIDIO PROJECTOR — FAILED (CABIN)

DURING CLIMB, FUMES EMITTED FROM THE FIRST CLASS GALLEY. TURNED OFF GALLEY POWER AND RETURNED TO NRT. AIRCRAFT LANDED WITHOUT INCIDENT. REPLACED FIRST CLASS VIDEO PROJECTOR, OPERATIONAL CHECK GOOD.

Part: LONGERON — CORRODED (BS 1880-1900)

DURING ARMAR, FOUND CORROSION ON STR 22R AT FS 1880 TO 1900. REPAIRED PER EA 66-153963.

Part: BEAM — CORRODED (BS 1248)

DURING M-CHECK, FOUND CORROSION ON UPPER SURFACE OF I-BEAM AT SLOPING PRESSURE DECK OF RIGHT MAIN LANDING GEAR WHEEL WELL FS 1248, RBL 102 TO 108. REPAIRED PER EA 66-153975.

Part: SKIN — CRACKED (BS 400)

DURING ARMAR, FOUND CRACK IN SKIN AT AFT CORNER OF NOSE LANDING GEAR WHEEL WELL FS 400. REPAIRED PER EA 66-152945.

Part: BULKHEAD — CRACKED (BS 140)

DURING ARMAR, FOUND CRACK IN OUTER RING AT BULKHEAD AT FS 140. REPAIRED PER EA 66-152946.

Part: FLOORBEAM — CRACKED (BS 460)

DURING ARMAR, FOUND CRACK IN UPPER DECK FLOORBEAM WEB FS 460, RBL 110, WL 300. REPAIRED PER EA 66-152673.

Part: EPR INDICATION — MALFUNCTIONED (NR 1 ENGINE)

WHEN FULL POWER WAS APPLIED AT TAKEOFF, THE NR 1 ENGINE ONLY INDICATED AN EPR OF 1.46. OTHER ENGINE INDICATIONS WERE NORMAL. TAKEOFF WAS ABORTED. MAINTENANCE VISUALLY CHECKED THE NR 1 ENGINE INLET AND EXHAUST WITH NO TROUBLE FOUND. THE NR 1 ENGINE EPR INDICATION WAS PLACED ON MEL 77-4. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: ENGINE — FAILED (NR 1)

ON CLIMBOUT, THE NR 1 ENGINE COMPRESSSOR STALLED WITH EPR DOWN TO 1.0 AND EGT IN RED. FOUR MINUTES LATER, ANOTHER STALL OCCURRED AND THE CREW SHUT THE ENGINE DOWN. DUMPED 120,000 LBS OF FUEL AND THE AIRCRAFT RETURNED TO MSP. MAINTENANCE INSPECTED THE ENGINE AND FOUND METAL IN THE TAILPIPE. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: CONNECTOR — DEFECTIVE (NR 1 ENGINE)

EN ROUTE, THE NR 1 ENIGNE OIL BYPASS FILTER LIGHT ILLUMINATED AT FL370. CREW FOLLOWED COM PROCEDURE, SHUT DOWN THE ENGINE AND FLIGHT CONTINUED TO NRT WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE ENGINE OIL FILTER AND A DEFECTIVE ELECTRICAL CONNECTOR D0013J AT HORIZONTAL ENGINE FIRE WALL. CHECK WAS NORMAL AND AIRCRAFT RETURNED TO SERVICE.

Part: SPAR WEB — CRACKED (WS 1087)

DURING P-CHECK, FOUND CRACKS AND CORROSION IN THE RIGHT WING FRONT SPAR WEB AT THE UPPER CHORD FSSI 1087. REPAIRED PER EA 66-106376.

Part: FUEL PUMP — FAILED (NR 4 ENGINE)

DURING DESCENT, THE NR 4 ENGINE ROLLED BACK TO IDLE WITH AUTO THROTTLE ON. CREW DECLARED AN EMERGENCY AS PRECAUTION AND MADE A THREE-ENGINE LANDING WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE FUEL FLOW PUMP AND FUEL CONTROL. PERFORMED LEAK AND OPERATIONAL CHECKS. CHECKS WERE NORMAL AND AIRCRAFT RETURNED TO SERVICE. PART TOTAL CYCLES, 9,858.

