N662US

Part: SKIN — CRACKED (BS 2638) · airframe 113,083 hrs · 14,259 cycles

DURING SERVICE CHECK, FOUND CRACK ON THE FUSELAGE SKIN BS 2638 WL 310, BETWEEN STRINGERS 4 - 10R. REPAIRED IAW SRM 53-80-03 SEC. 48 FIG 1.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 113,047 hrs · 14,256 cycles

FOUND EMERGENCY EXIT LIGHTS IN UPPER DECK OVER BOTH DOORS AND OVERHEAD INOPERATIVE. REMOVED AND REPLACED BATTERY PACK FOR POWER SUPPLY M7050 AND TEST OK PER AMM 33-51-04/201.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 112,364 hrs · 14,177 cycles

EMERGENCY LIGHTS AT SEATS 73A, 74A AND 75A ARE INOPERATIVE. MAINTENANCE REPLACED THE BATTERY POWER SUPPLY. SYSTEM OPERATION IS NORMAL.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 112,364 hrs · 14,177 cycles

EMERGENCY LIGHTS AT SEATS 77A, 78A, AND 79A ARE INOPERATIVE. MAINTENANCE REPLACED THE BATTERY AND SYSTEM OPERATION IS NORMAL.

Part: SKIN — CRACKED (L5 DOOR CUTOUT) · airframe 110,498 hrs · 13,977 cycles

TWO CRACKS FOUND ON L5 DOOR CUTOUT AFT UPPER CORNER. THE CRACK LENGTH: 1,0.08" 2,0.07". REPAIRED IAW OER 5330-01212-03A.

Part: SKIN — DAMAGED (HORIZONTAL STAB) · airframe 110,070 hrs · 13,917 cycles

ON RT HORIZONTAL STABILIZER 502 LOWER SURFACE 8" X 1" TEAR. REPAIRED IAW SRM 55-10-01. REPAIR 6, CATEGORY B.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 106,903 hrs · 13,528 cycles

UPPER DECK EMERGENCY FLOOR PATH LIGHTING INOPERATIVE .3 LIGHTS + 1 ROOF LIGHT AT TOP OF STRAIRCASE. R & R LIGHT AND BATTERY PACK.

Part: PANEL — CRACKED (BS 2160) · airframe 106,335 hrs · 13,458 cycles

CRACK ON BULKHEAD LINING PANEL, RT LOWER SECTION AT BS 2160.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHTS) · airframe 105,786 hrs · 13,399 cycles

UPPER DECK RT DOOR EMERGENCY LIGHT INOPERATIVE. REPLACED POWER PACK.

Part: CONNECTOR — UNSECURE (EMERGENCY LIGHTS) · airframe 105,530 hrs · 13,375 cycles

SHIP 6302. MAIN DECK CEILING EMERGENCY LIGHT ADJACENT TO SEAT 3A INOPERATIVE. RESEATED & SECURED CONNECTOR.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 105,177 hrs · 13,342 cycles

L1 DOOR MOUNTED EMERGENCY LIGHT INOPERATIVE. REPLACED THE EMERGENCY LIGHT.

Part: FUSE — INOPERATIVE (EMERGENCY LIGHTS) · airframe 102,939 hrs · 13,094 cycles

MAINTENANCE FOUND EXIT SIGN AFT OF R1 DOOR IN AISLE INOPERATIVE. REPLACED FUSE NR 4 IN BATTRY PACK, M7918. CHECKED GOOD IAW WDM 335141.

Part: CHARGER — INOPERATIVE (EMERGENCY LIGHTS) · airframe 102,783 hrs · 13,076 cycles

NON ROUTINE CHECK, ROW 9-13K EMERGENCY LIGHTS ON SEATS INOPERATIVE. R & R BATTERY CHARGER, OPS CHECKED GOOD.

Part: SKIN — CORRODED (LT WING) · airframe 102,572 hrs · 13,050 cycles

DURING A NON ROUTINE CHECK, LT WING LOWER SURFACE, WS 1430 FRONT SPAR LOWER RABBIT AREA FOUND BULGING. PERFORMED REPAIR IAW ERA522150-14, REV 0 PERFORMED HFEC INSPECTION TO REWORK AREA IAW NDT MANUAL PART 6 51-00-00 PROCEDURE 4 OR 23.

Part: SKIN — WORN (BS 2559-2578) · airframe 102,318 hrs · 13,021 cycles

FUSELAGE SKIN FOUND WORN BS 2559-2578. REMOVED DAMAGED AREA, INSTALLED DOUBLER AND FILLERS IAW SRM 53-00-01 REPAIR 5 FIG 201.

Part: SKIN — DAMAGED (BS 2559-2578) · airframe 102,040 hrs · 12,989 cycles

FOUND WEAR ON LT SIDE, BS 2559-2578. REMOVED DAMAGE IAW SRM 53-00-01, REPAIR 15, FIG. 201. PERFORMED HFEC OF CUT OUT IAW NDTM 51-00-00, PART 6, NO CRACKS NOTED. FABRICATED FILLER & DOUBLER IAW SRM 53-00-01, REPAIR 15, FIG. 201.

Part: SKIN — DAMAGED (BS 2557-2558) · airframe 102,040 hrs · 12,989 cycles

FOUND WEAR ON LT SIDE, BS 2557-2558 ON AFT EDGE OF DOUBLER. REMOVED DAMAGE IAW SRM 53-00-01, REPAIR 15, FIG. 201, PERFORMED HFEC OF CUT OUT IAW NDTM 51-00-00, PART 6, NO CRACKS NOTED. FABERICATED FILLER AND DOUBLER IAW SRM 53-00-01, REPAIR 15 FIG. 201. INSTALLED FASTENERS IN REPAIR DOUBLER. REQUIRED INSPECTION ITEM COMPLETED. OK TO PAINT, TOP COATED IAW SRM 53-00-01, R15 FIG. 201.

Part: SKIN — DAMAGED (BS 2545-2547) · airframe 102,040 hrs · 12,989 cycles

FOUND WEAR DAMAGE ON LT SIDE, BS 2545-2547. REPAIRED IAW ERA 488622-14AD REV A, REV 5.

Part: CHARGER — INOPERATIVE (EMERGENCY LIGHT) · airframe 101,983 hrs · 12,982 cycles

FOUND ROWS 77A THRU 79A EMERGENCY LIGHTS INOPERATIVE. FOUND BAD BATTERY CHARGER REMOVED BATTERY AND CHARGER. INSTALLED NEW BATTERY AND CHARGER IAW AMM 33-51. CHECKED GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 101,428 hrs · 12,913 cycles

ROW 4 LT, OVERHEAD EMERGENCY LIGHT INOPERATIVE. REMOVED AND REPLACED EMERGENCY LIGHT ASSY.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 100,166 hrs · 12,772 cycles

FORWARD AND AFT EMERGENCY LIGHTS OUT AT INSIDE OF UPPER DECK RT EMERGENCY EXIT DOOR. REPLACED EMERGENCY BATTERY PACK .

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT) · airframe 99,818 hrs · 12,729 cycles

U/D BOTH EXIT DOOR EMERGENCY LIGHT INOPERATIVE. R & R BATTERY, AND OPS CHECKED OK IAW AMM 33-51.

