N78019

Part: STRINGER — CORRODED (BS 2230-2250)

INSPECTION FOUND STRINGER 51R CORRODED AT BS 2230 TO 2250. THE STRINGER WAS REPAIRED IAW SRM 53-10-03, FIGURE 1.

Part: LONGERON — CORRODED (BS 1245-1345)

INSPECTION FOUND RT WLG WHEEL WELL FORWARD OVERWING LONGERON CORRODED AT BS 1245, 1305, AND 1345, RBL 120. THE LONGERON WAS REPAIRED IAW ECRA 5310-03457.

Part: SKIN — CORRODED (BS 2219)

INSPECTION FOUND BULK CARGO COMPARTMENT SKIN CORRODED AT BS 2219, STRINGER 46L TO 47L. THE SKIN WAS REPAIRED IAW SRM 53-30-03, FIGURE 4B.

Part: SKIN — CORRODED (BS 2205)

INSPECTION FOUND BULK CARGO COMPARTMENT SKIN CORRODED AT STA 2205, STRINGER 37L TO 38L AND STA 2221, STRINGER 45L TO 46L. THE SKIN WAS REPAIRED IAW ECRA 5330-02509.

Part: WEB — CORRODED (BS 1353)

INSPECTION FOUND RT BLG WHEEL WELL PRESSURE DECK WEB CORRODED AT STA 1353, RBL 115. THE PRESSURE DECK WEB WAS REPAIRED IAW SRM 53-10-07, FIGURE 2.

Part: SKIN — CRACKED (NR 3 PYLON)

INSPECTION FOUND OUTBOARD SKIN OF NR 3 PYLON CRACKED AT STA 180. THE SKIN WAS REPAIRED IAW ECRA 5340-01444. THE CRACK LENGTH WAS NOT IDENTIFIED.

Part: SHEAR TIE — CORRODED (BS 1900)

INSPECTION FOUND SHEAR TIE CORRODED AT BS 1900, STRINGER 44R TO 45R. THE SHEAR TIE WAS REPLACED IAW SRM 51-10-01.

Part: LONGERON — CORRODED (BS 1350-1480)

INSPECTION FOUND LT OVERWING LONGERON CORRODED AT BS 1350 TO 1480. THE LONGERON WAS REPLACED IAW BOEING SERVICE BULLETIN 747-53-2291.

Part: SKIN — CORRODED (BS 1741-1961)

INSPECTION FOUND FUSELAGE SKIN CORRODED AT BS 1741 TO 1961, STRINGER 4OR TO 46R. THE SKIN PANEL WAS REPLACED AND REPAIR WAS ACCOMPLISHED IAW SRM 51-10-01, PAGE 18 AND ECRA 5330-02508.

Part: SHEAR TIE — CORRODED (BS 1840)

INSPECTION FOUND SHEAR TIE CORRODED AT BS 1840, STRINGER 45R TO 46R. THE SHEAR TIE WAS REPLACED IAW SRM 51-10-01, PAGE 18.

Part: WEB — CORRODED (BS 1350)

INSPECTION FOUND WHEEL WELL PRESSURE DECK FORWARD AND AFT SUPPORT WEBS CORRODED AT BS 1350. THE SUPPORT WEBS WERE REPAIRED IAW SRM 51-10-01, PAGE 18.

Part: WEB — CORRODED (BS 1280)

INSPECTION FOUND WHEEL WELL PRESSURE DECK WEB CORRODED AT STA 1280, LBL 120. THE WEB WAS REPAIRED IAW SRM 53-10-07, FIGURE 2.

Part: WEB — CORRODED (BS 1280)

INSPECTION FOUND LT WLG WHEEL WELL PRESSURE DECK WEB CORRODED AT BS 1280, LBL 120. THE WEB WAS REPAIRED IAW SRM 53-10-07, FIGURE 2.

