N77303

Part: SKIN — CRACKED (FUSELAGE) · airframe 59,113 hrs · 30,569 cycles

INSPECTION FOUND 2.5 IN CRACK FORWARD OF STA 787 ABOVE S24L. DOUBLER REPAIR INSTALLED IAW SRM 53-00-01.

Part: WIRE — BROKEN (CHARGER) · airframe 57,629 hrs · 29,804 cycles

INSPECTION FOUND THE EMERGENCY LIGHTS AT SEATS 12ABC TO 20ABC INOPERATIVE. TROUBLESHOOTING FOUND A BROKEN WIRE AT PIN 18 ON AFT BATTERY CHARGER UNIT. THE WIRE WAS REPAIRED AND OPERATIONAL CHECKS WERE NORMAL.

Part: SIGN — SHORTED (LEFT AFT CABIN) · airframe 57,629 hrs · 29,804 cycles

THE LEFT AFT EMERGENCY EXIT SIGN WAS FOUND SHORTED. THE EXIT SIGN WAS REPLACED.

Part: WIRE — BROKEN (EMERGENCY LIGHTS) · airframe 57,179 hrs · 29,555 cycles

INSPECTION FOUND THE EMERGENCY LIGHTS INOPERATIVE AT SEAT ROWS 5-10. A BROKEN WIRE WAS FOUND AT ROW 5. REPAIRED WIRE PER WDM 33-51-01 AND AN OPERATIONAL CHECK OF THE LIGHTS WERE GOOD.

Part: BATTERY PACK — INOPERATIVE (SEATS 14-20) · airframe 56,851 hrs · 29,387 cycles

INSPECTION FOUND EMERGENCY LIGHTS INOPERATIVE ON SEATS 14-20. THE BATTERY PACK WAS REMOVED AND REPLACED AND OPERATIONAL CHECKS WERE GOOD.

Part: CONTROL VALVE — OUT OF ADJUST (WHEEL WELL) · airframe 54,308 hrs · 28,047 cycles

THE CREW RECEIVED 3 RED LIGHTS AND THREE GREEN LIGHTS WHEN GEAR WAS LOWERED ON APPROACH TO EWR. THE APPROACH WAS ABORTED AND THE CHECKLIST WAS ACCOMPLISHED. WHEN THE GEAR WAS LOWERED AGAIN NORMAL INDICATION WAS RECEIVED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. TROUBLESHOOTING FOUND THE NOSE LANDING GEAR CONTROL VALVE OUT OF ADJUSTMENT. THE LANDING GEAR CONTROL VALVE WAS ADJUSTED IAW MM 32-31-00, PAGES 501-504. OPERATIONAL CHECKS WERE GOOD.

Part: FRAME — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

CORROSION ON TOP OF FRAME AT STA 227.8, WL 148. COMPLETED INTERIM REPAIR AND PLACED ON DIP PER ECRA 5311-01148.

Part: SKIN — MISREPAIRED (CARGO DOOR) · airframe 54,262 hrs · 28,018 cycles

C1 DOOR IMPROPERLY REPAIRED ON INNER SKIN AT CENTER LINE NR 4 HOLE. INSTALLED REPAIR PER ECRA 5232-01028.

Part: SKIN — CANNING (CARGO DOOR) · airframe 54,262 hrs · 28,018 cycles

C2 DOOR SKIN OIL CANNING APPROXIMATELY 32 INCHES FROM TOP OF DOOR AND 7 INCHES FROM FORWARD EDGE. FABRICATED AND INSTALLED REPAIR PER SRM 52-00-01.

Part: INTERCOSTAL — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

AFT CARGO COMPARTMENT INTERCOSTAL CORRODED INBOARD OF CARGO DOOR JAMB STATION 807 AND 827. FABRICATED AND INSTALLED NEW INTERCOSTAL PER SRM 51-40-00.