Part: WIRE — DAMAGED (EMERGENCY LIGHT) · airframe 98,367 hrs · 12,548 cycles

FOUND FLOOR EMERGENCY LIGHT INOPERATIVE. REPAIRED WIRE.

Part: LIGHT — MALFUNCTIONED (CABIN) · airframe 97,765 hrs · 12,476 cycles

DURING SERVICE CHECK FOUND UPPER DECK LT EMERGENCY EXIT DOOR (BATTERY OK) TEST LIGHT INOPERATIVE. RETESTED OPS CHECK GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 97,765 hrs · 12,476 cycles

LT UPPER DECK EMERGENCY DOOR (BATTERY OK) LIGHT INOPERATIVE. SWAPPED M7037 WITH M7038, RETESTED BOTH BATTERY LIGHTS, BOTH TESTED GOOD.

Part: ACM — FAILED (NR 2) · airframe 96,502 hrs · 12,324 cycles

DURING CLIMB-OUT, PACK 2 TRIP OCCURRED AND SMOKE WAS REPORTED IN THE CABIN. AIRCRAFT RETURNED TO DEPARTURE. MAINTENANCE FOUND NR 2 PACK ACM FAILED. PACK DEFERRED AND AIRCRAFT RETURNED TO SERVICE.

Part: FRAME — DAMAGED (BS 570) · airframe 95,946 hrs · 12,254 cycles

DURING INSPECTION FOUND UPPER LEG OF FRAME DAMAGED BS 570 FORWARD CARGO APPROX 2 FT INBOARD OF THE DOOR OPENING. MAINTENANCE CUTOUT DAMAGE AND REPAIRED PARTS PER SRM 51-70-11 FIG 1.

Part: CARGO TRACK — DAMAGED (BS 570) · airframe 95,946 hrs · 12,254 cycles

DURING INSPECTION, FOUND FORWARD END OF FORWARD CARGO TRACK AT BS 570 APPROX 2 FEET INBOARD OFF DOOR OPENING DAMAGED. MAINTENANCE REMOVED AND REPLACED FORWARD CARGO TRACK AT BS 570 PER SRM 51-10-02 PG 8 PARA 9 AND DRAWING 65B0645.

Part: SOCKET — DAMAGED (CABIN) · airframe 95,207 hrs · 12,166 cycles

DURING INSPECTION FOUND AFT AIRCRAFT RIGHT OVERWING EMERGENCY LIGHT INOPERATIVE. MAINTENANCE FOUND LIGHT BULB LOOSE FITTING WITH SOCKET. REPAIRED AND SECURED SOCKET. OPERATIONAL CHECK NORMAL PER B747 AMM 33-51.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

DURING HFEC SURFACE INSP ON AFT CARGO DOOR CUTOUT UPPER FORWARD CORNER CRACK FOUND PROPAGATE FROM HOLE NR 2 TO THE EDGE APPROXIMATELY 3/4" AS MARKED. AFT CARGO DOOR CUTOUT UPPER FORWARD CORNER WORK CARRIED OUT AS PER PRI 500187-14AD REV 0, 1, 2 AND 3. REFER TO NRC 822-001 WORK DETAILS. DATED 12 MAR12 TIME 1100HRS. AFT CARGO DOOR CUTOUT UPPER FORWARD CORNER REV 0, 1, 2 AND 3 COMPARED WITH WITH ER/A 500187-14AD REV A.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

DURING HFEC OPEN HOLE INSP ON AFT CARGO DOOR CUTOUT UPPER AFT CORNER, HOLE NR 2 FOUND WITH CRACK INDICATION. AFT CARGO DOOR CUTOUT UPPER AFT CORNER WORK CARRIED OUT AS PER PRI 500187-14AD REV 1 DATED 02MAR12. AFT CARGO DOOR CUTOUT UPPER AFT CORNER PRI 500187-14AD REV 1.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

DURING HFEC OPEN HOLE INSP ON AFT CARGO DOOR CUTOUT UPPER FORWARD CORNER, HOLES NR 2 AND NR 4 FOUND WITH CRACK INDICATION. AFT CARGO DOOR CUTOUT UPPER FORWARD CORNER WORK CARRIED OUT AS PER PRI 500187-14D REV 0, 1, 2 AND 3 DATED 12 MAR12 TIME 1100HRS. COMPLIED WITH ER/A 500187-14 REV A COMPLIED AND ACCOMPLISHED. DATED 26MAR12.

Part: SILL — CORRODED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

DURING HCK, CORROSION WAS NOTED ON THE LT UPPER DECK EMERGENCY EXIT DOOR SILL, STA 685, STR 13L. ER/A 500558-14 SECTION I WAS COMPLETED AT THAT TIME. FOLLOW ON ACTION IS REQUIRED FOR THIRD STAGE APPROVAL.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

FLATBED MODIFICATION, DURING FLOORBOARD REMOVAL, CORROSION FOUND ON LBL 98.59 SEAT TRACK, BS 520 & STA 540. INTERCOSTAL REMOVED AND REPAIRED AT LBL 98.59 BS 520 & BS 540 PER ER/A 500561-14 REV.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

FLATBED MOD, MAIN DECK ZONE B, STA 760 TO 740, LBL 65, EDGE CRACK FOUND ON INTERCOSTAL DURING OPENING OF FLOORBOARD. CRACKED INTERCOSTAL AT MAIN DECK ZONE B STA 740 TO 760 LBL 65 AREA REMOVED AS PER B747-400 SRM 51-40-02 NEW INTERCOSTAL FABRICATED AS PER BOEING DWG 140U5497 REV D AND INSTALLED AS PER PER B747-400 SRM 51-40-02.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 94,888 hrs · 12,121 cycles

MAIN DECK CABIN, STA 1220, RBL 100 TO RBL 127, OVERWING INTERCOSTAL WEB, CRACK OF APPROXIMATELY 4" IN LENGTH FOUND FROM LOWER CHORD. MAIN DECK CABIN STA 1220 RBL 100 TO RBL 127 OVERWING INTERCOSTAL WEB CRACK AREA REPAIRED. REFER TO WORKCARD 5313-01014-02H (JOB #365-0002) FOR WORK DETAIL.

Part: SILL — CORRODED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

UPPER DECK LEFT DOOR CUTOUT SILL UPPER FACE FOUND WITH CORROSION AS INDICATED. UPPER DECK LT DOOR CUTOUT LOWER SILL UPPER FACE CORROSION REMOVED AS PER B747-400 SRM 51-10-02. CORRODED AREA REPAIRED AS PER PRI 500558-14 REV 0, REV 1, REV 2 AND REV 3 DATED 21MAR12.

Part: BULKHEAD — DAMAGED (FUSELAGE) · airframe 94,889 hrs · 12,121 cycles

CABIN ZONE A -STA 140 FWD BULKHEAD WEB BETWEEN STR 22R-23R FOUND WITH SHORT EDGE MARGIN. REPAIRED AS PER PRI 500565-14 REV 0 DATED 05MAR12.

