N728DA

Part: SKIN — CRACKED (FUSELAGE) · airframe 63,803 hrs · 29,745 cycles

COCKPIT EMERGENCY ESCAPE HATCH OPENING CRACKED AT AFT I/B CORNER. CRACK IS APPROX 1.25 INCH LENGTH, THRU VENT HOLE. REPAIRED PER SRM.

Part: SKIN — CRACKED (FUSELAGE) · airframe 63,803 hrs · 29,745 cycles

COCKPIT EMERGENCY EXIT HATCH OPENING CRACKED AT AFT I/B CORNER. FOUND DURING ROUTINE INSP OPN57161. INSTALLED REPAIR DOUBLER AND TRIPLER PER SRM 53-31-00 FIG 840.

Part: DUCT — LEAKING (NR 1 ENGINE) · airframe 63,571 hrs · 29,662 cycles

DURING CLIMB HAD SMOKE IN COCKPIT AND CABIN. FOUND LEFT COMPENSATOR DUCT LEAKING BENEATH C1 B/B. REPLACED DUCT.

Part: CONNECTOR — FAILED (NR 2 ENGINE) · airframe 63,288 hrs · 29,559 cycles

NR 2 ENG FUEL FLOW 4000 LBS HIGHER THAN NR 1 AND NR 3. HIGH FLOW CONFIRMED BY FUEL BURN ACTUAL.AFTER LANDING NR 2 ENG. SHUTDOWN IMMEDIATELY AND FUEL LEAK CONFIRMED BY EMERGENCY PERSONNEL AND MAINTENANCE. LOWER OIL TEMP AND FUEL TEMP VERIFIED HIGH FLOW. FOUND BLOWN O-RING AND BAD HELI-COIL AT HIGH PRESSURE LINE AND ELBOW ON FUEL PUMP. REPLACED ELBOW AND O-RINGS ON HP LINE. RAN ENGINE, LEAK CKS GOOD.

Part: ENGINE — SMOKE (NR 2) · airframe 62,946 hrs · 29,449 cycles

SMOKE SMELL IN AFT GALLEY WITH NO SMOKE VISIBLE. SMOKE ALARMS ACTIVATED. REPLACED NR 2 ENGINE DUE PRODUCING OIL SMOKE.

Part: ELBOW — CRACKED (-B- HYD SYSTEM) · airframe 62,896 hrs · 29,438 cycles

SYSTEM B HYDRAULIC RESEVIOR LEVEL DECREASED TO .25. TANK SHUT DOWN SYSTEM. REPLACED ELBOW ON PRESSURE LINE ON NR 2 ENGINE, HYD PUMP AND REPLACED PACKING ON TRANSFER LINE ON LEFT ELEVATOR FEEL UNIT. PERFORMED LEAK CHECK, NO DISCREPANCIES ENCOUNTERED.

Part: OVEN — FIRE (GALLEY)

BURNING IN LOWER GALLEY, FOOD LEFT IN OVEN. HALON BOTTLES USED ALONG WITH PBE-S BY FLT ATTN. ALL WAS CONTAINED IN OVEN. REMOVED REMAINS FROM OVEN. OVEN IS SERVICEABLE AND WORKS NORMAL.

Part: LIGHT — INTERMITTENT (CABIN)

L1 EVACUATION LIGHT OPERATES INTERMITTENTLY. REPLACED POWER SUPPLY.

Part: POWER SUPPLY — INOPERATIVE (PAX DOOR)

ON L/O, FOUND SEVERAL EMERGENCY LIGHT STRIPS IN 1ST CLASS AND COACH INOP. REPLACED EMERGENCY LIGHTS BATTERY PACK AT R1 DOOR, CKS GOOD.

Part: ACTUATOR — FAILED (RT MLG)

ATB, AFTER T/O MAIN LANDING GEAR TRUCK LIGHT ILLUMINATED. TROUBLESHOT PER FIM 32-30-00 PG 120. REPLACED RT LEVEL CYL, OPS AND LEAK CK NORMAL AND OK.

Part: WIRE — BROKEN (GALLEY)

GALLEY SMOKE WARNING LIGHT ILLUM INTERMITTANTLY. AURAL WARNING DOES NOT ACTUATE, ALL OVENS OFF. SMOKE DETECTOR C/B PULLED. REPLACED SMOKE DETECTOR AND AMPLIFIER.

Part: VALVE — FAILED (NR 1 ENGINE)

NR 1 ENGINE ANTI ICE INOP, C/B POPPED. DUE TO HISTORY FWD TO MCO AND PLAC PER MEL 30-21-01B. NEEDS VALVE ASSY P/N 307001045 NIS CVG VALVE LOCKED IN OPEN POSITION.