Part: DOOR — MISSING (AIR COND COMPT)

DURING DESCENT INTO NRT AT 15,000 FT, A LARGE BANG SOUND AND VIBRATION WAS EXPERIENCED. AFTER LANDING, FOUND THE NR 2 AIR CONDITION PACK ACCESS DOOR PANEL MISSING. ALSO, FOUND DAMAGE TO NR 3 AND NR 4 CANOE AND FUSELAGE PANEL 191KL. REPLACED THE NR 2 PACK DOOR AND NR 3 CANOE FORWARD FAIRING. REPAIRS MADE AS NECESSARY PER 51-40-09. AIRCRAFT RETURNED TO SERVICE.

Part: EPR INDICATION — MALFUNCTIONED (NR 4 ENGINE)

DURING TAKEOFF ROLL BELOW 60 KTS (TPE), THE NR 4 ENGINE HAD SLOW EPR RISE AND THE TAKEOFF WAS ABORTED. AN EPR CHECK BY THE CREW ON THE TAXIWAY CHECKED OK AND A NORMAL TAKEOFF WAS THEN MADE. THE ENGINE WAS INSPECTED. ALL SENSE LINES AND ELECTRICAL CONNECTORS WERE CHECKED AND FOUND TO BE OK.

Part: PANEL — CORRODED (WS 338)

DURING PERIODIC CHECK, FOUND THE LEFT WING LEADING EDGE UPPER WING FIBERGLASS PANEL CORRODED AT APPROXIMATELY ILES 338 AND GOING OUTBOARD APPROXIMATELY 24 INCHES OR TWO RIBS. INSTALLED NEW CHORD FROM BAC 1506-2664 EXTRUSION AND INSTALLED REPAIR.

Part: FRAME — CORRODED (FS 400)

DURING PRIODIC CHECK, THE FRAME INNER CHORD WAS FOUND CORRODED ON THE FRAME AT FS 400, STR 26L. THE FRAME INNER CHORD P/N 65B07936-327 IS MADE FROM 7075 EXTRUSION PER BAC 1506-2031. MADE REPAIR PER EA 66-97919.

Part: LONGERON — CRACKED (FS 460)

DURING PERIODIC CHECK, FOUND A CRACK IN SECTION 41 LOWER LOBE. CRACK IS LOCATED AT STR 28R, FS 460. REMOVED DAMAGED FLANGE, FABRICATED REPAIR, AND INSTALLED.

Part: ENGINE — FAILED (NR 1)

DURING CRUISE, A MIST WAS NOTED COMING FROM THE UNDERSIDE OF THE NR 1 ENGINE. THE AIRCRAFT RETURNED TO NRT. THE ENGINE WAS SHUT DOWN 15 MINUTES BEFORE LANDING. NO FUEL WAS DUMPED. THE GEARBOX SCAVENGE PUMP WAS REPLACED AND A RUN-UP SHOWED NO EVIDENCE OF ANY LEAKAGE. THE AIRCRAFT WAS POSITION FERRIED TO KIX AND AGAIN EXPERIENCED THE MIST. THE AIRCRAFT WAS FERRIED BACK TO NRT WHERE THE ENGINE WAS REPLACED.

Part: EVCB — MALFUNCTIONED (NR 4 ENGINE)

DURING TOP OF DESCENT FL410, THE NR 4 ENGINE EXPERIENCED A SURGE AND FLAMED-OUT. A RESTART AT FL340 WAS SUCCESSFUL AND OPERATION WAS NORMAL THE REMAINDER OF THE FLIGHT. THE ENGINE WAS INSPECTED, FUEL PRESSURES WERE CHECKED, AND A BORESCOPE WAS ACCOMPLISHED. THE EVBC WAS REPLACED, AND A PRECISION TRIM WAS ACCOMPLISHED. PROPER ENGINE OPERATION WAS CONFIRMED.