N771NC

Part: WEB — DAMAGED (FUSELAGE) · airframe 74,542 hrs · 72,096 cycles

DURING LINE CHECK, FOUND DAMAGE IN NOSE WHEEL AREA WEB ON LT SIDE DENTED AND SALAD BOWL DAMAGED. TRIMMED OUT DAMAGED WEB TO 1.125" DIA, ACCOMPLISHED HFEC INSP OF CUT OUT AREA, NO DEFECTS NOTED, TREATED & PRIMED, FABRICATED DOUBLER FROM 6AL-4V .040", INSTALLED REPAIR PARTS IAW SRM 53-05, FIG 1 & ER/A 487959-14.

Part: FRAME — DAMAGED (BS 1275 L3R) · airframe 72,525 hrs · 68,206 cycles

DURING M-CHECK, FOUND 2 EA MISDRILLED HOLES IN AFT ACCY CANTED FRAME AT BS 1275 L3R. REPAIRED IAW SRM 53-02 FIG 18 & SRM 51-30-5.

Part: SLIDE — READS LOW (L1 DOOR) · airframe 73,960 hrs · 71,568 cycles

DURING LINE CHECK MX FOUND THE L1 DOOR SLIDE AT 0 PSI. DOOR SLIDE L1 WAS REPLACED IAW AMM 25-62-00-201-925A-A.

Part: VALVE — LEAKING (NR 1 ENGINE) · airframe 73,812 hrs · 71,450 cycles

AFTER TAKEOFF CLIMBING THROUGH 12K THE NUMBER 1 ENGINE ROLLED BACK SMOOTHLY AND FLAMED OUT. THE FLIGHT CREW DECLARED AN EMERGENCY AND RETURNED TO DTW LANDING WITHOUT INCIDENT. ENGINE NR 1 INLET AND EXHAUST WERE INSPECTED WITH NO DAMAGE FOUND. MAINTENANCE FOUND A FUEL LEAK AT THE P&D VALVE TO FUEL OIL COOLER TUBE AT THE P&D VALVE REDUCER. MAINTENANCE REPLACED THE P&D VALVE AND SEALS.

Part: SKIN — CORRODED (BS 656 L27-30L) · corrosion level 2 · airframe 73,148 hrs · 70,865 cycles

DURING L-CHECK FOUND FUSELAGE SKIN CORRODED AT BS 656 L30R-L27L. REPAIRED IAW DWG 9923434 AND AMI CARD 5331-01180-02.

Part: FLOOR PANEL — CORRODED (CARGO BAY) · corrosion level 2 · airframe 73,148 hrs · 70,865 cycles

DURING L-CHECK FOUND CORROSION ON FWD CARGO CTR FLOOR PANEL RIBS NR 1 THRU NR 6. REPAIRED IAW SRM 51-10-4, 51-60-0, 51-30-5, 51-30-1 & DWG 9B53-35812.

Part: LONGERON — CORRODED (BS 674 L30) · corrosion level 2 · airframe 73,148 hrs · 70,865 cycles

DURING L-CHECK, FOUND CORROSION ON LONGERON 30 END FITTING AT BS 674. REPAIRED IAW SRM 51-10-4 AND 51-10-3.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 73,148 hrs · 70,865 cycles

DURING L-CHECK FOUND FLOOR SUPPORT AT FLOOR PANEL NR 69 HAS CRACKS AROUND RIVETS. REPAIRED IAW SRM 51-10-4, 51-30-2.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 73,148 hrs · 70,865 cycles

DURING L-CHECK FOUND DAMAGE TO CABIN FLOOR PANEL NR 69. REPAIRED IAW SRM 51-30-2 AND SRM 51-30-1.

Part: LONGERON SPLICE — CORRODED (BS 655 L28L) · corrosion level 2 · airframe 73,148 hrs · 70,865 cycles

DURING (H) CHECK FOUND LONGERON SPLICE FITTING CORRODED AT BS 655 L28L. REPAIRED IAW SRM 51-10-4 AND DWG NR 3932849.

Part: SKIN — CHAFED (NR 1 SLAT) · airframe 73,148 hrs · 70,865 cycles

DURING (L) CHECK FOUND RT WING L/E NR 1 SLAT OTBD LOWER SURFACE REPAIR DOUBLER CHAFED. REPAIRED IAW SRM 51-30-8, 51-30-8, 51-30-2.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 73,148 hrs · 70,865 cycles

DURING L-CHECK FOUND FORWARD DOOR JAMB UPPER CORNER HAS APPROXIMATELY A .1875 INCH CRACK. REPAIRED PER DRAWING SRO 5930117 AND ERA 480134-14AD.