Part: STRINGER — CORRODED (BS 660-670)

INSPECTION FOUND STRINGER 47L IN FORWARD CARGO COMPARTMENT CORRODED AT STA 660 TO 670. THE STRINGER WAS REPAIRED IAW SRM 53-10-03, FIGURE 1.

Part: FLOOR WEB — CORRODED (BS 460-480)

INSPECTION FOUND UPPER SURFACE OF TORQUE BOX (FLOOR WEB) CORRODED IN FORWARD CARGO AREA AT STA 460 TO 480, LBL 15. THE AREA WAS REPAIRED IAW SRM 51-40-02, FIGURE 1.

Part: FRAME — CORRODED (BS 520)

INSPECTION FOUND FRAME CORRODED AT STA 520, STRINGER 47L. THE FRAME WAS REPAIRED IAW ECRA 5310-03455.

Part: STRINGER — CORRODED (BS 1943)

INSPECTION FOUND STRINGER 44L CORRODED IN BULK CARGO COMPARTMENT AT STA 1943. THE STRINGER WAS REPAIRED IAW SRM 53-10-03, FIGURE 1.

Part: CHORD — CORRODED (BS 1265)

INSPECTION FOUND LT WLG WHEEL WELL INBOARD VERTICAL CHORD CORRODED AT BS 1265, LBL 115. THE AREA WAS REPAIRED IAW SRM 51-40-02, FIGURE 1.

Part: STRINGER — CORRODED (BS 1916)

INSPECTION FOUND STRINGER 49R CORRODED IN BULK CARGO COMPARTMENT AT STA 1916. THE STRINGER WAS REPAIRED IAW SRM 53-10-03, FIGURE 1.

Part: FITTING — CRACKED (NR 3 PYLON)

INSPECTION FOUND NR 3 PYLON STRUT TO DIAGONAL BRACE ATTACH FITTING CRACKED. THE CRACK LENGTH WAS NOT IDENTIFIED. THE FITTING WAS REPLACED IAW ECRA 5447-01019.

Part: SHEAR TIE — CORRODED (BS 1720)

INSPECTION FOUND SHEAR TIE CORRODED IN AFT CARGO COMPARTMENT AT BS 1720, STRINGER 50L TO 51L. THE SHEAR TIE WAS REPAIRED IAW SRM 53-10-04.

Part: FLOORBEAM — CORRODED (BS 1740)

INSPECTION FOUND FLOORBEAM LOWER CHORD CORRODED IN AFT CARGO COMPARTMENT AT BS 1740, STRINGER 49R TO 50R. THE FLOORBEAM CHORD WAS REPAIRED IAW SRM 51-40-03, FIGURE 1.

Part: SHEAR TIE — CORRODED (BS 980)

INSPECTION FOUND SHEAR TIE CORRODED AT BS 980, STRINGER 46L TO 47L. THE SHEAR TIE WAS REPAIRED IAW SRM 53-10-08, FIGURE 4.

Part: STRINGER — CORRODED (BS 741-800)

INSPECTION FOUND STRINGER 47R IN FORWARD CARGO BILGE AREA CORRODED AT STA 741 TO 800. THE STRINGER WAS REPAIRED IAW SRM 53-10-03, FIGURE 1.

Part: BULKHEAD WEB — CRACKED (BS 400)

INSPECTION FOUND BULKHEAD WEB CRACKED ON BOTH LT AND RT SIDE AT BS 400 WL 160, BL 90. THE CRACK LENGTH WAS NOT IDENTIFIED. THE WEB WAS REPAIRED IAW ECRA 5310-03459.

Part: SKIN — CORRODED (BS 2240)

INSPECTION FOUND FUSELAGE SKIN CORRODED AT BS 2240, STRINGER 49R TO 50R. THE SKIN WAS REPAIRED IAW SRM 53-30-03, FIGURE 1.

Part: SKIN — CORRODED (BS 2260)

INSPECTION FOUND FUSELAGE SKIN CORRODED AT BS 2260, STRINGER 50R TO 51R. THE SKIN WAS REPAIRED IAW SRM 53-30-03, FIGURE 1.

