N7519A

Part: BOLT — BROKEN (ENGINE MOUNT) · airframe 60,055 hrs · 31,157 cycles

AIRCRAFT ARRIVED WITH CDL FOR LEFT WING LOWER FORWARD PYLON VIBRATOR ABSORBER MISSING. FOUND THE BOLT HEAD BROKEN OFF OF THE BOLT WHERE THE VIBRATOR ISOLATOR MOUNTS. THIS IS THE SAME BOLT THAT ATTACHES THE ENGINE MOUNT TO THE FRAME. REF IPC 71-20-00-04 FIGURE 04 SHEET 1 ITEM 430. REPLACED BOLT.

Part: BATTERY PACK — MALFUNCTIONED (CABIN) · airframe 59,054 hrs · 30,595 cycles

TAIL CONE EMERGENCY LIGHTS DO NOT TEST. RE-SEATED BATTERY PACK. OPS CHECKED NORMAL.

Part: CONTROL VALVE — INOPERATIVE (LANDING GEAR) · airframe 57,886 hrs · 29,934 cycles

DFW - CREW REPORTED LANDING GEAR UNSAFE INDICATION. EMERGENCY EXTENSION WAS USED AND GEAR EXTENDED NORMALLY. EMERGENCY DECLARED LANDED DFW WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. FOUND LANDING GEAR HANDLE WAS JAMMED. REPLACED LANDING GEAR CONTROL VALVE AND COMPLETED FUNCTIONAL FLIGHT CHECK. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

FUSELAGE LEFT HAD GOUGES IN SKIN BETWEEN STATION 195 AND 215, BETWEEN LONGERON 4 LEFT AND LONGERON 5 LEFT. INSTALLED REPAIR DOUBLER PER ENGINEERING AUTHORITY MD80-53-00769 AND SRM 53-04-00 FIGURE 38 SHEET 21.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 56,637 hrs · 29,254 cycles

CORROSION ON CUSP AT STATION 215 TO 221 OUTBOARD OF NUMBER 6 SEAT TRACK. INSTALLED REPAIR DOUBLER PER AARD 53-20-00-16.

Part: FRAME — CRACKED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

RIGHT FRAME CRACKED AT STATION 886. INSTALLED FRAME AT STATION 886 RIGHT PER DRAWING SR09530282 AND ECO K3290AD.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

CRACK IN LEFT LONGERON NUMBER THREE AT STATION 160 OUTBOARD. INSTALLED LONGERON SPLICE PER SRM 53-02-00.

Part: BEAM — CORRODED (CARGO BAY) · corrosion level 2 · airframe 56,637 hrs · 29,254 cycles

TOP OF WEB INBOARD OF DOOR BEAM HAS CORROSION AT STATION 1155 TO 1211. INSTALLED NEW SECTION OF WEB AT STATION 1147-1162 PER AARD 53-10-00-24 AND SRM 53-01.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

FLOORBEAM SUPPORT IS CRACKED AT LOWER OUTBOARD SIDE OF STATION 927 BELOW SEAT TRACK NUMBER TWO. INSTALLED FLOORBEAM SUPPORT AT STATION 927 BELOW SEAT TRACK NUMBER TWO.

Part: DIAPHRAGM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 56,637 hrs · 29,254 cycles

CORROSION ON BOTTOM SIDE OF DIAPHRAGM BY FORWARD SERVICE DOOR. INSTALLED NEW DIAPHRAGM DOUBLER PER SRM 53-14-01 AND AARD 53-20-00-16.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

LEFT CUSP IS CRACKED AND CORRODED AT STATION 880 TO 882. INSTALLED DOUBLER REPAIR PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 56,637 hrs · 29,254 cycles

LEFT CUSP HAS CORROSION AT STATIONS 1268 TO 1308 IN MULTIPLE AREAS. REPLACED CUSP SHEET AT LEFT STATION 1250-1308 PER AARD 53-20-00-16.

