N645US

Part: SKIN — CRACKED (BS 727D) · airframe 73,385 hrs · 73,385 cycles

LBS 727D & LBS 727E, S-22L AND S-23L CRACKED. INSTALLED DOUBLER IAW BOEING SRM 53-00-01 FIG 201. DEFECT SIZE: 2 EACH CRACKS, 1.45 INCH AND 1 EACH CRACK 1.75 INCH.

Part: MODULE — FAULTY (TE FLAPS)

PHL FLT 564 EN-ROUTE PHL TO GLA - AFTER TAKE-OFF, FLAPS WOULD NOT RETRACT PAST 1 UNIT WITH THE FLAP HANDLE IN THE UP POSITION. EICAS STATUS MESSAGE, "FLAP/SLAT ELEC", WAS INDICATED. THE FLIGHT RETURNED TO PHL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE FLAPS AND STABILIZER POSITION MODULE. OPERATIONALLY CHECKS OK.

Part: FCU — FAULTY (TE FLAPS)

PHL - FLT 564 - EN ROUTE, PHL TO GLA - AFTER TAKEOFF, FLAPS WOULD NOT RETRACT PAST 1 UNIT WITH THE FLAP HANDLE IN THE UP POSITION. EICAS STATUS MESSAGE, "FLAP/SLAT ELEC", WAS INDICATED. THE FLIGHT RETURNED TO PHL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE FLAP SLAT ELECTRONIC UNIT. OPERATIONALLY CHECKS OK.

Part: WARNING LIGHT — ILLUMINATED (E/E BAY)

ENROUTE, THE FORWARD EQUIPMENT COOLING LIGHT ILLUMINATED AND WOULD NOT EXTINGUISH IN THE STANDBY MODE. FLIGHT DIVERTED AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE PERFORMED GROUND AND FLIGHT MODE TESTS OF THE EQUIPMENT COOLING SYSTEM AND COULD NOT DUPLICATE THE PROBLEM. THE AIRCRAFT WAS RELEASED FOR SERVICE.

Part: WIRE — LOOSE (EMERGENCY LIGHT)

CDG - FOUND FLOOR EMERGENCY LIGHTS FROM ROW 9 TO ROW 17, LEFT SIDE, INOPERATIVE. MAINTENANCE FOUND A LOOSE CONNECTION BETWEEN ROWS 9 AND 10 AND SECURED IT. (M)

Part: WIRE — INOPERATIVE (EMERGENCY LIGHT)

FOUND L1 DOOR EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE REPAIRED BROKEN WIRE W832-009016. (M)

Part: FLOORBEAM — CORRODED (FUSELAGE)

TOP OF FLOORBEAM, STA 287, RBL 26, RBL53 CORROSION (3 AREAS). INSTALLED CAP IN FLOORBEAM IAW SRM 53-00-51, FIG 201.

Part: ATTACH ANGLE — CRACKED (FUSELAGE)

FWD CABIN FLOOR UPPER ATTACH ANGLE, WEB STA 287-303, RBL 40, CRACKED. FABRICATED NEW ANGLE AND FILLER AND INSTALLED IAW SRM 51-10-02.

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHTS)

CLT - FOUND THE EMERGENCY LIGHTS IN FORWARD CABIN INOPERATIVE. MAINTENANCE REPLACED THE BATTERY. OPERATIONAL CHECK GOOD. (M)

Part: POWER SUPPLY — FAULTY (SLAT SYSTEM)

AFTER TAKEOFF, CREW RECEIVED THE EICAS MESSAGE 'LE SLAT DISAGREE' AND THE ASSOCIATED LIGHT. FLIGHT RETURNED TO PHL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE PERFORMED A BITE OF THE FSCU AND PSEU. NO PROBLEMS WERE FOUND. THE AIRCRAFT WAS RELEASED FOR FLIGHT. (M)

Part: SLAT — MALFUNCTIONED (WINGS)

PIT - FLT 740 - ON CLIMB-OUT FROM PIT, AT 3,500 FEET, CREW RECEIVED A LEADING EDGE SLAT DISAGREE EICAS MESSAGE AND A LEADING EDGE LIGHT WITH FLAP HANDLE AT ZERO POSITION. CREW DECLARED AN EMERGENCY AND RETURNED TO FIELD AT PIT. ON FLAP EXTENSION, CREW REPORTED AN UNUSUAL BINDING NOISE. FLIGHT LANDED WITHOUT FURTHER INCIDENT. AIRCRAFT WAS MAINTENANCE FERRIED FROM PIT TO PHL. FLIGHT CREW REPORTED NO FAULTS WITH LEADING EDGE SLATS DISAGREEMENT. MAINTENANCE PERFORMED FIM PROCEDURES 27-51-00/101-104 AND 27-81-00/101-104. NO FAULTS DETECTED. ALSO, PERFORMED VISUAL INSPECTION OF LEADING EDGE SLATS AND CYCLED SLATS/FLAPS NUMEROUS TIMES. ALL CHECKS NORMAL. (M)