Part: WEB — CRACKED (LT BLG WW) · airframe 94,889 hrs · 12,121 cycles

LT BLG W/W- STA 1480 O/B WEB FOUND CRACK AT ABOUT STR 34L. LT BLG W/W STA 1480 O/B WEB REPAIRED AS PER B747-400 SRM 53-40-08 REPAIR FIGURE 1.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 6,761 hrs · 840 cycles

DURING FLOORBOARD REMOVAL, CORROSION FOUND ON LBL 98.59 SEAT TRACK, BS 520 & STA 540. INTERCOSTAL REMOVED AND REPLACED AT LBL 98.59 BS 520 & BS 540 AS PER PRI 5000561-14 REV 0 AND REV 1 DATED 06MAR12.

Part: SEAT TRACK — CORRODED (BS 1640-1660) · airframe 6,761 hrs · 840 cycles

AFT CARGO CEILING AREA BS 1640-1660 LBL 60 SEAT TRACK FOUND BULGED. REPAIRED PER SRM 53-00-52, FIG 201, REPAIR 6.

Part: BULKHEAD — CRACKED (BS 140 S20R) · airframe 6,761 hrs · 840 cycles

CABIN ZONE A FWD BULKHEAD BS 140 OUTER CHORD RING NEAR STR 20R FOUND CRACKED. REPAIRED.

Part: LIGHT — INOPERATIVE (L5 DOOR) · airframe 94,322 hrs · 12,056 cycles

DURING A MAINTENANCE VISIT, THE EMERGENCY DOOR SLIDE LIGHT AT DOOR 5L WAS FOUND TO BE INOPERATIVE. MAINTENANCE REPLACED THE SLIDE LIGHT ASSEMBLY. SYSTEM OPERATION WAS NORMAL AFTER THE SLIDE LIGHT ASSEMBLY WAS REPLACED.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 94,073 hrs · 12,030 cycles

DURING A MAINTENANCE VISIT, THE AFT EMERGENCY EXIT SIGN IN THE UPPER DECK WAS FOUND TO BE INOPERATIVE. MAINTENANCE FOUND THE POWER SUPPLY INOPERATIVE AND REPLACED IT. SYSTEM OPERATION WAS NORMAL AFTER THE POWER SUPPLY WAS REPLACED.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 94,061 hrs · 12,029 cycles

DURING A MAINTENANCE VISIT, THE EMERGENCY FLOOR PATH LIGHT ON THE AFT LEFT SIDE UPPERDECK WAS FOUND TO BE INOPERATIVE. MAINTENANCE REPLACED THE BATTERY PACK. SYSTEM OPERATION WAS NORMAL AFTER THE BATTERY WAS REPLACED.

Part: WIRE — LOOSE (CABIN) · airframe 94,048 hrs · 12,028 cycles

DURING A MAINTENANCE VISIT, THE EMERGENCY FLOOR PATH LIGHTS FROM ROW 9 TO DOOR 2R WAS FOUND TO BE INOPERATIVE. MAINTENANCE FOUND THE WIRE LOOSE AND RE-ATTACHED IT. SYSTEM OPERATION WAS NORMAL AFTER THE WIRE WAS RE-ATTACHED.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 93,745 hrs · 11,985 cycles

DURING A LINE MAINTENANCE NON-ROUTINE CHECK, THE EMERGENCY EXIT SIGN AT AFT SIDE ON UPPER DECK WAS FOUND TO BE INOPERATIVE. MAINTENANCE REPLACED THE BATTERY PACK. SYSTEM OPERATION WAS NORMAL AFTER THE BATTERY PACK WAS REPLACED. (2011-00630)

Part: LIGHT — INOPERATIVE (CABIN) · airframe 93,424 hrs · 11,946 cycles

DURING A MAINTENANCE VISIT, THE EMERGENCY SLIDE LIGHT AT DOOR 1L WAS FOUND TO BE INOPERATIVE. MAINTENANCE REPLACED THE DOOR MOUNTED EMERGENCY LIGHT AT DOOR 1L. SYSTEM OPERATION WAS NORMAL AFTER THE LIGHT WAS REPLACED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 90,884 hrs · 11,643 cycles

DURING L-CHECK, FUSELAGE SKIN CRACKING WAS FOUND ON THE NOSE WHEEL WELL AFT CORNERS. ACCOMPLISHED SECT II INSP WITHIN 6000 CYCLES AFTER SECTION I. REPEAT SECTION II INSPECTIONS AT 1500 CYCLE INTERVALS. PERFORMED FUSELAGE EXTERIOR SKIN REPAIR IAW ER/A 488626-14AD.

Part: SKIN — WORN (BS 2521-2628) · airframe 90,884 hrs · 11,643 cycles

WEAR WAS FOUND AT FUSELAGE SKIN AND VERTICAL STABILIZER SEAL INTERFACE. STA 2521-2628. MAX DEPTH: 0.027" IAW ER/A 488622-14AD, REV 0 AND SRM 53-00-01, REPAIR 15, FIG 201 PERFORMED MED FUSELAGE SKIN-BUTT JOINT EXTERNAL REPAIR, THIS IS A CATEGORY" B" REPAIR INSP. REQUIREMENTS INSPECTION THRESHOLD: 1500 FLIGHT CYCLES, METHOD: INTERNAL HFEC INTERVAL 6000 FLIGHT CYCLES, REF: NDT PART6 51-00-00, FIG4. METHOD: EXTERNAL LFEC: INTERVAL: 1500 FLIGHT CYCLES, REF: NDT PART6, 53-30-00, FIG5.RII COMPLETED.

Part: SILL — CRACKED (FUSELAGE) · airframe 90,884 hrs · 11,643 cycles

RT NR 1 DOOR UPPER SILL CRACK,BS460,S-17R L=1.5 INCHES PERFORMED THE UPPER SILL WEB REPAIR PER ER/A488625-14 REV ORIG C /W ER/A488625-14 REV ORIG RII COMPLETED. PERFORMED THE UPPER SILL WEB REPAIR PER ER/A 488625-14AD REVORIG. C/W ER/A 488625-14AD REV ORIG RII COMPLETED.

Part: SKIN PANEL — DELAMINATED (ELEVATOR) · airframe 90,884 hrs · 11,643 cycles

LEFT INBOARD ELEVATOR FOR UPPER SKIN PANEL DELAMINATION. ELEVATOR STA 125 S: 1"X1 BONDING REPAIRED PER SRM55-20-01 / REPAIR 1.

Part: SKIN PANEL — DELAMINATED (ELEVATOR) · airframe 90,884 hrs · 11,643 cycles

LEFT INBOARD ELEVATOR FOR UPPER SKIN PANEL DELAMINATION. ELEVATOR STA 186 S:0.5"X0.5" BONDING REPAIRED PER SRM55-20-01/REPAIR 1.

Part: DOOR FRAME — CRACKED (CABIN DOOR) · airframe 90,884 hrs · 23,720 cycles

NR 2 RT MAIN DECK CABIN DOOR FORWARD FRAME CRACK BS 808 S-25R-26R L=0. DO THE VERTICAL FRAME WEB REPAIR PER SRM52-10-02 REPAIR 2 FIG 201. THIS IS A CATEGORY "B" REPAIR INSPECTION THRESHOLD: 15000 DOOR FLIGHT CYCLES METHOD: INTERNAL AND EXTERNAL DETAILED VISUAL INSPECTION INTERVAL: 000 DOOR FLIGHT CYCLES. P/N 65B04311-12 S/N001239.

