N643DL

Part: UNKNOWN — ODOR (CABIN) · airframe 79,930 hrs · 35,343 cycles

EXPERIENCED FUMES DURING CRUISE, F/A REPORTED FAINT PLASTIC BURNING ODOR AT ROW 42 RT. IAW MCC RT UTILITY BUSS WAS TURNED OFF AND WITHIN A FEW MINUTES THE ODOR WENT AWAY. RESET BREAKERS AND RAN SYSTEM FOR SEVERAL HOURS WITH NO TROUBLES FOUND. NO ODORS, FUMES, OR SMOKE. OK FOR SERVICE REF AMM 23-34.

Part: SUPPORT FITTING — CORRODED (RT MLG) · airframe 77,444 hrs · 34,415 cycles

THE CENTER MLG SUPPORT FITTING WAS FOUND CORRODED ON THE UPPER SURFACE OF THE LOWER RETENTION PIN LUG. REPAIRED IAW ERA 497084-14.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 77,280 hrs · 34,365 cycles

DURING LINE CHECK MAINTENANCE FOUND SEVERAL EMERGENCY LIGHTS IN AFT CABIN INOP. MAINTENANCE REPLACED BATTERIES ON M736 &M737 POWER SUPPLIES. EMERGENCY LIGHTS NOW CHECK OK PER MM 33-50.

Part: SUPPORT FITTING — CORRODED (LT MLG) · airframe 77,152 hrs · 34,324 cycles

CENTER MLG SUPPORT FITTING WAS FOUND CORRODED ON THE UPPER SURFACE OF THE LOWER RETENTION PIN LUG. REPAIRED IAW ERA 497305-14.

Part: SKIN — DENTED (BS 1500) · airframe 70,615 hrs · 31,932 cycles

MAINTENANCE FOUND A DENT ALONG THE FUSELAGE SKIN AT BS 1500 S28L. REPAIRED IAW ERA 477218-4.

Part: LINE — LEAKING (HYD SYSTEM) · airframe 68,849 hrs · 31,356 cycles

LOST LEFT HYDRAULIC SYSTEM PRESSURE AND SYSTEM FLUID ON TAKEOFF ROLL. FOUND STEERING LINE NOSE WHEEL WELL BURST. REPLACED LINE. FOUND NOSE STEERING LINE BURST. REPLACED SAME LINE WITH 000AE90-8D0322 PER ERA NO 414517-14, OPS AND LK CK OK.

Part: SILL — CORRODED (FUSELAGE) · airframe 67,336 hrs · 30,847 cycles

CORROSION WAS FOUND ON THE C1 DOOR CUTOUT LOWER SILL REQUIRING REPLACEMENT OF THE LOWER SILL OUTER CHORD. THE STA 620 FRAME WEB AND LOWER CHORD WERE ALSO CUT AND SPLICED. ER/A 06-382812-14 PROVIDES DETAILS OF THE REPAIR.

Part: SKIN — DENTED (BS 1621-1661) · airframe 65,395 hrs · 30,195 cycles

DURING HMV, SEVERAL DENTS AND TWO EXISTING SKIN REPAIRS WERE FOUND BETWEEN STA 1621 AND STA 1661, S19R TO S23R. THE DENTS AND EXISTING REPAIR DOUBLERS WERE REMOVED AND A SINGLE REPAIR WAS INSTALLED AND APPROVED BY BOEING VIA FAA FORM 8100-9 FOR STATIC STRENGTH. A DTA IS DUE WITHIN 12 MONTHS.

Part: SKIN — DENTED (BS 1690 S14R) · airframe 65,395 hrs · 30,195 cycles

DURING HMV, THE FUSELAGE SKIN AT STA 1690 BETWEEN S-14R AND S-15R WAS FOUND DENTED. THE DENT WAS CUT OUT AND REPAIRED PER BOEING INSTRUCTIONS.

