N637US

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT) · airframe 70,969 hrs · 9,533 cycles

DURING LINE CHECK, FOUND ZONE-A FLOOR PATH EMERGENCY LIGHTS INOPERATIVE. REPLACED EMERGENCY LIGHT BATTERY. OPERATIONAL CHECK GOOD.

Part: TERMINAL — BURNED (1L WINDOW) · airframe 70,240 hrs · 9,400 cycles

DURING CLIMB, A STRONG BURNING ODOR EMITTED FROM THE CAPTAIN'S L1 LOWER LEFT WINDOW HEAT ELECTRICAL CONNECTIONS. PLACED L1 IN OVERRIDE AND ODOR DISSIPATED. AIRCRAFT CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. REPLACED THE LEFT LOWER AND UPPER WINDOW HEAT TERMINALS ON L1 WINDOW AND REPLACED THE WINDOW HEAT CONTROLLER. OPERATIONAL CHECK GOOD.

Part: COFFEEMAKER — MALFUNCTIONED (GALLEY) · airframe 64,793 hrs · 8,567 cycles

DURING CRUISE, A BURNING SMELL EMITTED NEAR THE NR 3 GALLEY. DEACTIVATED THE NR 3 GALLEY, GASPER FAN AND RECIRCULATION FAN AND THE SMELL DISSIPATED. DECLARED AN EMERGENCY AND THE AIRCRAFT CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. REPLACED THE LEFT FORWARD COFFEEMAKER IN THE NR 3 GALLEY. OPERATIONAL CHECK GOOD.

Part: VIDEO UNIT — FAILED (CABIN) · airframe 63,865 hrs · 8,427 cycles

NR 2 VTR OVERHEATS AND SMELLS LIKE BURNING WIRE. FLIGHT CONTINUED TO NRT AND LANDED WITHOUT INCIDENT. REPLACED NR 2 VTR. OPERATIONAL CHECK OK.

Part: STRAP — CORRODED (BULKHEAD) · corrosion level 2 · airframe 58,029 hrs · 7,654 cycles

DURING M-CHECK FOUND CORROSION ON BULKHEAD SPLICE STRAP AT BS 400. REPAIRED PER EA 66-181942.

Part: STRINGER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 58,029 hrs · 7,654 cycles

DURING M-CHECK, FOUND CORROSION ON INBOARD VERTICAL SURFACE OF STRINGER AT STATION 2203, STR 51 L. REPAIRED PER EA 66-180581.

Part: KEELBEAM — DAMAGED (FUSELAGE) · airframe 58,029 hrs · 7,654 cycles

DURING M-CHECK FOUND DAMAGE TO LOWER KEEL BEAM AT STATION 1325, RBL 5. REPAIRED PER EA 66-180576.

Part: LIGHT — MALFUNCTIONED (CABIN) · airframe 57,370 hrs · 7,556 cycles

DURING OVERNIGHT MAINTENANCE LINE CHECK, FOUND ZONE A EMERGENCY LIGHTS ILLUMINATE UNCOMMANDED WHEN FLIGHT DECK SWITCH IS ARMED. MAINTENANCE REPAIRED BROKEN EMERGENCY LIGHTS WIRES AT DOOR 1L PER AMM 33-51-00. OPERATIONAL CHECK GOOD.

Part: FLOORBEAM — CRACKED (BS 700)

DURING PERIODIC CHECK, FOUND CRACK IN FORWARD CARGO FLOORBEAM UPPER 'T' CHORD FS 700, LBL 26. REPAIRED PER EA 66-171312.

Part: ROD — DISCONNECTED (RT MLG DOOR)

DURING CLIMB, THE RED DOOR OPEN AND GEAR LIGHTS REMAINED ILLUMINATED AFTER LANDING GEAR RETRACTION. RECYCLED LANDING GEAR AND LIGHTS REMAINED ILLUMINATED. AIRCRAFT DUMPED FUEL AND RETURNED TO HNL AND LANDED WITHOUT INCIDENT. RECONNECTED RIGHT WING LANDING GEAR DOOR SEQUENCE VALVE CONNECTING ROD, OPERATIONAL CHECK GOOD.

Part: SEAL — FAILED (NR 1 ENG GEARBOX)

WHILE IN CRUISE FLIGHT, THE NR 1 ENGINE OIL QUANTITY AND PRESSURE DROPPED. THE ENGINE WAS SHUT DOWN AND THE FLIGHT CONTINUED TO NRT WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE ACCESSORY GEARBOX CARBON SEALS FOR THE HYDRAULIC PUMP AND STARTER. SUBSEQUENT ENGINE RUN-UP FOUND NO LEAKS AND THE AIRCRAFT RETURNED TO SERVICE.

Part: PUMP — FAILED (NR 1 ENGINE)

WHILE IN CRUISE FLIGHT, THE NR 1 ENGINE OIL QUANTITY BEGAN TO DECREASE. THE ENGINE WAS SHUT DOWN WHEN THE INDICATED OIL QUANTITY WAS ONE-HALF GALLON. THE FLIGHT CONTINUED TO SIN AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE ENGINE OIL SCAVENGE PUMP AND RETURNED TO SERVICE.