Part: SKIN — DAMAGED (FLAP VANE) · airframe 56,637 hrs · 29,254 cycles

LEFT WING DAMAGE AT NUMBER 3 FLAP VANE LEADING EDGE SKIN. INSTALLED HOT BOND REPAIR PER ESO 80096.

Part: BRACKET — CORRODED (FUSELAGE) · corrosion level 2 · airframe 56,637 hrs · 29,254 cycles

AFT LOWER CORNER BRACKET HAS CORROSION IN DOOR OPENING AT STATION 1211. INSTALLED NEW BRACKET UNDER SRM 51-30-00.

Part: RIB — CRACKED (LT WING) · airframe 56,637 hrs · 29,254 cycles

LEFT WING NUMBER 5 SLAT OUTBOARD RIB AT NUMBER 15 SLAT TRACK ATTACH IS CRACKED. REMOVED NUMBER 15 TRACK ATTACH RIB AND INSTALLED NEW ATTACH RIB PER ESO 80117.

Part: SKIN — CRACKED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

CRACK IN LEFT FUSELAGE SKIN AT STATION 1474. INSTALLED DOUBLER PER SRM 53-01-00-FIG 2 SHEET 3.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 56,637 hrs · 29,254 cycles

CUSP CORRODED OUT OF LIMITS AT AFT SERVICE DOOR UNDER FORWARD GIRT BAR SUPPORT BRACKET. INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 56,637 hrs · 29,254 cycles

CORROSION ON CUSP AT STATION 968 TO 970. INSTALLED DOUBLER UNDER SRM 53-20-00-16.

Part: SKIN — GOUGED (CARGO DOOR) · airframe 56,637 hrs · 29,254 cycles

FORWARD CARGO DOOR HAD GOUGES IN SKIN ON LOWER RIGHT EDGE. INSTALLED REPAIR DOUBLER ON LOWER RIGHT EDGE PER ESO 80174.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 56,637 hrs · 29,254 cycles

FORWARD CARGO DOOR STOP PAD FITTING AT FORWARD END OF NUMBER 1 BEAM IS CRACKED. REMOVED AND REPLACED STOP PAD FITTING AT FORWARD END OF NUMBER 1 BEAM.

Part: STOP FITTING — CRACKED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

DOOR STOP FITTING AT FORWARD END OF NUMBER 3 BEAM IS CRACKED. REMOVED DAMAGED STOP PAD FITTING AND INSTALLED NEW FITTING PER ESO 80174.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 56,637 hrs · 29,254 cycles

AFT CARGO DOOR STOP PAD FITTING AT FORWARD END OF NUMBER 1 BEAM IS CRACKED. REMOVED AND REPLACED STOP PAD FITTING AT FORWARD END OF NUMBER 1 BEAM.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 56,637 hrs · 29,254 cycles

FORWARD CARGO DOOR STOP PAD FITTING AT FORWARD END OF NUMBER 3 BEAM IS CRACKED. REMOVED AND REPLACED STOP PAD FITTING PER ESO 80174.

Part: STOP FITTING — CRACKED (CARGO DOOR) · airframe 56,637 hrs · 29,254 cycles

MID CARGO DOOR STOP PAD FITTING AT FORWARD END OF NUMBER 5 BEAM IS CRACKED. REPLACED DOOR STOP PAD FITTING AT FORWARD END OF NUMBER 5 BEAM PER ESO 80174.

Part: TEE FITTING — CRACKED (CARGO DOOR) · airframe 56,637 hrs · 29,254 cycles

MID CARGO DOOR T-FITTING INSIDE UNDER LOWER AFT STOP PAD STRAP IS CRACKED. REPLACED T-FITTING INSIDE UNDER LOWER AFT STOP PAD STRAP PER ESO 80174.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 54,850 hrs

LGA- EMERGENCY LIGHTS AT FIRST CLASS INOPERATIVE. REPLACED BATTERY PACK IN FIRST CLASS.