Part: WIRE — CUT (CABIN)

CDG - FOUND RIGHT AISLE EMERGENCY LIGHT BETWEEN ENVOY CLASS AND COACH INOPERATIVE. WIRE WAS CUT/DISCONNECTED. MAINTENANCE SPLICED THE WIRE. (M)

Part: TERMINAL — BROKEN (RT ENGINE)

PHL - FLT 740 - EN ROUTE PIT-LGW, CREW RECEIVED THE EICAS MESSAGE 'R ENG HPSOV'. FLIGHT DIVERTED TO PHL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND THE NR 1 TERMINAL ON THE HPSOV BROKEN. THE WIRING WAS REPAIRED. (M)

Part: CONNECTOR — DEFORMED (ESCAPE SLIDE)

DURING AN OPERATIONAL CHECK OF THE RIGHT OVERWING SLIDE (AIRCRAFT IS IN A HEAVY MAINTENANCE VISIT), THE SLIDE DID NOT DEPLOY NORMALLY DUE TO THE FAILURE OF THE INBOARD SPOILER TO RETRACT. MAINTENANCE FOUND TWO BENT PINS IN THE CONNECTOR FOR THE SPOILER OVERRIDE SQUIB. THE PINS WERE BENT AS A RESULT OF IMPROPER INSTALLATION OF A BLANKING PLUG. A CHANGE HAS BEEN SUBMITTED TO THE MAINTENANCE PROGRAM CARD TO CAUTION MECHANICS CONCERNING THE INSTALLATION AND REMOVAL OF THE BLANKING PLUG. THE AIRCRAFT IS PROGRAMMED FOR REPAIR AND OPERATIONAL RETEST OF THE OVERWING SLIDE.

Part: CONTACTOR — LOOSE (CABIN)

PHL - FOUND FLOOR EMERGENCY LIGHT INOPERATIVE AT ROW 24. MAINTENANCE RESECURED A LOOSE CONNECTION. (M)

Part: PANEL — FAULTY (COCKPIT)

PHL - FLT 192 - EN ROUTE CLT-FRA, THE INTERIOR EMERGENCY LIGHTS ILLUMINATED AND COULD NOT BE TURNED OFF. THE LIGHTS ALSO VARIED IN INTENSITY FROM VERY BRIGHT TO DIM. THE FLIGHT DIVERTED TO PHL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE EMERGENCY LIGHT CONTROL PANEL. (M)

Part: WIRE — SHORTED (CABIN)

PHL - FLT 11 - EMERGENCY EXIT LIGHTS ILLUMINATED IN FLIGHT. MAINTENANCE REPAIRED A WIRE AT SEAT ROW 30 WHICH WAS SHORTING TO GROUND. (M)

Part: CHARGER — INOPERATIVE (CABIN)

SFO - THE RIGHT EXTERIOR EMERGENCY LIGHTS ILLUMINATED WHEN THE SWITCH WAS PLACED IN THE ARMED POSITION. MAINTENANCE REPLACED THE BATTERY CHARGER. (M)

Part: LIGHT — INOPERATIVE (COCKPIT)

CLT - FOUND COCKPIT EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE REPLACED THE LIGHT ASSEMBLY. (M)

Part: FSEU — FAULTY (E/E BAY)

PHL - FLT 196 - CLIMBING THROUGH 18,000 FEET, CREW RECEIVED AN INTERMITTENT LEADING EDGE SLAT DISAGREE LIGHT. THE CREW DECIDED TO RETURN TO PHL. WHILE ON APPROACH, THE CREW RECEIVED THE EICAS MESSAGE 'FLAP/SLAT ELEC'. MAINTENANCE REPLACED THE FSEU. (X)

Part: PUMP — FAILED (FUEL BOOST)

CLT - FLT 855 - EN ROUTE TO JAX, WITH THE RIGHT FORWARD FUEL BOOST PUMP ON MEL, CREW RECEIVED INDICATIONS OF LOW PRESSURE ON THE LEFT FORWARD BOOST PUMP. FLIGHT RETURNED TO CLT AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE RIGHT FORWARD BOOST PUMP PRESSURE SWITCH AND THE LEFT FORWARD BOOST PUMP. (M)