Part: RIB — GOUGED (LE FLAP) · airframe 54,262 hrs · 28,018 cycles

LEFT WING NUMBER TWO MID FLAP GOUGED AT MID SPAR CENTER FORE FLAP TRACK GUIDE. REPLACED RIB AT MID FLAP SPAR CENTER FORE FLAP TRACK GUIDE NUMBER TWO MID FLAP PER SRM 51-10-02.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

AFT CARGO RIGHT TIE DOWN RAIL CORRODED IN NUMEROUS PLACES BETWEEN STATIONS 727 AND 787 UPPER SURFACE. REMOVED AND REPLACED WITH NEW TRACK PER 53-60-53 AND INSTALLED SPLICE AND FASTENERS PER SRM 53-00-53.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

SEAT TRACK CORRODED STATION 277 - 294 AT RBL 42. REMOVED AND REPLACED DAMGED SEAT TRACK PER SRM 51-40-02.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

THREE FASTENERS CORRODED IN FLOORBEAM. REPLACED UPPER STRUCTUREAS REQUIRED IN SRM 53-10-51.

Part: CARGO TRACK — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

AFT BAG BIN CARGO TIE DOWN RAIL HAS CORROSION AT STATION 947. REMOVED AND REPLACED TIE DOWN TRACK STATION 877 - 947 PER SRM 51-40-02 AND 53-60-53.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

FLOORBEAM CORRODED AT STATION 284 RBL 42 BELOW SEAT TRACK. REMOVED DAMAGED SECTION. FABRICATED NEW FLOORBEAM, TREATED, PRIMED AND INSTALLED PER SRM 53-10-51 FIG 205.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 54,262 hrs · 28,018 cycles

RIGHT OUTBOARD SEAT TRACK HAS CORROSION AT AFT END STATION 927. REMOVED AND REPLACED SEAT TRACK PER SRM 51-10-2.

Part: SKIN — PUNCTURED (FUSELAGE) · airframe 54,263 hrs · 28,018 cycles

INSPECTION FOUND A HOLE MEASURING APPROXIMATELY 4 INCHES X 5 INCHES IN FUSELAGE SKIN BETWEEN STA 986.5 AND 1006 BETWEEN S3L AND S4L. A REPAIR WAS INSTALLED IAW SRM 53-00-01, FIGURE 210.

Part: SKIN — CRACKED (STA 727A) · airframe 53,434 hrs · 27,585 cycles

INSPECTION FOUND A 1.5" CRACK IN R/H FUSELAGE SKIN AT STA 727A JUST FORWARD AND BELOW EMERGENCY LIGHT AND AFT OF WHEEL WELL. A DOUBLER WAS INSTALLED IAW ECRA 5330-03090.

Part: SKIN — CRACKED (STA 727E) · airframe 52,477 hrs · 27,049 cycles

INSPECTION FOUND A 2" CRACK IN R/H FUSELAGE SKIN AT STA 727E, S24R. REPAIRED IAW SRM 53-00-01, FIGURE 201.

Part: VALVE — INOPERATIVE (GROUND SPOILER) · airframe 51,843 hrs · 26,710 cycles

THE LANDING GEAR LEVER WOULD NOT MOVE TO THE UP POSITION AFTER TAKEOFF FROM MSY. QRH PROCEDURES WERE COMPLIED WITH AND THE AIRCRAFT WAS RETURNED TO MSY WHERE IT LANDED SAFELY. MAINTENANCE FOUND THE GROUND SPOILER INTERLOCK VALVE AT FAULT. THE GROUND SPOILER INTERLOCK VALVE WAS REMOVED AND REPLACED AND SAFETY SENSORS WERE ADJUSTED IAW MM 27-62-61. THE GEAR WAS SWUNG SEVERAL TIMES AND OPERATIONAL CHECKS WERE GOOD.

Part: HINGE PIN — BROKEN (HORIZ STAB) · airframe 50,345 hrs · 25,926 cycles

INSPECTION FOUND LT HORIZONTAL STABILIZER HINGE PIN AND INSERT BROKEN. THE HINGE PIN AND INSERT WERE REMOVED AND REPLACED IAW MM 27-41-31.

Part: SKIN — CRACKED (#1 PYLON) · airframe 50,345 hrs · 25,926 cycles

INSPECTION FOUND A 1" CRACK IN #1 PYLON SKIN PANEL #5727L. A REPAIR WAS INSTALLED IAW ECRA 5430-01230.

Part: BATTERY PACK — INOPERATIVE (CABIN) · airframe 47,264 hrs · 24,390 cycles

INSPECTION FOUND OVERHEAD EMERGENCY LIGHTS AT L-1 DOOR INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED AND OPERATION CHECKED GOOD IAW MM 33-51-51.