Part: SEAL — LEAKING (NR 4 ENGINE)

THE NR 4 ENGINE OIL PRESSURE BEGAN TO DROP WHILE EN ROUTE FROM HNL TO NRT. THE ENGINE OIL PRESSURE LIGHT WAS INTERMITTENT WHILE OIL PRESSURE DECREASED INTO THE AMBER ZONE. THE LIGHT BECAME STEADY WHEN PRESSURE REACHED RED LINE. THE PRESSURE CONTINUED TO DECREASE AND THE OIL TEMP INCREASED FROM 99 TO 105 DEGREES DURING RETURN TO HNL. THE OIL QUANTITY REMAINED PEGGED FULL THROUGHOUT FLIGHT. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NR 4 ENGINE STARTER DRIVE SEAL LEAKING. THE SEAL WAS FLAT AND CRACKED. THE SEAL WAS REPLACED. THE ENGINE WAS SERVICED WITH OIL. THE ENGINE WAS RUN AND LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: LIGHT — INOPERATIVE (CABIN)

INSPECTION FOUND LEFT EMERGENCY CEILING LIGHT B-ZONE, FOURTH LIGHT BACK INOPERATIVE. THE EMERGENCY CEILING LIGHT WAS REMOVED AND REPLACED.

Part: SPRING — BENT (DOOR 2L)

DOOR 2L WOULD NOT DISARM, THE LEVER WOULD NOT MOVE TO DISARM. MAINTENANCE FOUND LEAF SPRING ON GIRT BAR BENT. THE LEAF SPRING CLIP WAS REPLACED AND OPERATIONAL CHECKS WERE GOOD.

Part: STATOR CONTL — INOPERATIVE (#1 ENGINE)

TAKEOFF WAS ABORTED AT 115 KNOTS AFTER THE NR 1 ENGINE WOULD NOT MAKE TAKEOFF POWER. THE AIRCRAFT WAS RETURNED TO GATE WHERE SIX TIRES BLEW DUE TO HEAT. MAINTENANCE FOUND THE NR 1 ENGINE COMPRESSOR STATOR CONTROL AT FAULT. THE COMPRESSOR STATOR CONTROL WAS REMOVED AND REPLACED IAW MM 75-31-401 AND GROUND TEST WAS GOOD. THE NR 1 ENGINE WAS BORESCOPED AND ALL CHECKS WERE GOOD. A HIGH ENERGY STOP/HEAT DAMAGE INSPECTION WAS PERFORMED PER MM 05-51-10 AND NO DISCREPANCIES WERE FOUND. IN ADDITION, THE BLOWN TIRES AND WHEEL ASSEMBLIES WERE REMOVED AND REPLACED.

Part: HEAT CONTROL — INOPERATIVE (R1 WINDOW)

CREW OBSERVED A STRONG ELECTRICAL INSULATION ODOR COMING FROM THE MAP AND APPROACH LIGHT CONTROL SWITCHES DURING FLIGHT. THE WIRE LEADING TO R-1 WINDOW WAS ALSO HOT. THE CIRCUIT BREAKERS WERE PULLED AND THE ODOR CEASED. MAINTENANCE CHECKED BOTH MAP AND APPROACH LIGHT CONTROLS AND NO DEFECTS WERE FOUND. MAINTENANCE FOUND THE R-1 WINDOW HEAT CONTROL AT FAULT. OPERATION OF THE R-1 WINDOW HEAT CHECKED GOOD IAW MM 30-41-04. MAINTENANCE ALSO FOUND A BAD TERMINAL ON CONTACT A OF WINDOW. THE TERMINAL WAS REPLACED.