Part: COALESCER — CONTAMINATED (CABIN)

SMOKE IN COCKPIT AND AFT CABIN. REPLACED WATER SEPARATORS. PERFORMED DUCT BURN-OUT.

Part: SPAR CAP — CRACKED (BS 1103)

THE UPPER SPAR CAP OF THE FS 1103 INTERMEDIATE SPAR WAS FOUND WITH TYPICAL CRACKING AT LEFT END. THE CRACK WAS BEYOND THE ALLOWABLE LIMITS SPECIFIED IN LAC S/B 093-57-087. THE CAP WAS CUT I/B OF LBL 94.5 AND A NEW SECTION WAS SPLICED IN WITH STEEL REPAIR ANGLES AND STRAPS PER ER/A 365477-14, REV B.

Part: ACTUATOR — INOPERATIVE (NR 3 PACK)

ON TAKEOFF, NR 3 PACK OVERHEATED CAUSING A GREAT DEAL OF SMOKE IN THE CABIN. FOUND NUMBER 3 PACK RAM AIR DOOR ACTUATOR STUCK. REPLACED ACTUATOR.

Part: POWER SUPPLY — FAILED (CABIN)

EMERGENCY LIGHTS FAILED AT L2, R2, LWR GAL AND RT GAL LIFT.REPLACED EMERGENCY LIGHT PWR SUPPLY UNIT.

Part: TIRE — SEPARATED (NLG)

AFTER V1 ON T/O ROLL, THERE WAS A LOT OF VIBRATION FROM THE NOSEWHEEL. AFTER LIFTOFF C-SYSTEM LOST MOST OF ITS QTY. RETURNED TO ATL. FOUND LT NOSE TIRE CAME APART AND BROKE THE C-SYS LINE TO THE NOSE STEERING ACTUATOR. REPLACED SAME AND RELACED WHEEL ASSY.

Part: PRESSURE PANEL — CRACKED (BS 378)

THE FUSELAGE HORIZTONAL PRESSURE DECK PANEL WAS FOUND WITH TWO CRACKS APPROX .75 INCH LONG EACH. THE CRACKS ARE LOCATED AT RBL 102, JUST AFT OF STA 378, AND EXTEND DIAGONALLY INBOARD/ AFT AND OUTBOARD/ AFT FROM THE FORWARD EDGE OF THE PANEL AT THE EXISTING FRAME CUTOUT. ONE OF THE CRACKS EXTENDS TO THE LOWER INTEGRAL PANEL STIFFENER AT APPROX RBL 102. THESE CRACKS WILL BE REPAIRED WITH A DOUBLER.

Part: SKIN — CORROSION (BS 1545)

MTC FOUND SKIN BULGING AT FS 1545 BETWEEN STR 28 AND 30. THE SKIN CUTOUT WAS 22.5 BY 12. THE BONDED SKIN DOUBLER JUST FORWARD OF THIS CUTOUT AT STR 30 WAS ALSO FOUND CORRODED, AND A 9 BY 9 SQAURE WAS REMOVED ALONG THE EDGE OF THIS SKIN PANEL. THIS DAMAGE WAS REPAIRED WITH A DOUBLER AND TRIPLER.

Part: SKIN — CORROSION (CARGO DOORWAY)

CORROSION DAMAGE WAS FOUND ON THE C-3 DOOR SURROUND DOUBLER, TRIPLER, AND EXTERNAL SKIN. THE DOOR SURROUND DOUBLER WAS CUT ABOVE STR 24 AND THE TRIPLER WAS LOCALLY TRIMMED IN THE OUTSIDE RADIUS JUST FWD OF FS 1677. NEW SECTIONS OF THE DOUBLERS WERE SPLICED IN. THIS REPAIR WAS APPROVED BY FAA/DER FORM 8110-3, DER DESIGNATION SO-889, DATED 8-21-97.

Part: DRAG STRUT — CORROSION (NR 1 ENG PYLON)

THE FORWARD O/B LUG OF THE NR 1 ENGINE PYLON DRAG STRUT WAS FOUND WITH CORROSION DAMAGE ON THE OUTER SURFACE OF THE LUG. THE LUG HAS BEEN SPOTFACED 0.050 TO REMOVE CORROSION. THE NR 1 PYLON DRAG STRUT O/B LUG THICKNESS REMAINING IS 1.353. THE LUG WAS REWORKED.