Part: FLASHLIGHT — INOPERATIVE (CABIN) · airframe 54,197 hrs

LAX - EMERGENCY FLASHLIGHT AT LEFT NUMBER ONE DOOR INOPERATIVE. REPLACED PORTABLE EMERGENCY LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: COMPRESSOR — STALLED (NR 2 ENGINE) · airframe 53,224 hrs

DFW INFLIGHT T1413/11JUN. CREW REPORTED NR TWO ENGINE COMPRESSOR STALL ON CLIMB. CREW REDUCED POWER TO IDLE. RETURNED TO DFW AND LANDED WITHOUT INCIDENT. REPLACED NR TWO ENGINE ON 11JUN AT DFW. SYSTEM GROUND CHECKED NORMAL OPERATION. (A)

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 52,596 hrs

LGA - EMERGENCY LIGHT AT OVERHEAD FIRST CLASS LAVATORY INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY LIGHT AT OVERHEAD FIRST CLASS LAVATORY. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ENGINE — BIRD INGESTION (LEFT)

ORD INFLIGHT T405/09NOV - AIRCRAFT EXPERIENCED NUMBER ONE ENGINE STALLS AT APPROXIMATELY 2000 FEET DURING CLIMB. ENGINE STALLS STOPPED WHEN NUMBER ONE ENGINE AT IDLE. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. FOUND EVIDENCE OF BIRD STRIKE. REPLACED ENGINE ON 10 NOV 2007 AT ORD. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: MEMBRANE — CRACKED (FUSELAGE) · airframe 56,637 hrs · 29,254 cycles

SUBFLOOR CRACKED 6.0 INCHES INBOARD OF DOOR FRAME AT STATION 200. REMOVED DAMAGE AND INSTALLED REPAIR DOUBLER PER AARD 53-20-00-16.

Part: FILTER — CLOGGED (RT ENGINE OIL)

DFW INFLIGHT T1141/24JAN - RIGHT ENGINE OIL STRAINER CLOG LIGHT ILLUMINATED IN FLIGHT AT FLIGHT LEVEL 300. OIL TEMPERATURE 114 DEGREES. SHUT DOWN RIGHT ENGINE AND DESCENDED. ENGINE WINDMILLED FOR 38 MINUTES. FOUND METAL IN OIL SCREEN AND FILTER. REPLACED RIGHT ENGINE ON 25 JAN AT DFW. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

ORD - EMERGENCY EXIT LIGHTS AT OVERWING INOPERATIVE. REPLACED BATTERY PACK FOR EMERGENCY EXIT LIGHTS AT OVERWING. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

ORD - EMERGENCY LIGHTS IN AFT CABIN INOPERATIVE. REPLACED BATTERY PACKS AT B527 FOR EMERGENCY LIGHTS IN AFT CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: COMPRESSOR — STALLED (LT ENGINE)

ORD - INFLIGHT AT LIFT OFF OF NOSE WHEEL AIRCRAFT JERKED TO THE LEFT. FLIGHT ATTENDANTS IN BACK HEARD A BANG. NO INDICATION OF AN ENGINE SURGE OR STALL. LANDED ORD WITHOUT INCIDENT. FLIGHT DATA RECORDER INDICATED A COMPRESSOR STALL AT TAKEOFF FOR THE LEFT HAND ENGINE. REPLACED LEFT HAND ENGINE ON 22 JUNE 2006 AT ORD.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

SFO - LEFT AND RIGHT NUMBER ONE DOOR EMERGENCY LIGHTS ON CEILING INOPERATIVE. REPLACED FORWARD BATTERY PACK FOR LEFT AND RIGHT NUMBER ONE DOOR EMERGENCY LIGHTS ON CEILING. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ENGINE — LEAKING (ZONE 600)

CLT INFLT T2288/23JUL ON DECENT TO CLT RT ENGINE OIL QUANTITY DROPPED TO ZERO. OIL TEMPERATURE BEGAN TO RISE INTO AMBER. N1 AND N2 APPEARED NORMAL. FOUND OIL LEAK IN NUMBER 6 BEARING COMPARTMENT. REPLACED RIGHT ENGINE. SYSTEM GROUND CHECKED NORMAL OPERATION. (CLOSED)