Part: CONNECTOR — LOOSE WIRE (R4 DOOR)

LAX - FLT 0023 - INSPECTION FOUND EMERGENCY EXIT LIGHTS AT R-4 DOOR INOPERATIVE. REPLACING BATTERY PACK DID NOT HELP. MAINTENANCE FOUND LOOSE WIRING ON CANNON PLUG AT CHARGING UNIT. THE WIRING WAS REPAIRED AND OPERATION OF THE R-4 DOOR EXIT LIGHTS CHECKED GOOD. (X)

Part: BATTERY PACKS — DISCHARGED (CABIN)

LAX - INSPECTION FOUND OVERHEAD EMERGENCY EXIT LIGHTS INOPERATIVE AT DOOR 1R, 4R, AND 5L. THE BATTERY PACKS AT EACH LOCATION WERE REMOVED AND REPLACED. OPERATION OF THE OVERHEAD EMERGENCY LIGHTS WAS RESTORED. (X)

Part: DOOR FRAME — CRACKED (DOOR 2R)

HNL - FLT 0908 - A LOUD HISSING NOISE WAS HEARD AT DOOR 2R DURING FLIGHT FROM NRT TO HNL. MAINTENANCE FOUND A 10 INCH LONGITUDINAL CRACK IN THE DOOR FRAME RADIUS ABOVE THE LOWER GATE ON THE FORWARD SIDE OF THE 2R DOOR. THE DOOR WAS REMOVED IAW MM 52-11-01, PAGES 401-407. THE DOOR WAS REPAIRED IAW SRM 52-10-02, FIGURE 10, PAGES 11-13 AND 17. THE DOOR WAS REINSTALLED IAW MM 52-11-01, PAGES 408-412. AN ADJUSTMENT/TEST WAS PERFORMED IAW MM 52-11-01, PAGES 501-521. PRESSURE CHECK WAS GOOD. (X)

Part: LIGHT — INOPERATIVE (L-5 DOOR)

LAX - FLT 0006 - THE A-ZONE LIGHTS ILLUMINATED WITH THE EMERGENCY EXIT LIGHT SWITCH IN THE ARM POSITION. ONLY THE A-ZONE DOOR EMERGENCY LIGHTS ILLUMINATED WITH THE SWITCH IN THE 'ON' POSITION. MAINTENANCE FOUND THE L-5 DOOR EMERGENCY LIGHT ASSEMBLY AT FAULT. THE L-5 DOOR EMERGENCY LIGHT WAS REPLACED. (X)

Part: SKIN — CORRODED (WS 660)

TLV - INSPECTION FOUND CORROSION UNDER UPPER SKIN OF TOP FIXED FAIRING AT LEFT WING LEADING EDGE, WS 660. A TEE ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-30-02. (M)

Part: FITTING — BROKEN (NR 5 SPOILER)

TLV - INSPECTION FOUND A LEFT WING NR 5 GROUND SPOILER ACTUATOR FITTING BROKEN. A REPAIR WAS INSTALLED IAW ECRA 5750-02392. (M)

Part: SKIN — CORRODED (WS 1330)

TLV - INSPECTION FOUND LOWER SKIN CORRODED ON LEFT WING AT WS 1330. A REPAIR ANGLE AND STRAP WERE INSTALLED IAW ENGINEERING ORDER MF MAN-B47-57-84000. (M)

Part: ENGINE — FAILED (NR 4 ENG)

FLT NR 0006 - HNL - THE NR 4 ENGINE FAILED AT TOP OF CLIMB WITH EGT AT 968 DEGREES. THE CREW SHUT THE ENGINE DOWN AND RETURNED TO HNL WHERE THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND METAL IN THE NR 4 ENGINE TAILPIPE. THE NR 4 ENGINE WAS REMOVED AND REPLACED. (M)

Part: ENGINE — FAILED (NR 1)

HNL - FLT 907 - THE NR 1 ENGINE MADE A LOUD BOOM AFTER ABOUT TWO HOURS OF FLIGHT. THE NOISE WAS ACCOMPANIED BY A RISE IN EGT AND A DECREASE IN EPR AND N1. THE NR 1 ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO HNL, WHERE IT LANDED WITHOUT INCIDENT. THE NR 1 ENGINE WAS REMOVED AND REPLACED. (W)