Part: DRAG STRUT — CORROSION (NR 3 ENG PYLON)

THE FWD O/B LUG OF THE NUMBER 3 ENGINE PYLON DRAG STRUT WAS FOUND WITH CORROSION DAMAGE ON THE INNER AND OUTER FACES. THE INNER FACE OF THE OUTBOARD LUG WAS MACHINED 0.041. THE OUTER FACE OF THE OUTBOARD LUG WAS MACHINED 0.023. A LOCAL BLEND OF 0.013 BY .375 DIAMETER WAS ALSO REQUIRED TO REMOVE CORROSION FROM THE OUTER FACE. THE NR 3 PYLON DRAG STRUT OUTBOARD LUG THICKNESS REMAINING IS 1.333.

Part: RIB — CRACKED (NR 1 TE FLAP)

THE LOWER FITTING ON THE I/B RIB OF THE RT NR 1 FLAP AT ITS 27.4 WAS FOUND COMPLETELY SEVERED APPROX 6 AFT OF THE FORWARD EDGE. ALSO, THE EXTERNAL WEB WAS FOUND WITH AN APPROX 4 LONG CRACK ON THE SAME RIB. THESE CRACKS ARE TYPICAL PER THE LAC S/B 093-57-109 AND WILL BE REPAIRED IN ACCORDANCE WITH THAT S/B.

Part: PACK — MALFUNCTIONED (FWD AC BAY)

SMOKE IN COCKPIT AND CABIN, COMPLIED WITH POM, SHUTOFF NR 3 PACK AND ISOLATION VLV SMOKE DECREASED.

Part: SPAR — CORRODED (CENTER WING)

THE CENTER WING REAR SPAR AT FS 1212 WAS FOUND WITH CORROSION ON THE UPPER WEB AT RBL 102.

Part: PRESS PANEL — CORRODED (BS 1212)

CORROSION ON FS 1212 BELOW CANTED PRESSURE PANEL IN RIGHT W/WAT APPROX RBL 96.5, NON-ROUTINE CARD 3. REMOVED VERT STIFFNER AT RBL 96, FABRICATED DOUBLER AND FILLER, REMOVED CORROSION. HFEC INSP OF BLENDED AREA OK. ROTO PEENED BLENDED AREA PER PS 900-4 NR 5, FABRICATED SHIMS, CONT ON NR 16, DRILLED TREATED AND PAINTED FILLERS AND FITTING. TREATED AND PAINTED EFFECTED AREA ON WEB, GOT OK TO INSTALL PER QA. INSTALLED AND FINISHED REPAIR, INSTALLATION OK PER QA.

Part: WASTE WATER PNL — MOISTURE CONTAM (FE PANEL)

ON TAXI OUT, FLT RCDR WASTE WATER PANEL BEGAN SPARKING DUE TO MOISTURE. PULLED CBS, RETURNED TO GATE.

Part: LONGERON — CORRODED (BS 328)

THE FUSELAGE NOSE WHEELWELL LONGERON AT LBL 22 WAS FOUND WITH EXTENSIVE CORROSION AT FS 328. DUE TO THE EXTENT OF THE CORROSION, THE LONGERON WILL BE CUT AT FS 339 AND A NEW REPLACEMENT SECTION WILL BE SPLICED IN.

Part: BATTERY PACK — DISCHARGED (CABIN)

L2 DOOR EMERGENCY LIGHT BATTERY PACK FAILS OPN. REPLACED BATTERY PACK.

Part: SKIN — CORRODED (BS 819)

DURING LTR CHK, THE FUSELAGE SKIN AT FS 819, BL 0 WAS FOUND CORRODED. THE DAMAGED SKIN WAS CUT OUT AND A FILLER/DOUBLER REPAIR WAS INSTALLED.

Part: BATTERY PACK — DISCHARGED (CABIN)

L-1 DOOR EMERGENCY LIGHT BATTERY PACK FAILS OPN. REPLACED BATTERY PACK, OPS CHECK NORMAL.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

PWR SUPPLY AT R-4 DOOR FAILS FUNCTION TEST. REPLACED POWER SUPPLY, OPS CHECK NORMAL.

Part: PWR SUPPLY — INOPERATIVE (CABIN)

NR 1 RT DOOR EMERGENCY SLIDE LIGHT INOP. REPLACED POWER SUPPLY, OPERATION NORMAL.

Part: BULKHEAD — CRACKED (FS 1212)

WHILE PERFORMING THE FS 1212 CANTED BULKHEAD INSPECTION PER SI 7-70645-12, A CRACK WAS FOUND AT LBL 10.0. THE CRACK WAS TRIMMED OUT AND REPAIRED PER DL ERA 273562-14.