Part: BATTERY PACK — DISCHARGED (CABIN)

TUL - OVERWING EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK AT STATION 1050 LEFT FOR OVERWING EMERGENCY LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (CABIN)

AUS - EXTERIOR EMERGENCY LIGHTS IN CABIN. REPLACED BATTERY PACK FOR EXTERIOR EMERGENCY LIGHTS IN CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: PISTON — INOPERATIVE (NLG)

ORD - INFLIGHT AFTER TAKEOFF NOSE GEAR OR DOORS WOULD NOT RETRACT. NOSE LANDING GEAR INDICATION WAS DOWN FLUSH BUT VERY LOUD AIRFLOW DISRUPTION AROUND COCKPIT. RED NOSE GEAR INDICATION AND TWO GREENS ON THE MAINS. CYCLED GEAR WITH SAME INDICATIONS. GOOD DOWN AND LOCKED INDICATION. RETURNED TO ORD AND LANDED WITHOUT INCIDENT. OUT OF SERVICE TO HANGAR FOR EVALUATION. REPLACED NOSE TURNING TUBE AND PISTON ASSEMBLY. SERVICED STRUT WITH NO LEAKS NOTED. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: RETRACT CYLINDER — INOPERATIVE (NLG)

AFTER TAKEOFF, NOSE GEAR FAILED TO RETRACT. FLEW EXTENDED DOWN WIND TO BURN FUEL. LANDED AT MIA WITHOUT INCIDENT. REPLACED NOSE GEAR INNER CYLINDER. ACCOMPLISHED NOSE LANDING AND DOORS CHECK. CHECK FLIGHT COMPLETED. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: PROXIMITY SWITCH — INOPERATIVE (MLG)

MIA - EN ROUTE MIA-DFW NOSE LANDING GEAR WOULD NOT RETRACT. RETURNED MIA AND LANDED WITHOUT INCIDENT. REPLACED PROXIMITY SWITCH ELECTRONIC UNIT AND CLEANED NOSE GEAR UP SENSOR. CYCLED NOSE GEAR NUMEROUS CYCLES. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

DFW - AFT OVERWING HATCH EXIT EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK FOR AFT OVERWING HATCH EXIT EMERGENCY LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS)

DFW - FORWARD OVERWING HATCH EMERGENCY EXIT LIGHT INOPERATIVE. REPLACED BATTERY PACK FOR FORWARD OVERWING HATCH EMERGENCY EXIT LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

DFW - CABIN CEILING EMERGENCY LIGHTS AT ROWS 22 THROUGH 27 INOPERATIVE. REPLACED BATTERY PACK AT B5-106 FOR CABIN CEILING EMERGENCY LIGHTS AT ROWS 22 THROUGH 27. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

DURING OVERNIGHT MAINTENANCE, OBSERVED EMERGENCY ESCAPE PATH LIGHTING INOPERATIVE AT SEAT ROWS 26 THROUGH 31. REPLACED BATTERY PACK. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, OBSERVED EMERGENCY ESCAPE PATH LIGHTING INOPERATIVE AT THE AFT GALLEY DOOR SECTION. REPLACED BATTERY PACK. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: OIL FILTER — CLOGGED (RT ENGINE)

FLT 700 - DFW-LGA - AFTER TAKEOFF RIGHT OIL STRAINER CLOGGING LIGHT CAME ON WHILE CLIMBING THROUGH 17,000. AIRCRAFT RETURNED DFW AND LANDED WITHOUT INCIDENT. REPLACED FILTER AND FILTER CLOG PRESSURE SWITCH. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: SKIN — DENTED (FUSELAGE)

TUL - FOUND DENT IN FUSELAGE SKIN AT OUTFLOW VALVE, STATION 1263 BETWEEN LONGERONS 21 AND 22 LEFT. DENTED UP TO 0.115 INCH DEEP. INSTALLED REPAIR DOUBLER PER ESO 80559. (M)