Part: SKIN — DELAMINATED (ELEVATOR) · airframe 90,884 hrs · 11,643 cycles

RIGHT OUTBOARD ELEVATOR FOR TRAILING EDGE PANEL UPPER SKIN DELAMINATION. ELEVATOR STA230 S=1.5"X1.5" BONDING REPAIRED THE RT O/B ELEVATOR PER SRM 55-20-01. REPAIR REBALANCED THE RT O/B ELEVATOR PER SRM51-60-02.

Part: DOOR FRAME — CRACKED (CABIN DOOR) · airframe 90,884 hrs · 11,643 cycles

NR 2 RT MAIN DECK CABIN DOOR AFT FRAME LOWER CRACK BS850, S-25R-26R, L=0.6" PER SRM52-10-02 REPAIR2 FIG201 DO THE VERTICAL FRAME WEB REPAIR. THIS IS A CATEGORY "B" REPAIR INSPECTION REQUIREMENTS. INSPECTION THRESHOLD: 15000 DOOR FLIGHT CYCLES, METHOD: INTERNAL AND EXTERNAL DETAILED VISUAL INSPECTION. INTERVAL: 3000 DOOR FLIGHT CYCLES. P/N 65B04311-12 S/N001239.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 90,884 hrs · 11,643 cycles

DURING L CHECK, FUSELAGE SKIN HAS WEAR DAMAGE AT THE VERTICAL STABILIZER SEAL INTERFACE. BLENDED SKIN.

Part: SKIN — CRACKED (BS 2370 S15L) · airframe 90,884 hrs · 11,643 cycles

FUSELAGE SKIN EXTERIOR CRACK, BS2370, S-15L, L=0.7" IAW SRM 53-00-01, REPAIR 1 AND ER/A 488628-14 REV ORIGINAL. PERFORMED FUSELAGE SKIN EXTERNAL REPAIR, THIS IS A CATEGORY"B" REPAIR INSP REQUIREMENTS. INSPECTION THRESHOLD: AFTER REPAIR 1500 FLIGHTS METHOD: INTERNAL HFEC, INTERVAL 6000R/C REF: NDT, PART6, 51-00-00, FIG4. EXTERNAL LFEC, INTERVAL:1500 F/C REF: NDT, PART6 , 53-30-00, FIG 5, DEFERRED.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 90,884 hrs · 11,643 cycles

ER/A 488627-14AD, SECTION I WAS ISSUED FOR FUSELAGE SKIN REPAIR AT NOSE WHEEL WELL RT AFT CORNER. SECTION I IS REQUIRED. ACCOMPLISH SECTION II, REPEAT INSPECTIONS BEGINNING NO LATER THAN 15000 CYCLES AFTER SECTION I, THEN REPEATING AT 1500 CYCLE INTERVALS THEREAFTER.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 90,884 hrs · 11,643 cycles

ER/A 488626-14AD, SECTION I, WAS ISSUED FOR FUSELAGE SKIN REPAIR AT NOSE WHEEL WELL LT AND RT AFT CORNERS. SECTION I, ACCOMPLISHED DURING L-CHECK. FOLLOW ON ACTION IS REQUIRED. ACCOMPLISH SECTION II REPEAT INSPECTIONS BEGINNING NO LATER THAN 15000 CYCLES AFTER SECTION I, THEN REPEATING AT 1500 CYCLE INTERVALS THEREAFTER.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 90,696 hrs · 11,619 cycles

DURING A LAYOVER CHECK, MX FOUND THE DOOR 2L EMERGENCY EXIT LIGHT INOPERATIVE. MX REPLACED THE LIGHT ASSY. OPS CHECK WAS GOOD.

Part: OVEN — SMOKE (GALLEY) · airframe 90,525 hrs · 11,592 cycles

DURING FLIGHT, OVEN EMITTED SMOKE AND FUMES. OVEN WAS SHUTOFF AND SMOKE DISSIPATED. CIRCUIT BREAKER WAS PULLED AND FLIGHT CONTINUED. MX FOUND MELTED PASTIC CONTAINERS IN THE OVEN AND REPLACED THE OVEN, CONTROLLER, RELAYS AND TERMINAL LUGS. OPS CHECK WAS GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 90,133 hrs · 11,538 cycles

DURING A LINE CHECK, MAINTENANCE FOUND THE EMERGENCY PATH LIGHTS AT ROWS 77 - 79 INOPERATIVE. MAINTENANCE REPLACED THE POWER SUPPLY AND BATTERY. OPERATIONAL CHECK WAS GOOD. (2010-00858)

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 89,710 hrs · 11,478 cycles

DURING A SERVICE CHECK, MX FOUND THE DOOR 5R EMERGENCY SLIDE LIGHT INOPERATIVE. MX RELAMPED 1 SOCKET AND REPAIRED A WIRE AT THE OTHER SOCKET. OPS CHECK WAS GOOD.

Part: FRAME — DAMAGED (BS 240) · airframe 89,556 hrs · 11,548 cycles

DURING LINE CHECK, FOUND FREEZE PLUG REQUIRED DOUBLER AT BS 240 BETWEEN S13 & S14. REPAIRED IAW ERA 485386-14.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 89,032 hrs · 11,392 cycles

DURING LINE CHECK, MAINTENANCE FOUND THE MOST AFT EMERGENCY EXIT SIGN INOPERATIVE. MAINTENANCE REPLACED THE POWER SUPPLY. OPERATIONAL CHECK WAS GOOD.

Part: BATTERY PACK — DISCHARGED (EMERGENCY EXIT) · airframe 87,837 hrs · 11,240 cycles

DURING LINE CHECK FOUND UPPER DECK RIGHT EMERGENCY DOOR BATTERY CHECK MODULE INOPERATIVE. REMOVED AND REPLACED BATTERY PACK PER AMM 52-23-00 AND OPERATIONS CHECKED GOOD.

Part: LIGHT — INOPERATIVE (R5 DOOR) · airframe 87,837 hrs · 11,238 cycles

DURING LINE CHECK, MAINTENANCE FOUND THE DOOR 5R EMERGENCY SLIDE LIGHT INOPERATIVE. MAINTENANCE REPLACED THE DOOR MOUNTED LIGHT ASSEMBLY. OPERATIONAL CHECK WAS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 87,826 hrs · 11,237 cycles

DURING LAYOVER CHECK, MAINTENANCE FOUND THE UD EMERGENCY EXIT SIGN AT SEAT 80J INOPERATIVE. MAINTENANCE REPLACED THE BATTERY PACK. OPERATIONAL CHECK WAS GOOD.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 87,468 hrs · 11,195 cycles

DURING LAYOVER CHECK, MX FOUND THE UPPER DECK CEILING (STA 930) EMERGENCY EXIT LIGHT INOPERATIVE. MX REPLACED THE BATTERY PACK. OPS CHECK WAS GOOD.

