N766DA

Part: WIRE — FAILED (LAVATORY)

AT PUSHBACK, THE BATTERY CONDITION LIGHT CAME ON AND THE FLIGHT ATTENDANTS REPORTED FLAMES AT THE BASE BOARD BEHIND 2L LAV. PAX, F/A, AND SECOND OFFICER CONFIRMED FLAMES AND AN EXTINGUISHER WAS DISCHARGED. AIRCRAFT WAS EVACUATED PER THE CHECK LIST. FOUND WIRE BUNDLE BELOW LAV BURNT. SIGNS OF BLUE WATER STATION BU NDLE. SUSPECT INSULATION BREAK DOWN DUE TO BLUE WATER. NO CHAFING NOTED.

Part: POWER PACK — INOP (R2 DOOR)

OVERHEAD RT AND R2 ENTRY EMERGENCY LIGHTS INOP. REPLACED POWER PACK.

Part: HYD LINE — LEAKING (RT AILERON)

HYDRAULIC SYSTEM-B LOW QTY LIGHT CAME ON IN FLIGHT. QUANTITY INDICATED LESS THAN QUARTER FULL. FOUND RT O/B AILERON ACTUATOR PRESSURE LINE LEAKING AT ANGULAR SEAL PLATE (P/N 277203191). REPLACED SEAL, SERVICED HYDRAULICS AND LEAK CHECKS SATISFACTORY.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

EMERGENCY LIGHTS INOP AT L2. REPLACED POWER SUPPLY.

Part: BATTERY PACK — DISCHARGED (CABIN)

SECTION OF EMERGENCY LIGHTS FAILED TO TEST. REPLACE BATT PACK.

Part: HYD MOTOR — FAILED (A-HYD SYST)

DURING SLAT RETRACTION AFTER TAKEOFF A SYSTEM HYDRAULIC QTY DECREASED. TRIED POWER TRANSFER UNIT, QTY STILL DECREASED. FOUND A SYSTEM HYDRALIC MOTOR ON SLAT PWR DRIVE UNIT. MOTOR HOUSING SEVERLY CRACKED AND LEAKING. REPLACED MOTOR ASSY LRU. PERFORMED FUNCTIONAL CK AS PER MM 27-81-10. RTND FAILED MOTOR DAL P/N 277001240 TO SHOP.

Part: HYD PUMP — FAILED (NR 2 ENGINE)

C-HYD QTY DROPPED TO HALF, ALL PUMPS TURNED OFF AND QTY CONTINUED TO DROP. FOUND C-ENG DRIVEN PUMP CASE BROKEN. REPLACED PUMP AND FILTERS.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

EXTERIOR EMERGENCY LIGHT AT R2 INOP ON LIGHTS TEST. REPLACED POWER SUPPLY, CHECKS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHTS IN EXIT SIGN AT 1 LT DOOR INOP. REPLACED BATT PACK.

Part: TRIPLER — CORROSION (FS 1403-1423)

CORROSION WAS FOUND ON THE INNER SURFACE OF THE AFT PRESSURE OUTFLOW VALVE SURROUND TRIPLER. THE CORROSION WAS ISOLATED TO THE .244 INCH THICK PORTION OF THE TRIPLER. ACCOMPLISHED REPAIRS PER DL ERA 273432-14.

Part: REAR SPAR — CRACKED (WS 293-346)

CRACKS WERE FOUND EMANATING FROM EXISTING FASTENER HOLES BETWEEN IWS 293.58 AND IWS 346.109 ON THE LT AND RT WING. THE CRACKS WERE FOUND IN THE REAR SPAR UPPER CAP, WEB, UPPER WING SKIN. THE SUBJECT FASTENER HOLES WERE OVERSIZED TO REMOVE THE CRACKS IN THE DAMAGED MEMBERS ONLY WITH INSURANCE CUTS TAKEN. THE REAR SPAR UPPER CAP IS MADE FROM 7075-T76511 ALUMINUM EXTRUSION (LS12086). THE UPPER WING SKIN AT THE REAR SPAR LOCATION IS MANUFACTURED FROM 7075-T7651 PLATE. THE REAR SPAR WEB IS MANUFACTURED FROM 7075-T651 BARE PLATE. ACCOMPLISHED REPAIRS PER DL ERA 27304-14 AD REV D.