Part: FRAME — CHAFED (FUSELAGE) · airframe 73,148 hrs · 70,865 cycles

DURING L-CHECK FOUND RIGHT FRAME CHAFED AT BS 1326. REPAIRED PER SRM 53-03-04.

Part: OIL SYSTEM — OVERHEATED (RT ENGINE) · airframe 72,906 hrs · 70,657 cycles

AFTER TAKEOFF THE RT ENGINE OIL QUANTITY INDICATION WENT TO ZERO. OIL TEMPERATURE OF 100 DEGREES AND OIL PRESSURE OF 40 PSI APPEARED NORMAL. THRUST ON THE NR 2 ENGINE WAS REDUCED TO IDLE, WHICH CAUSED THE RT PACK TO AUTO SHUTDOWN. AFTER THROTTLE WAS PULLED BACK A BURNING ODOR WAS NOTICED BY CABIN AND COCKPIT CREW MEMBERS. THE ACFT RETURNED TO DEPARTURE AND LANDED UNEVENTFULLY BUT WHILE ON FINAL APPROACH THE AMBER "AFT CARGO DOOR" LIGHT ILLUMINATED.

Part: WIRE — BROKEN (EMERGENCY LIGHTS) · airframe 72,008 hrs · 69,896 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE EMERGENCY PATHWAY LIGHTING FOR THE CATWALK IN THE TAIL COMPARTMENT WAS INOPERATIVE. MAINTENANCE REPLACED THE BATTERY PACK AND REPAIRED A BROKEN GROUND WIRE. THE LIGHTS RETURNED TO AN OPERATIONAL CONDITION.

Part: WIRE — CORRODED (EMERGENCY LIGHTS) · airframe 71,748 hrs · 69,658 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE EMERGENCY PATHWAY LIGHTING FOR THE TAIL COMPARTMENT WAS INOPERATIVE. MAINTENANCE FOUND CORRODED WIRES IN THE LIGHT ASSEMBLY AND REPLACED THOSE WIRES. THE FUNCTIONAL CHECK OF THE SYSTEM WAS SATISFACTORY.

Part: CONNECTOR — LOOSE (CABIN) · airframe 70,652 hrs · 68,718 cycles

DURING LINE CHECK MX FOUND THAT THE EMERGENCY PATHWAY LIGHTING IN ROWS 14-18 OF THE CABIN WERE INOPERATIVE. MX CORRECTED A LOOSE CONNECTION AND THEN OPS CHECKED THE SYSTEM.

Part: SKIN — CRACKED (FUSELAGE) · airframe 70,231 hrs · 68,334 cycles

DURING H-CHECK, FOUND CRACK IN FUSELAGE SKIN AT THE UPPER FORWARD CORNER OF PASSENGER ENTRY DOOR JAMB. REPAIRED PER EA 98-213637. (S)

Part: SKIN — CRACKED (FUSELAGE) · airframe 61,551 hrs · 60,493 cycles

DURING "L" CHECK FOUND CRACK IN FUSELAGE SKIN AT BS 69.55 3.5 INCHES BELOW L14L. REPAIRED IAW EA 98-197450.

Part: CONTROL CABLE — BINDING (AILERONS) · airframe 60,533 hrs · 59,572 cycles

CREW EXPERIENCED SIGNIFICANT BINDING OF THE AILERONS IMMEDIATELY AFTER TAKEOFF. AS AIRSPEED INCREASED, THE CONTROLLABILITY IMPROVED AND LESS FORCE WAS NEEDED TO MOVE THE CONTROL YOKE. FLIGHT RETURNED TO AN UNEVENTFUL LANDING BACK AT DTW. MAINTENANCE CONFIRMED BIND AT ABOUT 10 DEGREES OF RT AILERON DEFLECTION BUT DISAPPEARED AFTER MOVING THE YOKE SEVERAL TIMES. FOUND EVIDENCE OF CHAFING OR BINDING ON CABLE SECTOR ON FIRST OFFICER'S CONTROL COLUMN AND AGAINST A HYDRUALIC LINE IN THE WING.