Part: CONNECTOR — DAMAGED (EMERGENCY LIGHTS) · airframe 87,468 hrs · 11,195 cycles

DURING LAYOVER CHECK, MX FOUND THE RT UPPER DECK EMERGENCY DOOR MOUNTED SLIDE LIGHT INOPERATIVE. MX REPAIRED THE POWER SUPPLY CONNECTOR. OPS CHECK WAS GOOD.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 87,468 hrs · 11,195 cycles

DURING LAYOVER CHECK, MX FOUND THE UPPER DECK LT EMERGENCY DOOR MOUNTED SLIDE LIGHT INOPERATIVE. MX REPLACED THE BATTERY PACK.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 87,392 hrs · 11,186 cycles

DURING LAYOVER, MX FOUND LT EMERGENCY PATH LIGHTS AT ROWS 1-14 INOPERATIVE. MX REPLACED THE BATTERY PACK. OPS CHECK WAS GOOD.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 87,099 hrs · 11,147 cycles

DURING OVERNIGHT CHECK, MAINTENANCE FOUND EMERGENCY EXIT LIGHT NEAR SEAT 80J INOPERATIVE. MAINTENANCE REPLACED THE EMERGENCY LIGHT BATTERY AT ROW 79 RIGHT. OPERATIONAL TEST WAS GOOD.

Part: SIGN — INOPERATIVE (EMERGENCY LIGHT) · airframe 86,694 hrs · 11,105 cycles

DURING OVERNIGHT CHECK FOUND EMERGENCY EXIT SIGN INOPERATIVE AT UPPER DECK SEAT 80JK. MAINTENANCE REPLACED BATTERY. OPERATIONAL CHECKED GOOD AND RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 86,053 hrs · 11,033 cycles

DURING MAINTENANCE FOUND UPPER DECK OVERHEAD EMERGENCY EXIT LIGHT AT SEAT 80J INOPERATIVE. MAINTENANCE REPLACED BATTERY PACK M6378. SYSTEM OPERATION WAS NORMAL AFTER BATTERY PACK REPLACED.

Part: BATTERY PACK — DEFECTIVE (CABIN) · airframe 85,649 hrs · 10,989 cycles

DURING AN OVERNIGHT LINE CHECK THE UPPER DECK, AFT MOST EMERGENCY EXIT SIGN WAS FOUND TO BE INOPERATIVE. MAINTENANCE FOUND BATTERY PACK M6378 TO BE DEFECTIVE AND REPLACED IT. SYSTEM OPERATION WAS NORMAL AFTER THE BATTERY PACK WAS REPLACED.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 85,057 hrs · 10,923 cycles

DURING OVERNIGHT CHECK, FOUND UPPER DECK AFT EMERGENCY SIGN INOP. MAINTENANCE REMOVED AND REPLACED BATTERY PACK. OPERATIONAL CHECKED GOOD, AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: BATTERY — DISCHARGED (CABIN)

DURING LINE CHECK FOUND EMERGENCY EXIT SIGN UPPER DECK AFT INOP. MX R&R POWER SUPPLY AND BATTERY. OPS CHECKED GOOD AND ACFT WAS RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 81,944 hrs · 10,526 cycles

DURING LINE CHECK FOUND RT UPPER DECK EMERGENCY BATTERY PACK INOPERATIVE. R&R BATTERY PACK PER AMM 52-23-14. OPS CHECK GOOD.

Part: LINE — CRACKED (HYD SYSTEM) · airframe 80,498 hrs · 10,328 cycles

DURING CRUISE, LOST NR 1 HYDRAULIC SYSTEM. DUMPED 20,000 LBS OF FUEL. RETURNED TO MSP AND LANDING WAS UNEVENTFUL. MAINTENANCE REMOVED AND REPLACED NR 1 EDP AND A CRACKED PRESSURE LINE. LEAK AND PRESSURE CHECKS OK.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 80,466 hrs · 10,324 cycles

DURING OVERNIGHT CHECK FOUND ZONE A LEFT SIDE EMERGENCY FLOOR LIGHTS INOP. MAINTENANCE REMOVED AND REPLACED BATTERY PACK. OPERATIONAL CHECKED GOOD AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: OVEN — CONTAMINATED (GALLEY) · airframe 79,760 hrs · 10,233 cycles

AFTER TAKEOFF, NR 2 MAIN TANK FORWARD PUMP MESSAGE AND LIGHT CAME ON, FOLLOWED BY RIGHT UTILITY BUSS LIGHT AND MESSAGE. PERFORMED FUEL PUMP PROCEDURE AS PER COM FIRST AND COMPLIED. THEN PERFORMED RIGHT UTILITY PROCEDURE AS PER COM AND COORDINATED WITH PURSER. HER REPORT THERE AFTER WAS ACRID ODOR AND FUZZY VISIBILITY BUT NO FIRE WAS VISIBLE. ODOR WAS REPORTED AT BOTH ENDS OF THE CABIN. AN EMERGENCY WAS DECLARED AND AN IMMEDIATE LANDING (UNEVENTFUL) WAS MADE BACK AT NRT. MAINTENANCE REMOVED AND REPLACED CONTROL UNIT BUSS, BOOST FUEL PUMP, LOAD CONTROL UNIT, EPESC (ENHANCED PASSENGER ENTERTAINMENT SYSTEM), RELAY R50, AND C/B C401, OVEN CONTROLLER, AND NEED TO REPLACE 2 OVEN RELAYS AND OVEN. ALSO INSPECTED OVEN AND COFFEE CONNECTORS, FEEDER LINES AND CONNECTORS, UTILITY POWER, RECIRCULATION FANS, GALLEY ELECTRIC DISTRIBUTION, ALSO INSPECTED FORWARD AND AFT CARGO COMPARTMENT CEILING AREAS AND FOUND NO ABNORMALITIES. EVERYTHING CHECKED FINE. DID FIND GALLEY UNIT 1 OVEN CONTAMINATED WITH BURNED FOOD RESIDUE AND EMITTING A STRONG ODOR WHEN HEATED. OVEN IS TO BE REPLACED. PULLED AND COLLARED OVEN C/B. AIRCRAFT CHECKED GOOD, AND WAS RETURNED TO SERVICE.

Part: ELECTRICAL SYS — MALFUNCTIONED (COCKPIT) · airframe 79,756 hrs · 10,232 cycles

AFTER TAKE OFF NR 2 MAIN TANK FORWARD PUMP MSG AND LIGHT CAME ON FOLLOWED BY RT UTILITY BUS LIGHT AND MSG. PERFORMED FUEL PUMP PROCEDURE AS PER COM FIRST AND COMPLIED. THEN PERFORMED RT UTILITY PROCEDURE AS PER COM AND COORDINATED WITH PURSER. HER REPORT WAS ACRID ODOR AND FUZZY VISIBILITY BUT NO FIRE WAS VISIBLE. ODOR WAS REPORTED AT BOTH ENDS OF THE CABIN. AN EMERGENCY WAS DECLARED AND AN IMMEDIATE UNEVENTFUL LANDING WAS MADE BACK AT NRT. MX R&R CONTROL UNIT BUS, BOOST FUEL PUMP, LOAD CONTROL UNIT, EPESC ENHANCED PASSENGER ENTERTAINMENT SYSTEM, RELAY R50 AND CB C401, OVEN CONTROLLER AND NEED TO REPLACE 2 OVEN RELAYS AND OVEN. ALSO INSPECTED OVEN AND COFFEE CONNECTORS, FEEDER LINES AND CONNECTORS, UTILITY POWER, RECIRCULATION FANS, GALLEY ELECTRIC DISTRIBUTION, FORWARD AND AFT CARGO COMPARTMENT CEILING AREAS AND FOUND NO ABNORMALITIES. EVERYTHING CHECKED FINE. GALLEY UNIT 1 OVEN CONTAMINATED WITH BURNT FOOD RESIDUE AND EMITTING A STRONG ODOR WHEN HEATED. OVEN IS TO BE REPLACED. PULLED AND COLLARED OVEN CB. ACFT CHECKED GOOD AND WAS RETURNED TO SERVICE.

