N646DL

Part: LIGHT — INOPERATIVE (CABIN) · airframe 67,800 hrs · 32,062 cycles

DURING A LAYOVER CHECK, MAINTENANCE FOUND THE EMERGENCY PATH LIGHTS AT SEAT 40DEF INOPERATIVE. MAINTENANCE REPLACED THE LIGHT ASSEMBLY. OPERATIONAL CHECK WAS GOOD.

Part: WIRE — DAMAGED (CABIN) · airframe 67,441 hrs · 31,911 cycles

DURING A LAYOVER CHECK, MAINTENANCE FOUND THE EMERGENCY PATHLIGHT AT ROW 5 INOPERATIVE. MAINTENANCE REPAIRED A DAMAGED WIRE. OPERATIONAL CHECK WAS GOOD.

Part: WIRE — DAMAGED (EMERGENCY LIGHT) · airframe 66,905 hrs · 31,680 cycles

DURING A LAYOVER CHECK, MX FOUND THE EMERGENCY PATHLIGHT AT SEAT 33DEF INOPERATIVE. MX REPAIRED A WIRE. OPS CHECK WAS GOOD.

Part: SKIN — DENTED (NR 4 SLAT) · airframe 65,095 hrs · 30,850 cycles

NR4 SLAT LOWER SURFACE HAS 2 EA DENTS. REMOVED DAMAGE, FABRICATED DOUBLER AND BONDED AT ST AEROSPACE SAT REF NON ROUTINE CARD 175296. (DL757101334).

Part: SKIN — DENTED (BS 486 S27L) · airframe 65,095 hrs · 30,850 cycles

FUSELAGE HAS DENT W/GOUGE STA 486 INBD STR 27L. ACCOMPLISHED ER/A 482422-14, REF NON ROUTINE CARD 154263. (DL757101330)

Part: SKIN — DAMAGED (BS 720 S20-22L) · airframe 65,095 hrs · 30,850 cycles

ACCOMPLISH PERM REPAIR IAW ERA 378611-14, CODE 6-53-31-20, REV F, ACTL LINE 2105" LIGHTNING STRIKES ON FUSELAGE SKIN AT STA 720 BETWEEN 20L AND 22L" (REF.OMI LOG W/CN CO04220109) COMPLIED WITH ER/A 482423-14 REV ORIGINAL AT ST AEROSPACE SAT REF NON ROUTINE 154954. (DL757101335).

Part: SEAT TRACK — GOUGED (BS 440-640) · airframe 65,092 hrs · 30,849 cycles

MAIN CABIN SEAT TRACK GOUGED STA 440-640 RBL 45. REMOVED DAMAGED SEAT TRACK AND INSTALLED REPAIR AT ST AEROSPACE SAT REF NON ROUTINE 158931

Part: START VALVE — INTERMITTENT (NR 2 ENGINE) · airframe 64,887 hrs · 30,744 cycles

PUSHED UP THROTTLES FOR TAKEOFF AND BEFORE REACHING 60 KTS THE "R STARTER CUTOUT" LIGHT CAME ON. WHEN PULLED POWER BACKFOR ABORT, LIGHT WENT OUT. REPLACED RT START VALVE PER MM CKS OK.

Part: STRUCTURE — CRACKED (NR 1 PYLON) · airframe 63,211 hrs · 29,934 cycles

HMV AT SAA, A CRACK WAS FOUND IN THE UPPER CHORD OF THE NR 1 PYLON, RT SIDE, AT NACELLE STA 136. THE CRACK WAS REPAIRED PER BOEING INSTRUCTIONS.

Part: FITTING — DAMAGED (NR 2 PYLON) · airframe 63,211 hrs · 29,934 cycles

DURING HMV, AN ELONGATED HOLE WAS FOUND IN THE AFT BULKHEAD FITTING OF THE NR 2 PYLON. THE HOLE WAS REPAIRED PER BOEING INSTRUCTIONS.

Part: STRUCTURE — DAMAGED (NR 1 PYLON) · airframe 63,211 hrs · 29,934 cycles

DURING HMV AT SAA, THE NR 1 PYLON INBOARD SIDE HAD AN ELONGATED HOLE IN THE UPPER CHORD AT N STA 128. THE ELONGATED HOLE WAS REPAIRED PER BOEING INSTRUCTIONS.

Part: FRAME — CORRODED (BS 1640) · airframe 63,211 hrs · 29,934 cycles

DURING HMV AT SAA, CORROSION WAS FOUND ON THE STA 1640 FRAME AT WL 210. THE CORRODED SECTION WAS REMOVED AND A REPAIR WAS INSTALLED PER BOEING DIRECTIONS.