Part: IDG — LEAKING (COCKPIT)

PIT - FLT 48 - AFTER TAKEOFF FROM PIT, CREW RECEIVED A FLICKERING E/M 'R GEN DRIVE' AND THE ASSOCIATED LIGHT. FLIGHT RETURNED TO PIT AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED A LEAKING IDG SERVICE FITTING. (M)

Part: SEAT TRACK — CORRODED (BS 1310)

CLT - DURING Q-4 CHECK VISUAL INSPECTION, FOUND 1 INCH BY 1 INCH AREA OF CORROSION BS 1310, RBBL 88.5 SEAT TRACK INST. SEAT TRACK REPLACED PER EA 62977. (M)

Part: HINGE — BROKEN (SLIDE DOOR)

PIT - ON WALK AROUND, MECHANIC FOUND RIGHT OVERWING SLIDE DOOR NOT FAIRED. MAINTENANCE REPLACED TWO BROKEN HINGES ON SLIDE DOOR. (M)

Part: LIGHT — INOPERATIVE (CABIN)

PIT - FOUND THE LOW LEVEL EMERGENCY LIGHTING INOPERATIVE FROM ROW 5R TO ROW 11R. MAINTENANCE FOUND THE WIRING DISCONNECTED AT ROW 12 AND RECONNECTED IT. (M)

Part: EICAS — MALFUNCTIONED (E/E BAY)

PHL - FLT 12 - AFTER TAKEOFF FROM PHL, CREW RECEIVED THE EICAS MESSAGE 'FLAP/SLAT ELEC'. CREW CONTACTED MAINTENANCE ON GROUND AND DECIDED TO RETURN TO PHL RATHER THAN FACE MAINTENANCE PROBLEMS IN MAD. FLIGHT LANDED WITH NO FURTHER INCIDENT. MAINTENANCE PERFORMED A BITE CHECK OF THE SYSTEM AND CYCLED THE FLAPS. NO PROBLEMS WERE FOUND. (M)

Part: HPSOV — FAULTY (RT ENGINE)

PHL - FLT 894 - EN ROUTE PHL-FRA - CREW RECEIVED THE EICAS MESSAGE 'R ENG HPSOV' AND ASSOCIATED BLEED LIGHT. THE RIGHT ENGIEN PRESSURE WAS LOW. CREW ALSO HAD NO RIGHT ENGINE ANTI-ICE. FLT RETURNED TO PHL AND LANDED WITH NO FURTHER INCIDENT. MX REPLACED TEH RT ENGINE HIGH PRESSUR SHUTOFF VALVE. (M)

Part: WIRE — LOOSE (CABIN)

PHL - TWO EMERGENCY LIGHTS OUT AT ROW 18. MAINTENANCE SECURED LOOSE WIRE TO LIGHT MODULE. (M)

Part: SLIDE — MALFUNCTIONED (PAX DOOR)

PHL - FL11, ON ARRIVAL IN PHL, THE LEFT FORWARD DOOR WAS OPEN WITH THE ESCAPE SLIDE STILL IN THE ARMED POSITION. THE SLIDE DID NOT DEPLOY. MAINTENANCE REPLACED THE SLIDE. AN EVALUATION BY THE SLIDE SHOP AND ENGINEERING COULD NOT DETERMINE THE CAUSE FOR THE NON-DEPLOYMENT OF THE SLIDE. PER COMPANY PROCEDURE, TWO MORE SLIDES WERE SCHEDULED FOR A DEPLOYMENT CHECK. (M)

Part: SLIDE — SELF-ACTUATED (RT OVERWING)

AFTER COMPLETION OF ANNUAL INFLATION/ACTUATIONS TEST, MAINTENANCE REPLACED THE RIGHT OVERWING ESCAPE SLIDE. UPONC OMPLETION OF THE REPLACEMENT, THE SIDE SELF-ACTUATED INSIDE THE COMPARTMENT. MAINTENANCE REPLACED THE SLIDE. THE INCIDENT OCCURRED DUE TO IMPROPER INSTALLATION. (X)

Part: SLIDER SQUIB — DIRTY (LEFT)

PIT - THE LT EMERGENCY SLIDER SQUIB DOES NOT TEST IN NR 1 POSITION, AND THE RT SLIDER SQUIB DOES NOT TEST IN THE NR 2 POSITION. MAINTENANCE CLEANED THE SWITCHES AND RELAYS. (W)