Part: SKIN — CRACKED (BS 2285) · airframe 78,315 hrs · 10,042 cycles

DURING "L" CHECK FOUND CRACK IN FUSELAGE SKIN AT UPPER AFT CUTOUT FOR NR 5 RT DOOR AT BS 2285. REPAIRED PER EA 63-210884.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 76,791 hrs · 9,844 cycles

DURING LINE CHECK TEST, FOUND UPPER DECK RT EMERGENCY DOOR POWER SUPPLY AND BATTERY PACK INOPERATIVE. MAINTENANCE REMOVED AND REPLACED POWER SUPPLY AND BATTERY PACK PER AMM 33-51-04. SECURED AND FUNCTIONAL TEST OK.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 76,791 hrs · 9,844 cycles

DURING LINE CHECK TEST FOUND UPPER DECK RT EMERGENCY DOOR POWER SUPPLY AND BATTERY PACK INOPERATIVE. MNL MAINTENANCE REMOVED AND REPLACED POWER SUPPLY AND BATTERY PACK PER AMM 33-51-04. SECURED AND FUNCTIONAL TEST OK.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 76,791 hrs · 9,844 cycles

DURING LINE CHECK TEST FOUND UPPER DECK RT EMERGENCY DOOR POWER SUPPLY AND BATTERY PACK INOPERATIVE. MNL MAINTENANCE REMOVED AND REPLACED POWER SUPPLY AND BATTERY PACK PER AMM 33-51-04. SECURED AND FUNCTIONAL TEST OK.

Part: RECEPTACLE — BURNED (LAVATORY) · airframe 75,260 hrs · 9,643 cycles

DURING CRUISE, FLIGHT ATTENDANT REPORTED LIGHTS IN LAV BY DOOR 2L INOP AND STRONG ELECTRICAL BURNING SMELL. AIRCRAFT WAS DIVERTED TO ANC, AND AN EMERGENCY WAS DECLARED. LANDING WAS UNEVENTFUL. MAINTENANCE FOUND CHARRING IN ELECTRIC SOCKET. BALLAST WIRING WAS DISCONNECTED AND SECURED. LAV WAS MEL’D PER 38-30-1A, AND AIRCRAFT WAS RETURNED TO SERVICE. BALLAST 63-3300-3-0185 IS ON ORDER AND ASSIGNED TO BE INSTALLED 09FEB07 IN NRT.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 72,356 hrs · 9,260 cycles

DURING LINE CHECK FOUND UPPER DECK RT DOOR EMERGENCY POWER SYSTEM INOPERATIVE. REPLACED BATTERY PACK, TESTS OK. Â

Part: INTERCOSTAL — CRACKED (BS 1978) · airframe 70,670 hrs · 9,044 cycles

DURING "M" CHECK, FOUND CRACK IN INTERCOSTAL AT BS 1978 RBL 55. REPAIRED PER EA 63-205730.

Part: CONTROL UNIT — BURNED (SEAT) · airframe 69,280 hrs · 8,854 cycles

FLIGHT ATTENDANT REPORTED A BURNING ELECTRICAL ODOR BY ROW 80. MEL`D SEATS 80J&K. DTW - MAINTENANCE 01AUG05, REMOVED AND REPLACED ECU (SEAT ELECTRONIC CONTROL UNIT), AND RECALIBRATED SEATS. OPERATIONAL CHECKED GOOD, REMOVED MEL'S.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 64,172 hrs · 8,201 cycles

DURING LINE CHECK, FOUND B-ZONE RIGHT FLOOR PATH EMERGENCY LIGHTS INOPERATIVE. REPLACED POWER SUPPLY AND BATTERY PACK. OPERATIONAL CHECK GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 62,829 hrs · 8,037 cycles

DURING LINE CHECK, FOUND LEFT AND RIGHT SIDE FLOOR PATH EMERGENCY LIGHTS INOPERATIVE. REPAIRED LIGHTS. OPERATIONAL CHECK GOOD.

Part: LIGHT — INOPERATIVE (ROW 21A) · airframe 62,736 hrs · 8,025 cycles

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROW 21A TO DOOR 4L. REPAIRED LIGHT ASSEMBLY AT DOOR. OPERATIONAL CHECK GOOD.

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 62,378 hrs · 7,980 cycles

DURING L-CHECK, FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 21ABC - 31ABC. REPAIRED WIRING. OPERATIONAL CHECK GOOD.

Part: COMPRESSOR — MALFUNCTIONED (POTABLE WATER) · airframe 61,702 hrs · 7,893 cycles

DURING CRUISE, AN ELECTRICAL BURNING SMELL EMITTED IN THE CABIN AND FLIGHT DECK. TURNED OFF CABIN VIDEO AND FOLLOWED COM PROCEDURES FOR ELECTRICAL SMOKE AND REMOVED POWER TO THE RECIRCULATION AND GASPER FANS. SMELL DISSIPATED AND AIRCRAFT CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. REPLACED THE POTABLE WATER COMPRESSOR AND PRESSURE SWITCH. OPERATIONAL CHECK GOOD.

Part: WIRE — DISCONNECTED (EMERGENCY LIGHT) · airframe 60,543 hrs · 7,745 cycles

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 21-31. RECONNECTED WIRES. OPERATIONAL CHECK GOOD.

Part: WIRE — DISCONNECTED (EMERGENCY LIGHT) · airframe 59,763 hrs · 7,645 cycles

DURING LINE CHECK FOUND RIGHT FLOOR PATH EMERGENCY LIGHTS INOP IN A & 1/B ZONES. RECONNECTED AND SECURED WIRING. OPERATIONAL CHECK GOOD.

Part: CONTROLLER — FAILED (OVENS) · airframe 59,524 hrs · 7,614 cycles

DURING FLIGHT A ELECTRICAL ODOR WAS NOTICED AT THE TOP OF THE STAIRS LEADING TO THE UPPER DECK AND IN THE MAIN CABIN BY THE VIDEO CONTROLS. TURNED OFF GALLEY POWER AND VCR'S. AIRCRAFT CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. REPLACED 2-33/34 OVENS/CONTROLLERS AND REPOSITIONED 2-23 OVEN VENT HOLE. OPERATIONAL CHECK GOOD.