Part: FITTING — DAMAGED (LT WING) · airframe 65,395 hrs · 30,195 cycles

DURING HMV AT SAA, TWO OF THE NR 1 ENGINE PYLON SIDE LOAD FITTING FASTENER HOLES WERE OVERSIZED TO CLEAN UP TOOLING DAMAGE. THE HOLES WERE REAMED UP TO TRANSITION FIT HOLE SIZES FOR OVERSIZE FASTENERS APPROVED BY BOEING.

Part: GATE — CORRODED (L2 DOOR) · airframe 65,395 hrs · 30,195 cycles

FOUND CORROSION ON LOWER GATE OF L2 DOOR. REPLACED GATE IAW MM 52-11-38.

Part: DOUBLER — CORRODED (BS 1530) · airframe 65,395 hrs · 30,195 cycles

CORROSION ON TRANSITION PANEL SPLICE DOUBLER STATION 1530 LT SIDE IS OUT OF LIMITS. REPAIRED DOUBLER IAW SRM 51-40-05 AND SRM 51-20-01.

Part: STRINGER — CORRODED (BS 1644-1654) · airframe 65,395 hrs · 30,195 cycles

STRINGER 520R REPAIR SPLICE AT STA 1644-1654 IS CORRODED SEVERAL PLACES WITH A MISDRILLED HOLE. FABRICATED SPLICE IAW SRM 51-10-02.

Part: PANEL — CORRODED (BS 620) · airframe 65,395 hrs · 30,195 cycles

CORROSION EXIST ON FWD CARGO RT CATWALK PANEL STA 620 RBL 29. REPLACED WITH FABRICATED PANEL IAW SRM 51-40-02.

Part: SLIDE — NO TEST (RT OFF WING) · airframe 65,395 hrs · 30,195 cycles

RIGHT OFF WING SLIDE FAILED OPS TEST FOR MANUAL DEPLOYMENT OF CARRIER. READJUSTED CARRIER HOOK LOCK AND PERFORMED OPS TEST FOR MANUAL DEPLOYMENT OF CARRIER IAW MM 25-65-08.

Part: FLOOR PANEL — CORRODED (CARGO BAY) · airframe 65,395 hrs · 30,195 cycles

FWD CARGO FLOOR PANEL 121BF HAS CORROSION ON UPPER AND LOWER SURFACE. FABRICATED FLOOR PANEL IAW SRM 51-20-01 AND INSTALLED IAW SRM 51-40-02.

Part: FLOORBEAM — DAMAGED (BS 329) · airframe 65,395 hrs · 30,195 cycles

MAIN CABIN FLOOR SUPPORT STA 329 RBL 23 HAS ELONGATED FASTENER HOLE. REFABRICATED FLOOR SUPPORT IAW DWGJ141N5150.

Part: SLIDE — NO TEST (LT OFF WING) · airframe 65,395 hrs · 30,195 cycles

LEFT OFF WING SLIDE FAILED AMNUAL BACK-UP SYSTEM TEST. REPLACED BOTTLE BACK-UP CABLE IAW MM 25-65-06.

Part: FLOOR PANEL — CORRODED (CARGO BAY) · airframe 65,395 hrs · 30,195 cycles

AFT CARGO FLOOR PANEL 153AF HAS CORROSION. FABRICATED FLOOR PANEL IAW SRM 53-60-53 FIG 1 AND INSTALLED.

Part: FLOOR SUPPORT — CORRODED (BS 1650-1670) · airframe 65,395 hrs · 30,195 cycles

CORROSION ON FLOOR SUPPORT AFT CABIN STA 1650-1670 RBL 60. REMOVED AND REPLACED SUPPORT IAW SRM 51-40-02.

Part: FLOOR PANEL — CORRODED (CARGO BAY) · airframe 65,395 hrs · 30,195 cycles

AFT CARGO PANEL 153CF CORRODED, PUNCTURED. FABRICATED PANEL IAW SRM 53-60-53.

Part: SILL — CORRODED (CARGO DOORWAY) · airframe 65,395 hrs · 30,195 cycles

CORROSION AROUND SEVERAL FASTENER HOLES AT AFT CARGO ENTRY DOOR LOWER SILL UPPER SURFACE. REMOVED CORR IAW SRM 51-10-02 AT AFT CARGO ENTRY DOOR LOWER SILL "T" CHORD. INSTALLED "T" CHORD IAW SRM 51-40-02.