Part: FRAME — CRACKED (FUSELAGE)

TUL - FOUND 1485 CANT FRAME IS CRACKED AT STAIR ACTUATOR CASTING. INSTALLED REPAIR DOUBLER PER AARD 53-10-00-33. (M)

Part: SHEAR TIE — CRACKED (FUSELAGE)

TUL - FOUND SHEAR TIE CRACKED AT STATION 1451 JUST INBOARD OF LONGERON 2L. REPLACED SHEAR TIE AT STATION 1451 INBOARD OF LONGERON 2L SRM 51-01. (M)

Part: SKIN — WORN (FUSELAGE)

TUL - FOUND VERY DEEP WORN AREA BL '0' STATION 148 TOP OF FUSELAGE. REMOVED DAMAGED AREA. INSTALLED DOUBLER PER ESO 80559. (M)

Part: WEB — DAMAGED (FUSELAGE)

TUL - FOUND RIGHT TUNNEL (MID CARGO) STATION 625, CUSP HAS HOLE IN IT. REAMED HOLE AND INSTALLED HI-LOCK PER ESO NR 80559, DATED 8-30-01. (M)

Part: SEAT TRACK — CORRODED (FUSELAGE)

FOUND NR 6 SEAT TRACK CORRODED STATION 609-610. REMOVED DAMAGE AND INSTALLED SEAT TRACK PLUG REPAIR PER SRM 53-05 FIG 4. (M)

Part: SEAT TRACK — CORRODED (FUSELAGE)

TUL - FOUND NR 1 SEAT TRACK CORRODED OUT OF LIMITS AT STATION 1237. INSTALLED SEAT TRACK PLUG REPAIR PER SRM 53-05 FIG 40. (M)

Part: SKIN — CRACKED (FUSELAGE)

TUL - FOUND WINDOW PANEL CRACKED AT AFT UPPER CORNER BETWEEN STRINGER 1041-1060. CUT OUT CRACK PORTION. INSTALLED DOUBLER ON WINDOW PANEL AT STATION 1041-1060 SRM 53-10-00-25. (M)

Part: WEB — CORRODED (FUSELAGE)

TUL - FOUND RIGHT CUSP CORRODED BETWEEN STATION 1155 TO STATION 1170. INSTALLED DOUBLER ON RIGHT CUSP STATION 1155 TO 1170 PER AARD 53-00-00-02. (M)

Part: LONGERON — CRACKED (FUSELAGE)

TUL - FOUND CRACK LEFT SIDE OF L4L AT STATION 160. SPLICED IN NEW SECTION OF LONGERON L4L FROM STATION 147 TO 170 PER SRM 53-02 FIG 18. (M)

Part: SEAT TRACK — CORRODED (FUSELAGE)

TUL - FOUND NR 3 SEAT TRACK CORRODED STATION 1304. INSTALLED PLUG REPAIR PER SRM 53-05 FIG 4A. (M)

Part: SEAT TRACK — CORRODED (FUSELAGE)

TUL - FOUND NR 1 SEAT TRACK HAS CORROSION AT AFT G-4 GALLEY MOUNT. INSTALLED SEAT TRACK PLUG REPAIR PER SRM 53-05 FIG 4A. (M)

Part: SKIN — DENTED (FUSELAGE)

TUL - FOUND DENT AT STATION 218 BETWEEN L22R AND 23R ADL 0001. CUT OUT DAMAGE AND INSTALLED FLUSH PATCH PER SRM 53-04-00 PERMANENT REPAIR. (M)

Part: CLAMP — LOOSE (ACM)

DFW - FLT 68 - EN ROUTE DFW-MIA - DETECTED TAIL COMPARTMENT HIGH TEMPERATURE LIGHT ILLUMINATE. AIR INTERRUPTED, RETURNED DFW AND LANDED WITHOUT INCIDENT. RE-SECURED CLAMP AT FORWARD SIDE OF PACK COOLING SYSTEM. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)