Part: COMPRESSOR — STALLED (NR 4 ENGINE)

AFTER STARTING AND WITH ENGINE STABLE AT IDLE, THE NR 4 ENGINE COMPRESSOR STALLED. N1, N2, AND OIL PRESSURE DROPPED WITH EGT RISING TO 490 CELSIUS. SECOND START WAS NORMAL. MAINTENANCE RAN ENGINE WITH NO DEFECTS NOTED. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: COMPRESSOR — STALLED (NR 1 ENGINE)

AFTER STARTING AND WITH ENGINE STABLE AT IDLE, THE NR 1 ENGINE COMPRESSOR STALLED. N1, N2, AND OIL PRESSURE DECREASED WITH EGT RISING TO 490 CELSIUS. AFTER SECOND START, ENGINE OPERATION WAS NORMAL. MAINTENANCE RAN ENGINE WITH NO DEFECTS. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: FITTING — CRACKED (MID SPAR)

DURING PERIODIC CHECK, FOUND THE FORWARD LOWER INBOARD MIDSPAR FITTING CRACKED AT SECOND FROM AFT INBOARD FASTENER HOLE TO INBOARD EDGE OF FITTING. REPLACED FITTING. WORK COMPLETED ON CITEXT 66-5441-1-0088, FM 65 THROUGH FM 72 REPLACEMENT PROCEDURE, DRAWING NR SA5441-01048-7 AND SB 5441-01048-9.

Part: COUPLING — CRACKED (NR 1 ENGINE)

DURING TAKEOFF AND CLIMB, THE NR 1 ENGINE EPR AND N1 DROPPED AND THE FIRE LIGHT ILLUMINATED. SHUT DOWN NR 1 ENGINE AND RETURNED TO DTW. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. REPLACED THE 15TH STAGE COUPLING, HIGH STAGE VALVE, TWO DUCTS FORWARD OF HIGH PRESSURE VALVE, AND CLAMPS CONNECTING HIGH STAGE VALVE. OPERATIONAL CHECK GOOD.

Part: COMPRESSOR — STALLED (NR 3 ENGINE)

DURING INITIAL CLIMB, THE NR 3 ENGINE EXPERIENCED A COMPRESSOR STALL. THE ENGINE WAS SHUTDOWN AND RESTARTED. FLIGHT CONTINUED AND AT TOP OF DESCENT, THE NR 3 ENGINE STALLED AGAIN. HOWEVER, ENGINE SHUTDOWN WAS NOT ACCOMPLISHED. FLIGHT CONTINUED TO HKG WITHOUT FURTHER INCIDENT. MAINTENANCE PERFORMED BORESCOPE INSPECTION OF 8TH, 9TH, 15TH STAGES OF HPT AND 13TH STAGE OF OUTER SHROUD. NO DISCREPANCIES WERE FOUND. REPLACED EVBC AND ACCOMPLISHED PRECISION TRIM OF EVBC AND FCU.

Part: Y-DUCT — CRACKED (NR 3 PYLON)

DURING TAKEOFF, THE NR 3 FIRE WARNING LIGHT ILLUMINATED ACCOMPANIED BY HIGH NACELLE TEMPERATURE INDICATIONS. AIRCRAFT ABORTED TAKEOFF AND RETURNED TO GATE. FOUND CRACK IN Y-DUCT AT PYLON AREA. REPAIRED DUCT AND REPLACED HIGH STAGE VALVE AND CONTROLLER, OPERATIONAL CHECK GOOD.

Part: COMPRESSOR — STALLED (NR 2 ENGINE)

DURING CLIMB, THE NR 2 ENGINE EXPERIENCED A COMPRESSOR STALL. WITH NO SPIKE IN EGT AND ALL ENGINE INDICATIONS BEING NORMAL, CREW FOLLOWED COM PROCEDURES AND CONTINUED TO AMS WITHOUT FURTHER INCIDENT. BORESCOPE INSPECTION OF HIGH PRESSURE COMPRESSOR REVEALED NO DISCREPANCIES. EVBC REPLACEMENT AND PRECISION TRIM OF EVBC/FUEL CONTROL WILL BE DONE WITHIN FIVE CYCLES.

Part: BLEED VALVE — MALFUNCTIONED (NR 3 ENGINE)

DURING TAKEOFF THE NR 3 ENGINE EXPERIENCED A FIRE WARNING WITH THE NACELLE TEMPERATURES GOING INTO THE RED AND AT 115 KNOTS TAKEOFF WAS ABORTED. THE EGT HAD GONE TO 715 DEGREES FOR 15 SECONDS AND A BORESCOPE INSPECTION WAS PERFORMED. THE HIGH STAGE BLEED VALVE WAS FOUND PARTIALLY OPEN AND WAS LOCKED CLOSED. UNDER INVESTIGATION.

Part: INS — MALFUNCTIONED (E/E COMPARTMENT)

DURING CRUISE, THE NR 1 AND NR 2 INS RED WARNING LIGHT ILLUMINATED CONSECUTIVELY. CREW FOLLOWED COCKPIT OPERATING MANUAL AND DIVERTED FLIGHT TO ANC. MAINTENANCE REPLACED THE NR 1 INS AND PERFORMED CHECK, CHECK WAS NORMAL. THE NR 1 INS RED WARNING LIGHT ILLUMINATED. THE NR 2 INS DID NOT HAVE A PROBLEM. THE FLIGHT DIVERTED TO ANC, BECAUSE THE FLIGHT COULD NOT USE RUSSIAN AIRSPACE.