Part: LONGERON — CORRODED · corrosion level 2 · airframe 58,327 hrs · 57,573 cycles

During MCK in ATL, Corrosion was found around fastener holes in four places in the base flange of longeron 30 between frame 377 and 389. Repaired per EA 98-189737.

Part: BATTERY — LOOSE (OVERWING) · airframe 55,212 hrs · 54,746 cycles

DURING LINE CHECK, FOUND THE EMERGENCY LIGHTS ABOVE BOTH LEFT AND RIGHT OVERWING EXITS INOPERATIVE. MAINTENANCE RESEATED THE BATTERIES IN THE POWER SUPPLY. OPERATIONAL CHECK NORMAL.

Part: BATTERY — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND THE FIRST CLASS SECTION OVERHEAD EMERGENCY LIGHTING INOPERATIVE. MAINTENANCE REPLACED BATTERIES. OPERATIONAL CHECK NORMAL.

Part: EPR TRANSMITTER — FAILED (LT ENGINE)

AS TAKEOFF POWER WAS APPLIED, THE LEFT ENGINE WOULD NOT REACH TARGET EPR INDICATION. CREW ABORTED TAKEOFF AND RETURNED TO THE GATE. MAINTENANCE REPLACED THE LEFT ENGINE EPR TRANSMITTER AND INDICATOR, OPERATIONAL CHECK OK.

Part: DOOR — OUT OF ADJUST (PAX DOOR)

MAIN CABIN DOOR COULD NOT BE OPENED FROM THE OUTSIDE. MAINTENANCE REPLACED NYLON WASHERS ON BAYONET ROD, ADJUSTED DOOR ROTATION, AND BAYONET ROD, FUNCTIONAL CHECK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND LEFT AND RIGHT OVERWING EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE REPLACED BATTERY PACKS, OPERATIONAL CHECK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND OVERHEAD EMERGENCY LIGHTS INOPERATIVE ABOVE SEATS 13, 14 AND 15. REPLACED BATTERY PACK, OPERATIONAL CHECK OK.

Part: OVERHEAT SENSOR — MALFUNCTIONED (TAIL COMPT)

TAIL COMPARTMENT TEMPERATURE HIGH LIGHT ACCOMPANIED BY MASTER WARNING LIGHT ILLUMINATED DURING TAKEOFF ROLL. CREW ABORTED TAKEOFF AT 110 KNOTS AND AIRCRAFT WAS RETURNED TO THE GATE. MAINTENANCE INSPECTED SYSTEM AND NO LEAK OR PROBLEMS WERE FOUND. REPLACED THE LEFT TAIL COMPARTMENT OVERHEAT SENSOR AS A PRECAUTION.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND SEVERAL CEILING EMERGENCY LIGHTS INOPERATIVE. REPLACED B5-58 BATTERY PACK AND BATTERIES, OPERATIONAL CHECK OK.

Part: EPR INDICATOR — MALFUNCTIONED (COCKPIT INST PNL)

AS TAKEOFF POWER WAS APPLIED, THE LEFT ENGINE EPR INDICATION WOULD NOT REACH TARGET EPR LEVEL. CREW ABORTED TAKEOFF AND RETURNED TO GATE. MAINTENANCE REPLACED THE LEFT ENGINE EPR TRANSMITTER AND EPR INDICATOR. ENGINE OPERATIONAL CHECK WAS OK, ALL PARAMETERS WERE NORMAL, AND AIRCRAFT RETURNED TO SERVICE.

Part: AMPLIFIER — FAILED (PRESSURE CONTROL)

ON CLIMBOUT, AIRCRAFT FAILED TO PRESSURIZE. FOLLOWED COCKPIT OPERATING MANUAL PROCEDURE AND RETURNED TO DTW. FLIGHT LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE PRESSURE CONTROL AMPLIFIER, SYSTEM OPERATIONAL CHECK OK.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND THE LEFT AND RIGHT OVERWING EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERIES, OPERATIONAL CHECK OK.

Part: GASKET — FAILED (RT PACK)

DURING CLIMBOUT OF DTW, THE TAIL COMPARTMENT TEMPERATURE ANNUNCIATOR AND MASTER WARNING LIGHT ILLUMINATED. REDUCED POWER AND WENT TO HP BLEED OFF ON PACKS AND LIGHTS WENT OUT. RESUMED POWER AND MASTER WARNING CAME ON MOMENTARILY AFTER ABOUT 5 MINUTES. RETURNED TO DTW AND LANDED WITHOUT INCIDENT. FOUND RIGHT AC TEMPERATURE HIGH SENSOR GASKET DETERIORATED. REPLACED GASKET AND PERFORMED LEAK CHECK DURING DUAL ENGINE RUN. OPERATIONAL CHECK OK.