Part: SKIN — CRACKED (BS 532 S26L) · airframe 63,211 hrs · 29,934 cycles

DURING HMV AT SAA, A CRACK WAS DISCOVERED IN THE SKIN LAP JOINT AT STA 532, S-26L. THE CRACK WAS REMOVED AND A PERMANENT REPAIR WAS INSTALLED PER BOEING INSTRUCTIONS. REPETITIVE INSPECTIONS FOR FURTHER DAMAGE WILL BEGIN AT 37,500 TOTAL AIRCRAFT CYCLES AND EVERY 3000 CYCLES THEREAFTER.

Part: COMPRESSOR — DAMAGED (NR 1 ENGINE) · airframe 57,417 hrs · 27,528 cycles

NR 1 ENGINE HAD COMPRESSOR STALL ON TAKEOFF OUT OF LGA. BORO OF COMPRESSOR SHOWED NUMEROUS BLADES DAMAGED BEYOND LIMITS. ENGINE TO BE REPLACED.

Part: FAIRING — MISINSTALLED (NR 2 PYLON) · airframe 55,067 hrs · 26,699 cycles

DURING MODIFICATION OF THE NR 2 PYLON FAIRING PER EO 06-075080-03AD THE MOD DOUBLER FOR THE NR 1 PYLON WAS INADVERTENTLY INSTALLED. INCORRECT DOUBLER WAS REPLACED WITH A SIMILAR DOUBLER CONTOURED TO MATCH THE NR 2 PYLON FAIRING. REF AD 2003-18-05.

Part: SKIN — DENTED (FS 1720, S-20R) · airframe 44,746 hrs · 22,431 cycles

FUSELAGE / SKIN / FS 1720 / STRG. 19R-20R : DENT CUTOUT REPAIR THE FUSELAGE SKIN WAS FOUND DENTED NEAR THE SKIN BUTT LINE AT FS 1720 JUST ABOVE THE SKIN LAP JOINT AT STRG. 20R. THE DENT WAS REMOVED WITH A CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 383012-14, REV A.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 44,745 hrs · 22,430 cycles

THE OUTER CHORD OF THE C2 DOOR OPENING LOWER SILL WAS FOUND CORRODED AND REQUIRED REPLACEMENT. THE LOWER SECTION OF CHORD AND WEB WERE REMOVED. A NEW SILL CHORD WAS INSTALLED AND THE FRAME CHORD AND WEB SPLICED WITH ALUMINUM REPAIR ANGLES AND DOUBLERS PER ER/A 383023-14, REV A.

Part: SKIN — GOUGED (FS 1459, S-28R) · airframe 44,745 hrs · 22,430 cycles

FUSELAGE / SKIN / FS 1455-1478 / STRG. 28R-29R : GOUGE CUTOUT REPAIR THE FUSELAGE SKIN WAS FOUND WITH A LONG GOUGE BETWEEN STRINGERS 28R & 29R FROM FS 1455-1478. THE GOUGE SPANNED THE BUTT JOINT AT FS 1459. THE GOUGE WAS CUT OUT OF BOTH SKIN PANELS AND REPAIRED WITH 2 EXTERNAL ALUMINUM DOUBLERS PER ER/A 383014-14, REV A.

Part: SKIN — GOUGED (FS 722, S-26L) · airframe 44,745 hrs · 22,430 cycles

FUSELAGE / SKIN / FS 722 / STRG. 26L-27L : GOUGE REPAIR THE FUSELAGE SKIN WAS FOUND GOUGED AT FS 722 BELOW THE STRINGER 26L SKIN LAP JOINT. THE GOUGE WAS REMOVED WITH A 2" CUTOUT AND REPAIRED WITH AN EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 383096-14, REV A.

Part: BULB — OPEN (45D) · airframe 43,792 hrs · 21,939 cycles

BULL NOSE EMERGENCY LIGHT AT ROW 45D INOP. RELAMPED. OP CK GOOD

Part: BRAKE ASSY — FIRE (NR 4 MLG) · airframe 43,530 hrs · 21,800 cycles

UPON ARRIVAL AT GATE C08 NR 4 MLG BRAKE ASSY ON FIRE. EXTINGUISHED WITH DRY CHEMICAL EXTINGUISHER. BRAKE TEMP IN COCKPIT READS 3 WITH BLUE BOX. NR 8 MAIN TEMP READS 3 WITH WHITE BOX. ALL OTHER BRAKE TEMPS INDICATE 1 OR 2. REPLACED BRAKE ASSEMBLY.