Part: FLOORBEAM — CORRODED (BS 294)

INSPECTION FOUND FLOORBEAM CORRODED AT STA 294 FROM LBL 32 TO LBL 51. A NEW SECTION OF FLOORBEAM WAS INSTALLED IAW SRM 53-10-51.

Part: FLOORBEAM — CORRODED (BS 344)

INSPECTION FOUND FLOORBEAM CAP CORRODED AROUND FASTENER HOLES AT STA 344 FROM RBL 12 TO LBL 15. REPLACED BEAM IAW SRM 53-10-51.

Part: FLOORBEAM — CORRODED (BS 312)

INSPECTION FOUND FLOORBEAM CAP CORRODED AT STA 312 FROM LBL 10 TO RBL 10. THE CORRODED SECTION WAS REMOVED AND FILLER AND DOUBLERS WERE INSTALLED IAW SRM 53-10-51, FIGURE 205.

Part: FRAME — CRACKED (CARGO DOOR)

INSPECTION FOUND A 9 INCH CRACK IN FORWARD CARGO DOOR FRAME UNDER AFT LOCK ROLLER. THE DOOR FRAME WAS REMOVED AND REPLACED IAW SRM 51-10-2 AND 51-30-2.

Part: OVEN — FAILED (GALLEY)

AFT GALLEY CENTER OVEN SMOKED. REPLACED CENTER OVEN.

Part: GCU — INOPERATIVE (APU)

WHILE OPERATING THE APU, WITH THE NR 2 GENERATOR PLACARDED INOPERATIVE, THE APU GENERATOR DROPPED OFF LINE ENROUTE FROM PDX TO IAH. THE GENERATOR COULD NOT BE RESTORED. THE CREW ELECTED TO DIVERT TO DFW DUE TO BAD WEATHER AT IAH. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE APU GENERATOR CONTROL UNIT AT FAULT. THE APU GCU WAS REMOVED AND REPLACED. OPERATIONAL CHECKS WERE GOOD.

Part: ANGLE — CORRODED (BS 990)

INSPECTION FOUND SUPPORT ANGLE CORRODED AT STA 990, LBL 14. A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-2.

Part: FLOORBEAM — CORRODED (BS 986.5)

INSPECTION FOUND CABIN FLOORBEAM CORRODED AT STA 986.5 BETWEEN RBL 15 AND LBL 15. REPAIRED IAW ECRA 5310-03450.

Part: FLOORBEAM — CORRODED (BS 986.5)

INSPECTION FOUND CORROSION ACROSS TOP AND SIDES OF FLOORBEAM AT STA 986.5 BETWEEN ANGLE BEAMS. AN ANGLE AND HAT SECTION WERE FABRICATED AND INSTALLED IAW SRM 51-10-2.

Part: SKIN — CRACKED (PYLON)

INSPECTION FOUND A .25 INCH CRACK IN PYLON OUTER SKIN AT UPPER FORWARD CORNER OF PANEL NR 5824R. A 1.25 INCH CRACK WAS FOUND IN INNER SKIN OF SAME AREA. A DOUBLER REPAIR WAS FABRICATED AND INSTALLED IAW ECRA 5430-01204.

Part: BATTERY PACK — DISCHARGED (CABIN)

THE OVERHEAD EMERGENCY LIGHT AT ROW 14 RIGHT DID NOT REMAIN ILLUMINATED FOR AT LEAST 15 MINUTES DURING TEST. THE BATTERY PACK WAS REPLACED AND FUNCTIONAL TEST WAS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

THE OVERHEAD EMERGENCY LIGHT AT ROWS 15 TO 23 LEFT DID NOT REMAIN ILLUMINATED FOR AT LEAST 15 MINUTES. THE BATTERY PACK WAS REPLACED AND FUNCTIONAL TEST WAS GOOD.

Part: EEL BATT CHARGER — INOPERATIVE (CABIN)

HOU - THE FWD ENTRY DOOR EMERGENCY EXIT LIGHT FAILED TO ILLUMINATE DURING A SCHEDULED MAINTENANCE TEST. THE BATTERY CHARGER AND BATTERY PACK WERE REMOVED AND REPLACED. OPERATION OF THE EMERGENCY EXIT LIGHT WAS RESTORED. (W)