Part: AUGMENTATION VLV — MALFUNCTIONED (LEFT ANTI ICE)

DURING CRUISE WITH LEFT ANTI-ICE ON, THE LEFT ICE PROTECTION TEMPERATURE ANNUNCIATOR LIGHT ILLUMINATED. PERFORMED COM AND LIGHT WENT OUT. WHEN RIGHT SYSTEM WAS LATER SHUT DOWN BEFORE CROSSFEED CLOSED, THE RIGHT ICE PROTECTION TEMPERATURE ANNUNCIATOR LIGHT ILLUMINATED. FLIGHT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. CHANGED THE LEFT AND RIGHT AUGMENTATION VALVE, ANTICIPATOR, AND THERMOSTAT. PERFORMED ICE PROTECTION SYSTEM OPERATINAL CHECK. CHECKED OK.

Part: SKIN — DISBONDED (FS 965)

DURING FLIGHT, AN AIR LEAK WAS HEARD IN THE AFT CABIN. LANDED IN DTW WITHOUT FURTHER INCIDENT. FOUND APPROXIMATELY 18 TO 20 FASTENERS LOOSE ALONG THE FS 965 SKIN LAP SEAM FROM LONGERON 10L TO 10R. REPLACED LOOSE FASTENERS. PRESSURE CHECK REVEALED AN ADDITIONAL AIR LEAK FOUND FROM THE MAIN LANDING GEAR DOWNLOCK INSPECTION COVER. CLEANED AND LUBRICATED COVER SEAL, PRESSURIZATION CHECK OK.

Part: PRESS AMPLIFIER — BROKEN WIRES (CABIN)

AFTER TAKEOFF, CABIN PRESSURIZATION STARTED CLIMBING AND DESCENDING ABOUT 800 FEET IN EACH DIRECTION. THE LEFT MAIN LANDING GEAR UNSAFE LIGHT REMAINED ILLUMINATED. ACFT RETURNED TO ATL AND LANDED WITHOUT INCIDENT. FOUND WIRES H538A24-RD AND H539A24-BL BROKEN AT P1-230 CABIN PRESSURE AMPLIFIER. RECRIMPED WIRES AND AUTO PRESSURE SYSTEM TESTED GOOD. FOUND LEFT INBOARD DOOR PROXIMITY SENSOR TARGET CONTACTING DOOR JAMB STRUCTURE THUS NOT LETTING DOOR FULLY CLOSE. ADJUSTED DOOR SENSOR TARGET AND SWUNG GEAR, OPERATIONAL CHECK GOOD.

Part: BULKHEAD FORMER — CRACKED (AFT PRESS BLKHD)

DURING H-CHECK, FOUND A .50 INCH CRACK IN THE AFT PRESSURE BULKHEAD HORIZONTAL FORMER AT Z=14. REPAIRED FORMER (P/N 9915558-27) PER EA 98-108866.

Part: FITTING — CORRODED (NR 3 TE FLAP)

DURING H-CHECK, FOUND CORROSION IN THE NR 3 FORWARD FLAP HINGE FITTING BOLT HOLE. REPLACED FITTING (P/N 5919217-502) PER CITEXT 90-2750-1-9806.

Part: FITTING — CRACKED (FS 674)

DURING H-CHECK, FOUND A CRACK IN THE LONGERON 25R END FITTING AT FS 674. REPLACED FITTING PER SRM 51-30.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND OVERHEAD EMERGENCY LIGHTS AT ROWS 20 THROUGH 24 INOPERATIVE. REPLACED BATTERIES IN PACK AT AFT CABIN AND OPERATIONAL CHECK NORMAL.

Part: FUEL TEMP SENSOR — DEFECTIVE (RT ENGINE)

AFTER DEPARTURE, THE NR 2 FUEL TEMPERATURE WAS FLUCTUATING FROM PLUS 30 TO MINUS 60 DEGREES. AIRCRAFT RETURNED TO DTW AND LANDED WITHOUT INCIDENT. FOUND FUEL TEMPERATURE SENSOR DEFECTIVE. REPLACED SENSOR. ENGINE TUNE-UP CHECKED OK. AIRCRAFT RETURNED TO SERVICE.