Part: GIRT BAR — BROKEN (PAX DOOR) · airframe 41,456 hrs · 20,825 cycles

L 4 DOOR GIRT BAR BROKEN AND GUST ASSIST BOTTLE ACTIVATED C/A REPLACED L 4 DOOR GIRT BAR AND DOOR ASSIST BOTTLE. REPLACED L4 DOOR SLIDE PRECAUTIONARY. (IT DID NOT DEPLOY,DUE TO MALFUNCTIONING GIRT BAR.) ORIGINAL PROBLEM WAS FLT ATT COULD NOT ARM L4 DOOR. BWI MTC ARMED DOOR AND OPENED, ACTIVATING ASSIST BOTTLE. A/C FERRIED TO ATL FOR MTC.

Part: CONNECTOR — SHORTED (WINDOW TERMINAL) · airframe 40,122 hrs · 20,210 cycles

ODOR REPORTED IN COCKPIT AND CABIN. FOUND L1 WINDOW TERMINAL PLUG SHORTED. REPLACED WINDOW, CONTROLLER, AND TERMINAL PLUG.

Part: OVEN — STEAMING (GALLEY)

AFT F/A REPORTED SMOKE NEAR CEILING JUST PRIOR TO TAKEOFF. FOUND EXCESSIVE MOISTURE/STEAM COMING FROM MEALS IN THE OVENS.

Part: WIRE — CHAFED (VIDO MONITOR)

VIDEO MONITOR BY 2L DOOR SPARKED ON LANDING. FOUND CHAFED WIRES ON MONITOR. REPAIRED SAME.

Part: FLOORBEAM — CORRODED (BS 1681)

THE UPPER CAP OF THE STA 1681.8 FLOORBEAM WAS FOUND CORRODED ALONG ITS ENTIRE LENGTH LBL 61.95 TO RBL 61.95. THE UPPER CAP WAS TRIMMED OFF AND AN EXTRUDED CAP INSTALLED IN ITS PLACE PER ER/A 364222-14, REV B.

Part: WEDGE — DELAMINATED (LE FLAP TE)

TRAILING EDGE WEDGE DELAMINATED. REPLACED WEDGE PER SRM 57-43-02.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY TRACK LIGHT BATTERY IN F/C INOP. REPLACED SAME.

Part: AIR DISTR — ODOR (CABIN)

RETURNED DUE TO SMELL OF BURNING RUBBER ON TAKEOFF IN COCKPIT AND MID PORTION OF CABIN. CKD E/E COMP, CARGO COMP AND WHEEL WELL AREAS AND NO DISCREPANCIES NOTED. RAN BOTH ENGS AND OPERATED PACKS FROM ENG BLEEDS, FOUND NO ODOR.

Part: LIGHT — INOPERATIVE (CABIN)

IRREG: FOUND ON L/O R2 SLIDE LIGHT INOPERATIVE. CORR: REPLACED LIGGT ASSY. SYSTEM CHECKS GOOD.

Part: TE WEDGE — DELAMINATED (NR 4 LE SLAT)

DURING INSPECTION, FOUND THE TRAILING EDGE WEDGE ON THE NR 4 SLAT DELAMINATED IN THE UPPER SKIN. THERE IS A PREVIOUS REPAIR DOUBLER THAT MEASURES 2 INCHES FORE/AFT AND 10 INCHES WIDE, INSTALLED IN THE DAMAGED REGION. REPAIRED TRAILING EDGE WEDGE IN ACCORDANCE WITH B757 SRM 51-70-10.

Part: BULB — FAILED (CABIN)

R2 DOOR OUTSIDE EMERGENCY LIGHT INOP. EMERGENCY TRACK LIGHT AT ROW 1, 28 INOP. RELAMPED AND OPERATION NORMAL.

Part: TE WEDGE — DELAMINATED (NR 5 TE FLAP)

DURING SHOP INSPECTION, NR 5 L/E SLAT WAS FOUND WITH DELAMINATION TO TRAILING EDGE WEDGE. REPLACED WEDGE PER SRM 57-43-02.

Part: TE PANEL — SEPARATED (NR 5 LE SLAT)

ON CLIMBOUT FROM CVG HAD AIRFRAME VIBRATION, RETURNED CVG. FOUND A 4 FOOT SECTION OF LEFT WING NR 5 L/E SLAT TRAILING EDGE WEDGE HAD SEPARATED FROM THE SLAT PANEL. THE SLAT WAS REMOVED AND ROUTED TO SHOP FOR REPAIRS, NEW SLAT PANEL WAS INSTALLED FOR RETURN TO SERVICE.