Part: FLOOR PANEL — CORRODED (CARGO BAY) · airframe 65,395 hrs · 30,195 cycles

AFT CARGO FLOOR PANEL 161AF HAS CORROSION AND REPAIR DOUBLER BUCKLED. FABRICATED AND INSTALLED FLOOR PANEL IAW 53-60-53.

Part: FLOORBEAM — CORRODED (BS 1640) · airframe 65,395 hrs · 30,195 cycles

CORROSION ON MAIN CABIN FLOORBEAM STA 1640 RBL 2. REMOVED DAMAGE IAW SRM 53-00-51. FABRICATED AND INSTALLED BEAM IAW SRM 53-00-51.

Part: INTERCOSTAL — CORRODED (BS 1480-1500) · airframe 65,395 hrs · 30,195 cycles

AFT CARGO PIT WEB INTERCOSTAL BETWEEN STA 1480-1500 LBL 27 CORRODED. FABRICATED NEW INTERCOSTAL IAW SRM 53-60-04 AND INSTALLED IAW SRM 51-40-02.

Part: FRAME — CORRODED (BS 690) · airframe 65,395 hrs · 30,195 cycles

SURFACE CORROSION ON FRAME AT FS 690 RBL 13. FABRICATED "U" CHANNEL IAW B757 DRAWING 453N1853 AND SRM 51-70-11. INSTALLED IAW SRM 51-40-02.

Part: SPLICE — CORRODED (BS 1500) · airframe 65,395 hrs · 30,195 cycles

AFT CARGO PIT-STA 1500, LBL 28 HAS SEVERE CORROSION. REPAIRED IAW SRM 53-00-03 FIG 201 AND DRAWING NR 146N3110.

Part: FLOOR PANEL — CRACKED (CARGO BAY) · airframe 65,395 hrs · 30,195 cycles

FWD CARGO FLOOR PANEL 121BF CORRODED UPPER AND LOWER SURFACES AND CRACKED IN CUTOUT. REPAIRED IAW SRM 53-30-53 FIG/SHT 7 AND SRM 51-20-01.

Part: STRUCTURE — CORRODED (AFT CARGO) · airframe 65,395 hrs · 30,195 cycles

AFT CARGO PIT BS 1480, LBL 29; AREA CORRODED. REMOVED CORROSION IAW SRM 51-40-02, MEASURED AREA IAW NDTM PT 4, 51-00-00. CHECKED GOOD. TREATED AND PRIMED AREA IAW SRM 51-00-01.

Part: SEAT TRACK — CORRODED (BS 365-440) · airframe 65,395 hrs · 30,195 cycles

MAIN CABIN STA 365-440; SEAT TRACK AT RBL 24 HAS SECTION OF SEVERE COROSION. FABRICATED AND REPLACED SEAT TRACK SECTION IAW SRM 53-10-52.

Part: FLOOR SUPPORT — CORRODED (BS 1650-1670) · airframe 65,395 hrs · 30,195 cycles

CORROSION ON FLOOR SUPPORT AFT CABIN STA 1650-1670 RBL 60. FABRICATED AND REPLACED FLOOR SUPPORT IAW SRM 51-40-02.

Part: UNKNOWN — SMOKE (CABIN/COCKPIT) · airframe 61,923 hrs · 29,121 cycles

ON LAND ROLLOUT, SMOKE VISIBLE IN COCKPIT AND CABIN. POSSIBLE SULPHUR SMELL. ALSO NOTICED OUTSIDE A/C BY GROUND CONTROL. NO UNUSUAL ODOR NOTED. INSPECTED ENGS AND PACKS. RAN BOTH ENGINES WITH PACKS ON ALL OK.

Part: SKIN — BULGED (BS 437-440 S22L) · airframe 60,472 hrs · 28,591 cycles

THE SKIN IS BULGED FROM STA. 437-440 AND S-22L TO S-25L. THE DAMAGED SKIN WAS CUT OUT AND A REPAIR DOUBLER WAS INSTALLED.