Part: WIRE — DISCONNECTED (EMERGENCY LIGHT) · airframe 59,066 hrs · 7,551 cycles

DURING LINE CHECK FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROW 10JK-DOOR 2R. RECONNECTED WIRES AND OPERATIONAL CHECK GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN) · airframe 58,813 hrs · 7,516 cycles

DURING LINE CHECK FOUND FLOOR PATH EMERGENCY LIGHTS INOP FROM 1L-2L. REPAIRED WIRES AND REPLACED POWER SUPPLY. OPERATIONAL CHECK GOOD.

Part: ODOR — DETECTED (GALLEY) · airframe 58,253 hrs · 7,445 cycles

DURING DESCENT, A BURNING ODOR EMITTED IN THE FORWARD PART OF THE GALLEY BY THE NR 4 DOOR. TURNED OFF GALLEY LIGHTS AND PULLED GALLEY CIRCUIT BREAKERS. AIRCRAFT CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. INSPECTED AND OPERATIONALLY CHECKED THE GALLEY EQUIPMENT WITH NO FAULTS FOUND.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 57,218 hrs · 7,309 cycles

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE. AFT OF ROW 52R, INSTALLED CONNECTOR ON LIGHT AT 52R. OPERATIONAL CHECK GOOD.

Part: CONNECTOR — DAMAGED (CABIN) · airframe 52,217 hrs · 6,705 cycles

DURING LINE CHECK, FOUND EMERGENCY ESCAPE PATH LIGHTS INOPERATIVE FROM ROWS 26ABC - 36ABC AND FROM ROW 11JK - DOOR 2R. REPAIRED ELECTRICAL CONNECTORS. OPERATIONAL CHECK GOOD.

Part: CONNECTOR — LOOSE (CABIN) · airframe 51,978 hrs · 6,675 cycles

DURING LINE CHECK, FOUND CABIN EMERGENCY ESCAPE PATH LIGHTING INOPERATIVE IN C AND D ZONE. RECONNECTED NUMEROUS LOOSE ELECTRICAL CONNECTORS AT LIGHT FIXTURES. OPERATIONAL CHECK NORMAL.

Part: WIRE — DAMAGED (CABIN) · airframe 51,713 hrs · 6,643 cycles

DURING LINE CHECK, FOUND EMERGENCY ESCAPE PATH LIGHTING INOPERATIVE BETWEEN SEAT ROWS 30-39R, 26-41L, 10-21R, AND AT LAVATORY DOOR 4R2. REPAIRED WIRING AND RESEATED ELECTRICAL CONNECTORS. OPERATIONAL CHECK NORMAL.

Part: PAN — DAMAGED (CABIN) · airframe 51,486 hrs · 6,614 cycles

DURING CRUISE, PASSENGER ENTERTAINMENT SYSTEM BECAME INOPERATIVE. FLIGHT ATTENDANT ATTEMPTED NUMEROUS SYSTEM RESETS FOLLOWED BY THE SMELL OF SMOKE IN A-ZONE. SMOKE SMELL DISAPPEARED WHEN SYSTEM WAS TURNED OFF AND LEFT OFF. REPAIRED DRIP BASIN ABOVE PROJECTOR BECAUSE OF WATER DRIPPINGS. REPLACED PROJECTOR AS A PRECAUTION.

Part: WIRE — DISCONNECTED (CABIN) · airframe 51,074 hrs · 6,563 cycles

DURING LINE CHECK, FOUND EMERGENCY ESCAPE PATH LIGHTS INOPERATIVE AT PASSENGER DOORS 1R AND 4L. RECONNECTED WIRING. OPERATIONAL CHECK NORMAL.

Part: WIRE — BROKEN (CABIN) · airframe 51,057 hrs · 6,561 cycles

DURING CRUISE, EMERGENCY ESCAPE PATH LIGHTS ILLUMINATED BETWEEN ROWS 39R-60R. REPAIRED OPEN WIRE. OPERATIONAL CHECK NORMAL.

Part: CONNECTOR — LOOSE (CABIN) · airframe 49,900 hrs · 6,419 cycles

DURING LINE CHECK, FOUND EMERGENCY FLOOR PATH LIGHTING INOPERATIVE IN B-ZONE ON LEFT SIDE. RECONNECTED LOOSE CONNECTION. OPERATIONAL CHECK NORMAL.

Part: WIRE — LOOSE (CABIN) · airframe 49,553 hrs · 6,375 cycles

DURING LINE CHECK, MAINTENANCE FOUND EMERGENCY ESCAPE PATH LIGHTING INOPERATIVE ROWS 51 - 62L. RECONNECTED LOOSE WIRING AT ROW 62ABC - 51ABC. OPERATIONAL CHECK NORMAL.

Part: VIDEO UNIT — SHORTED (CABIN) · airframe 6,184 hrs · 48,039 cycles

DURING PUSHBACK, HAD STRONG ELECTRICAL SMELL FROM VIDEO MONITOR LOCATED AT DOOR 4R. FLIGHT CREW STOPPED FLIGHT ON RAMP AND REQUESTED MAINTENANCE PERSONNEL FOR REPAIR. REPLACED THE 16 INCH VIDEO MONITOR. OPERATIONAL CHECK OK.

Part: FLOORBEAM — CORRODED (BS 940) · airframe 44,504 hrs · 5,756 cycles

DURING M-CHECK, FOUND CORROSION ON FLOORBEAM UPPER CHORD, TOP FLANGE. REPAIRED PER EA63-173152.

Part: FLOORBEAM — CORRODED (BS 860) · airframe 44,504 hrs · 5,756 cycles

DURING M-CHECK, FOUND CORROSION ON FLOORBEAM, UPPER CHORD. REPAIRED PER EA63-171416.

Part: FLOOR SUPPORT — CORRODED (BS 480 - 520) · airframe 44,504 hrs · 5,756 cycles

DURING M-CHECK, FOUND CORROSION ON FLOOR SUPPORT. REPAIRED PER EA 63-173153.

Part: LIGHT — INOPERATIVE (ROW 51-65)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 51A - 65A. RECONNECTED LIGHTS, OPERATIONAL CHECK GOOD.

Part: WIRE — LOOSE (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE AT ROWS 43ABC AND 51ABC AND FROM ROWS 36HJK TO 43HJK. RECONNECTED WIRES, OPERATIONAL CHECK GOOD.

Part: WIRE — LOOSE (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM DOOR 3L-4L AND FROM 3R-4R. RECONNECTED WIRES. OPERATIONAL CHECK OK

Part: WIRE — LOOSE (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 35C TO 43C AND AT ROW 52H. RECONNECTED WIRES, OPERATIONAL CHECK GOOD.

Part: CONNECTOR — FAILED (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 35ABC TO 43ABC. FOUND CONNECTOR PINS BAD. REPLACED LIGHT ASSEMBLY, OPERATIONAL CHECK OK.