Part: COALESCER BAG — DIRTY (LT/RT)

ON SHORT FINAL, AFT OF A/C FILLED WITH HAZY SMOKE AND ALL LAV SMOKE DETECTORS WENT OFF, PACK TEMPS NORMAL. RAN ENGS AND ALL THREE PACKS. FOUND NR 2 PACK RUNNING HOT AND GIVING OFF ODOR. LOCKED NR 2 PACK VALVE CLOSED AND FWD TO MCO AND PLAC PER 21-51-07A. REPLACED WATER SEPARATOR BAGS, RAN ALL PACKS AND NO ODOR NOTED, INSPECTED CROSSFEED VALVES FOR OIL CONTAMINATION, NONE FOUND.

Part: N2 INDICATOR — INTERMITTENT (NR 2 ENG)

DURING TAKEOFF, EPR AT 1.522 THE N2 GAUGE WAS PEGGED OUT HIGH ABOVE 120 PERCENT ON NR 1 ENGINE FOR 4 SECONDS. REPLACED NR 1 ENG N2 INDICATOR AS PRECAUTIONARY. SWAPPED N2 PROBE TO ALTERNATE PICK UPS. RAN ENGINE TO TAKEOFF POWER, CKS OK.

Part: OIL PRESS TRANS — FAILED (NR 3 ENGINE)

ON TAKEOFF, NR 3 ENG OIL PRESS INDICATED HIGH, 100 PSI PLUS. ABORTED TAKEOFF UNDER 60 KTS, RETURNED TO GATE AT LOW POWER, EQUAL N2 ON NR 1 AND NR 3 ENG AT 85 PERCENT, NR 2 ENG OIL PRESS READ 58 PSI, NR 3 ENG OIL PRESS INDICATING 82 PSI. REPLACED OIL PRESS TRANSMITTER, BLEW OUT TRANSMITTER AND PRESS SW LINE AND CHECKED CHIP DETS. RAN ENG LEAK AND OPS CK NORMAL.

Part: PUMP — LEAKING (C-HYD SYST)

DURING GEAR EXT ON APPROACH, C-SYS HYD QTY LO QTY LIGHT ON AND C-SYS PRESSURE DROPPED TO ZERO. HOWEVER, GEAR HAD FULLY EXTENDED, 3 GREEN QTY IN C-SYS DROPPED TO AND REMAINED AT .125 FULL. FOUND C-SYS ATM HYD PUMP LEAKING AT SPLIT LINE. REMOVED PUMP AND REPLACED SAME.

Part: DOOR FRAME — CORRODED (FS 829)

THE FS 829 DOOR FRAME HAD CORROSION DAMAGE AT THE FWD FLANGE JUST O/B OF THE SILL. ALSO, THE FS 829 FRAME SUSTAINED CORROSION DAMAGE TO THE WEB JUST O/B OF THE SILL TENSION FITTING. ACCOMPLISHED REPAIRS PER DL ERA 272242-14.

Part: DUCT — RUPTURED (NR 2 PACK)

ON LANDING, SMOKE NOTICED IN COCKPIT AND CABIN. NR 2 TURBINE BYPASS DOOR, FULL HOT IN AUTO OR MANUAL. THE C-AREA OVERHEAT CAME ON, FOLLOWED BY B-AREA. SHUTOFF NR 2 AND 3 PACKS. ACM DISCHARGE TEMPS OVER 96 FOR BOTH PACKS. THE NR 2 FLOW CONTROL C/B POPPED. FOUND DUCT BLOWN FROM NR 2 ACM AND WATER SEPARATOR. LOCKED OUT FLOW CONTROL PER MEL.

Part: TGT INDICATOR — SMOKING (NR 2)

DURING CRUISE, NR 2 TGT GAUGE BEGAN SMOKING IN FLIGHT. OFF FLAG APPEARED, PULLED CIRCUIT BREAKER, SMOKE STOPPED. LANDED IAD. REPLACED NR 2 TGT INDICATOR OPERATION NORMAL.

Part: DUCT — BLOWN (LOWER MID FUS)

ON TAKOFF ROLL HAD LOUD BANG MID CABIN AREA. RETURNED TO GATE, FOUND RUPTURED NR 3 ENGINE PNEUMATIC DUCT AT RT MID FUSELAGE AFT OF GALLEY SERVICE DOOR. REPLACED DUCT AND AS A PRECAUTION, REPLACED NR 3 OVERPRESSURE SHUTOFF VLV AND ENGINE ISOLATION VLV. OPERATION NORMAL.