Part: BATTERY — DISCHARGED (L1 DOOR) · airframe 58,097 hrs · 27,730 cycles

FOUND L1 CABIN EMERGENCY FLASHLIGHT CHARGE LOW. REPLACED FLASHLIGHT BATTERY.

Part: FUSE — FAILED (EMERGENCY LIGHT) · airframe 51,617 hrs · 25,433 cycles

SEATS 2-8 EMERGENCY LIGHTS INOP. REPLACED BAD FUSE.

Part: TIRE — DAMAGED (NLG) · airframe 49,374 hrs · 24,565 cycles

LT NOSE TIRE HAS FOD DAMAGE - REPLACED SAME

Part: RESERVOIR — DISCHARGED (L-1 DOOR) · airframe 49,244 hrs · 24,511 cycles

FOUND L1 DOOR ASSIST RESERVOIR LOW ON PRESSURE. SERVICED SAME.

Part: SKIN — DENTED (FS 1715, S-16L) · airframe 45,706 hrs · 22,846 cycles

FUSELAGE / SKIN / FS 1715.5 / STRG. 15L-17L : DENT CUTOUT REPAIR THE FUSELAGE SKIN WAS FOUND WITH 2 DENTS NEAR FS 1715.5 BETWEEN STRINGERS 15L & 17L. THE DENTS WERE REMOVED WITH CUTOUTS IN THE SKIN. THE 2 CUTOUTS WERE REPAIRED WITH A SINGLE EXTERNAL ALUMINUM DOUBLER PER ER/A 412647-14, REV A.

Part: SKIN — GOUGED (FUSELAGE) · airframe 45,705 hrs · 22,845 cycles

A LONG GOUGE WAS FOUND IN THE FUSELAGE SKIN BETWEEN FS 390 & 435 AND BETWEEN STRINGERS 14L & 15L. THE GOUGE WAS CUTOUT. THE CUTOUT WAS REPAIRED PER ER/A 382877-14, REV A.

Part: SILL — CORRODED (FUSELAGE) · airframe 45,705 hrs · 22,845 cycles

CORROSION WAS FOUND ON THE OUTER CHORD OF THE LOWER SILL BEAM OF THE C1 DOOR OPENING.

Part: SKIN — GOUGED (FUSELAGE) · airframe 45,705 hrs · 22,845 cycles

THE FUSELAGE SKIN WAS FOUND GOUGED AT FS 460 BETWEEN STRINGERS 16L & 17L. THE GOUGE WAS REMOVED AND REPAIRED WITH EXTERNAL DOUBLERS PER ER/A 382910-14.

Part: SPOILER — DAMAGED (WING) · airframe 45,549 hrs · 22,766 cycles

SPOILER WAS FOUND WITH ELONGATED HOLE IN THE OUTBOARD VERTICAL FLANGE COMMON TO THE SPAR. REPAIR PER ER/A 411144-14 AND NORDAM EWO E0037096.

Part: ODOR — DETECTED (FWD GALLEY) · airframe 44,531 hrs · 22,256 cycles

ELECTRICAL BURN ODOR COMING FROM FORWARD GALLEY. UTILITY BUSES TURNED OFF IN FLIGHT. RE-APPLIED POWER, FULLY LOADED GALLEY POWER. DEMAND OPS OK, NO FURTHER ODOR NOTED.

Part: LIGHT — INOPERATIVE (EXTERIOR) · airframe 43,625 hrs · 21,863 cycles

ON LAYOVER CK FOUND LT WING EXTERIOR EMER LIGHT INOP. RELAMPED SAME AND CKS GOOD.

Part: SIGN — BROKEN (CABIN) · airframe 42,909 hrs · 21,540 cycles

JUMPSEAT LFT AFT ENTRY DOOR 4L FOR MAINT ON EMERGENCY EXIT SIGN (SOCKET BROKEN). REPLACED EMERGENCY EXIT LIGHT ASSY, OPS CK GOOD.