Part: ENGINE — FAILED (NR 4)

ON TAKEOFF ROLL, THE CREW HEARD A LOUD POP FROM THE NR 4 ENGINE. THE EGT ROSE INTO THE RED AND OIL PRESSURE BEGAN TO DROP. THE ENGINE WAS SHUT DOWN AND TAKEOFF WAS ABORTED AT 20 TO 25 KTS. THE AIRCRAFT RETURNED TO THE GATE WHERE MAINTENANCE FOUND METAL IN THE TAILPIPE. THE ENGINE WAS REPLACED. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: LIGHT — LOOSE (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 36-43. RECONNECTED LIGHT ASSEMBLIES. OPERATIONAL CHECK GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING LINE CHECK, FOUND 3 UPPER DECK FLOOR PATH EMERGENCY LIGHTS INOPERATIVE BY THE STAIRS. REPLACED POWER SUPPLY. OPERATIONAL CHECK GOOD.

Part: WIRE — LOOSE (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 35H TO 42H. RECONNECTED ELECTRICAL WIRES, OPERATIONAL CHECK GOOD.

Part: WIRE — LOOSE (CABIN)

DURING LINE CHECK, FOUND FLOOR PATH EMERGENCY LIGHTS INOPERATIVE FROM ROWS 35HJK TO 43HJK AND FROM ROWS 77AB TO 79AB. SECURED WIRE, OPERATIONAL CHECK GOOD.

Part: CONNECTOR — LOOSE (CABIN)

DURING LINE CHECK, FOUND EMERGENCY FLOOR PATH LIGHTS INOPERATIVE ROWS 35 TO 43. RECONNECTED CANNON PLUG, OPERATIONAL CHECK GOOD.

Part: WIRE — LOOSE (CABIN)

DURING LINE CHECK, FOUND THE EMERGENCY FLOOR PATH LIGHT INOPERATIVE FROM ROWS 35C TO 43C AND 35H TO 43H AND FOUND EMERGENCY CEILING LIGHT INOPERATIVE AT 23C. RECONNECTED WIRES AND TIGHTENED LIGHT ASSEMBLY, OPERATIONAL CHECK GOOD.

Part: WIRE — BROKEN (CABIN)

DURING LINE CHECK, FOUND FLOOR EMERGENCY LIGHTS INOPERATIVE FROM ROWS 36HJK TO 40HKJ. REPAIRED WIRE, OPERATIONAL CHECK GOOD.

Part: WIRE — FAILED (LE FLAPS)

DURING CLIMB, THE NR 3 LEADING EDGE FLAP DID NOT RETRACT ACCOMPANIED BY A LEADING EDGE FLAP STATUS MESSAGE. AIRCRAFT RETURNED TO AMS AND LANDED WITHOUT INCIDENT. REPAIRED AN OPEN WIRE FROM THE COCKPIT CIRCUIT BREAKER TO THE LEADING EDGE FLAP CONTROL RELAY, OPERATIONAL CHECK GOOD.

Part: DRIVE UNIT — FAILED (NR 3 LE FLAP)

DURING CLIMB, THE NR 3 LEADING EDGE FLAP DID NOT RETRACT ACCOMPANIED BY A LEADING EDGE FLAP STATUS MESSAGE. AIRCRAFT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. REPLACED THE NR 3 LEADING EDGE FLAP DRIVE UNIT AND FOUR RELAYS, OPERATIONAL CHECK GOOD.

Part: FAN — FAILED (COCKPIT)

DURING CRUISE, SMOKE ACCUMULATED IN THE CABIN. AIRCRAFT DIVERTED TO NRT AND LANDED WITHOUT INCIDENT. REPLACED THE LOWER RECIRCULATION FAN, OPERATIONAL CHECK GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND C-ZONE LEFT AND STAIRWAY EMERGENCY TRACK LIGHTS INOPERATIVE. REPLACED BATTERY PACK AND POWER SUPPLY, OPERATIONAL CHECK GOOD.

Part: LIGHTS — INOPERATIVE

DURING LINE CHECK, FOUND EMERGENCY FLOOR PATH LIGTHS INOPERATIVE FROM ROWS 36R TO 43R. REPAIRED PLUG, OPERATIONAL CHECK GOOD.

Part: METERING VALVE — MALFUNCTIONED (RUDDER STEERING)

DURING TAKEOFF, THE STEERING TILLER WAS BINDING AND THE RUDDER STEERING HAD LIMITED CAPABILITY. ABORTED TAKEOFF AND RETURNED TO THE GATE. REPLACED THE STEERING METERING VALVE. OPERATIONAL CHECK GOOD.

Part: OIL LINE — FAILED (NR 2 ENGINE)

DURING CRUISE, THE NR 2 ENGINE WAS SHUT DOWN DUE TO LOW OIL QUANTITY. ENGINE WAS RESTARTED DURING APPROACH AND THE AIRCRAFT LANDED WITHOUT INCIDENT. REPLACED THE ANGLE GEARBOX PRESSURE LINE.

Part: CONNECTOR — LOOSE (CABIN)

DURING LINE CHECK, THE FLOOR MOUNTED EMERGENCY PATH LIGHTS AT SEAT ROWS 51L THROUGH 63L WERE FOUND INOPERATIVE. RECONNECTED CONNECTOR PIN AT SEAT ROW 63L AND OPERATIONAL CHECK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE CHECK, THE DOOR 3L AND LEFT OVERWING EMERGENCY LIGHTS WERE FOUND INOPERATIVE. REPLACED THE EMERGENCY LIGHTS BATTERY PACK AND OPERATIONAL CHECK OK.

Part: CONNECTOR — LOOSE (CABIN)

DURING LINE CHECK, THE FLOOR PATH EMERGENCY LIGHTS BETWEEN SEAT ROWS 35 TO 43 WERE FOUND INOPERATIVE. RECONNECTED EMERGENCY LIGHT CONNECTOR AT SEAT ROW 43 AND OPERATIONAL CHECK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE CHECK, THE OVERHEAD EMERGENCY LIGHTS AT BOTH DOOR 2L AND 2R WERE FOUND INOPERATIVE. REPLACED EMERGENCY LIGHT BATTERY PACK AND CHARGE, OPERATIONAL CHECK OK.

Part: LIGHT — INOPERATIVE (DOOR 5R)

DURING LINE CHECK, THE DOOR 5R EMERGENCY SLIDE LIGHT WAS FOUND INOPERATIVE. REPLACED THE DOOR 5R SLIDE LIGHT ASSEMBLY AND OPERATIONAL CHECK OK.

Part: EEL CONNECTOR — LOOSE (CABIN)

TPE - DURING LINE CHECK, THE EMERGENCY PATH FLOOR LIGHTS BETWEEN SEAT ROWS 20L TO 14L WERE FOUND INOPERATIVE. RECONNECTED PIN IN FLOOR TRACK AT LIGHT ASSEMBLY AND OPERATIONAL CHECK OK.

Part: CONNECTOR — LOOSE (L5 DOOR SLIDE)

TPE - DURING LINE CHECK, THE DOOR 5L EMERGENCY SLIDE LIGHT WOULD NOT EXTINGUISH. CHECKED WIRING AND RESEATED CANNON PLUG, OPERATIONAL CHECK OK.

Part: DOOR — MISSING (AIR COND COMPT)

UPON ARRIVAL INTO NRT, THE NR 3 AIR CONDITIONING PACK INLET DOOR WAS DISCOVERED MISSING, ACCOMPANIED WITH ADJACENT PANEL DAMAGE. REPLACED DOOR ASSSEMBLY, AIRCRAFT APPROVED FOR SERVICE.