Part: SKIN — DENTED (FS 1795-1745)

FUSELAGE SKIN WAS FOUND DAMAGED FROM STR 41 TO STR 44. ERA 268511-14. REPAIRED A PREVIOUS PUNCTURE IN THE SKIN, STR, AND FUSELAGE SKIN LOCATED FROM STR 44 TO STR 46 AT THE TEAR STRAP. ERA 268517-14 COVERED A DENT LOCATED BETWEEN STR 41 AND STR 42 AT STA 1725. ADDITIONAL DAMAGE WAS FOUND BETWEEN THESE TWO PREVIOUSLY DAMAGED LOCATIONS. REPAIRED PER DL ERA 273344-14, REV B.

Part: REAR SPAR — FATIGUE (LT/RT WING)

DURING THE ACCOMPLISHMENT OF EO 7-59089-3AD, CRACKS WERE FOUND EMANATING FROM EXISTING FASTENER HOLES BETWEEN IWS 293.58-346 ON THE LT AND RT WING. THE CRACKS WERE FOUND IN THE REAR SPAR UPPER CAP, WEB, UPPER WING SKIN. THE SUBJECT FASTENER HOLES WERE OVERSIZED TO REMOVE CRACKS IN THE DAMAGED MEMBERS PER DL ERA 273404-14AD.

Part: SKIN — WORN (NR 1 FLAP VANE)

GROOVE WORN THROUGH UPPER SKIN, I/B END. INSTALLED EXTERNAL REPAIR DOUBLER PER SRM 57-53-00. FOUND DURING INSPECTION OF NR 1 RT FLAP VANE.

Part: DOUBLER — CORRODED (BS 620)

AT HMV, THE FWD OUTFLOW VALVE DOUBLER (P/N 1512371) WAS REPLACED DUE TO CORROSION AT THE FWD AND AFT CORNERS OF THE OUTFLOW VALVE CUTOUT. ACCOMPLISHED REPAIRS PER SRM 53-31-00.

Part: FUEL PUMP — FAILED (NR 2 ENGINE)

DURING CLIMBOUT, NR 2 ENG FUEL PRESS LIGHT BLINKED AND CAME ON STEADY. AT 25,000 FT COULD NOT ADVANCE ENG PAST 5,000 PPH F/F. ALSO, DECREASE IN N1 FROM 90 PERCENT TO 80. REPLACED NR 2 FUEL PUMP, OPERATION NORMAL.

Part: HYD LINE — CHAFED (BS 1975)

SHORTLY AFTER LEVEL OFF AT FL 330, B-HYD QTY DROPPED TO BELOW .25 AND LOW QTY LIGHT ILLUMINATED. FOLLOWED PROCEDURES, DIVERTED ATL. FOUND CHAFED B-SYS PRESS LINE AT FS 1975, ABOVE STABILIZER. REPAIRED LINE, OPERATION NORMAL.

Part: FUEL CAP — WORN (LT WING)

ONE HOUR INTO FLIGHT, PASSENGER NOTICED LIQUID LEAKING FROM VICINITY OF LT OVERWING INBD FUEL CAP. F/O VERIFIED FUEL LEAKING AND CAP SECURE. CAPT AND FLT CONTROL CONCURRED TO RETURN TO ATL. REPLACED NR 1 TANK GRAVITY FILL CAP. LEAK CK GOOD.

Part: ROD — BROKEN (NLG DOOR)

AFTER TAKOFF WHEN GEAR RETRACTED, HAD VIBRATION AND NOISE FROM NOSE GEAR AREA, RETURNED ATL. REPLACED BROKEN LEFT ROD ASSEMBLY FOR FWD DOOR. RIGGED DOORS, OPERATION NORMAL.

Part: GEN CONTL UNIT — LIGHTNING DAMAGE (MID E/E COMP)

DURING CLIMB-OUT LIGHTNING STRUCK AIRCRAFT, HAD NR 3 DIFFERENTIAL FAULT ON GENERATOR WITH ACCOMPANING LOSS OF NR 3 FLIGHT STATION BUS. RETURNED ATL, REPLACED NR 3 GENERATOR CONTROL UNIT, OPERATION NORMAL.