Part: WIRE — BROKEN (CABIN) · airframe 42,738 hrs · 21,458 cycles

PAX SEAT 6CD EMERGENCY LITES INOPERATIVE. REPAIRED BROKEN WIRE

Part: CHIP DETECTOR — WORN (NR 2 ENGINE) · airframe 41,396 hrs · 20,836 cycles

IRR/ NR 2 ENG CHIP DETECTOR FELL OUT AT PUSHBACK/ENG START. CORR/ FOUND CHIP DETECTOR HOUSING WORN THROUGH BOSS. REPLACED DETECTOR ASSY. RAN ENG LK CK GOOD.

Part: AIR DIST — ODOR (COCKPIT)

FAINT ELECTRICAL ODOR IN THE COCKPIT DURING DESCENT. CREW REPORTED FAINT SMELL AT 15000FT AND DISAPPEARED BY 11000 FT. PULLED INST PNLS OUT. CHECKED C/B'S, NONE POPPED, RAN PACKS CHECKED RECIRC FAN. CHECKED OPS OF COCKPIT LTS. CHECKED E AND E COMPT, NO IND OF ELECTRICAL PROBLEMS OR ODORS NOTED. ALL COCKPIT IND NORMAL.

Part: COMPRESSOR — STALLED (NR 2 ENGINE)

ON DEPARTURE HAD SEVERAL ENGINE AUDIBLE COMPRESSOR STALLS ON THE RT ENG RPM FLUCTUATED 5 TO 6 PERCENT SEVERAL TIMES, THEN SETTLED AT NORMAL SETTING. BORESCOPED 12TH AND 13TH STAGE HPC PER FIM. FOUND 20, 12TH HPC BLADES WITH DAMAGE AND 21, 13TH STAGE BLADES DAMAGED OUT OF LIMITS PER M/M 72-00-00-6. ENG CHANGE IN PROGRESS.

Part: LIGHT — INOPERATIVE (CABIN)

PASSENGER SEAT 1B EMERGENCY TRACK LIGHTING. REPAIRED DAMAGE TRACK LIGHTING AND SECURED SAME.

Part: SKIN — CRACKED (NR 2 PYLON)

THE NR 2 PYLON OUTBD STRUT SKIN WAS FOUND WITH A CRACK IN THE UPPER FWD CORNER OF THE STRUT SKIN CUTOUT. THE CRACK WAS ROUTED OUT AND REPAIRED WITH A DOUBLER AND TRIPLER PER SRM 54-51-01-2, FIG 203. OVERSIZED FASTENERS WERE AUTHORIZED PER ER/A 365652-14, REV A.

Part: LIGHT — INOPERATIVE (CABIN)

L3 EMER SLIDE LT INOP. REPLACED SAME, CKS GOOD.

Part: SOCKET — FAILED (CABIN)

EMERGENCY TRACK LIGHTING SOCKET OUT OF HOLDER IN F/C AREA. REPLACED SOCKET, OPN NORMAL.

Part: OVEN — FAILED (MID GALLEY)

HOT ELECTRICAL SMELL IN MID GALLEY, SEEMS TO BE COMING FROM AFT FACING OVENS. PULLED C/BS NO SUBSEQUENT PROBLEMS. REPLACED MID GALLEY AFT FACING DOUBLE OVEN OPS OK. ALSO, INSPECTED ELECTRICAL CABLES TO OVEN, ALL OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHTS INOP AFT LT FLOOR PATH LIGHTS. REPLACED BATT PACK.

Part: PWR SUPPLY — INOPERATIVE (CABIN)

EMERGENCY LIGHTS INOP AFT LT DOOR AND AFT LT OVERHEAD. REPLACED BATTERY PACK AND PWR SUPPLY.

Part: HOSE — RUPTURED (NR 1 ENGINE)

LOST LEFT HYDRAULIC SYSTEM ON APPROACH, QUANITY WENT TO ZERO. FOUND ENGINE DRIVEN PUMP PRESSURE LINE RUPTURED. REPLACED LINE AND PUMP.