N79746

Part: CHANNEL — CRACKED (NR 1 PYLON)

INSPECTION FOUND A 1 INCH CRACK IN NR 1 ENGINE LOWER PYLON PANEL NR 5107 AND A SMALL SECTION MISSING ON THE TRAILING END INNER FRAME U CHANNEL. THE U CHANNEL ON LOWER PYLON PANEL WAS REMOVED AND A NEW CHANNEL WAS INSTALLED IAW SRM 51-40-3, 51-30-2, 51-10-2 AND MM 51-20-0.

Part: RIB — CRACKED (RT MLG DOOR)

RIGHT MLG STRUT DOOR INTERNAL RIB CRACKED 2.5 NR 4 RIB. REMOVED CRACKED SECTION, FABRICATED REPAIR, LOCATED, DRILLED, DEBURRED, ALODINED, PRIMED AND INSTALLED PER SRM 51-40-3, 51-20-2, 51-30-2 AND MM 51-20-12.

Part: BEAM — MISDRILLED (RT MLG DOOR)

RIGHT MLG STRUT DOOR HAS 2 MISDRILLED HOLES IN MAIN BEAM. REMOVED FITTING, LOCATED, DRILLED, DEBURRED, TREATED, PRIMED AND INSTALLED NEW FITTING PER SRM 51-10-2, 51-30-2, 51-30-3 AND MM 51-20-11.

Part: RIB — CRACKED (RT MLG DOOR)

RIGHT MLG STRUT DOOR HAS INTERNAL RIB NR 1 CRACKED .5 INCH. STOP DRILLED CRACK, FABRICATED ANGLE DOUBLER, LOCATED, DRILLED, DEBURRED, TREATED, PRIMED AND INSTALLED PER SRM 51-40-3, 51-20-2 AND MM 51-20-11.

Part: RIB — CRACKED (RT MLG DOOR)

RIGHT MLG STRUT DOOR HAS INTERNAL RIB CRACKED .75 NR 2 RIB. STOP DRILLED CRACK, FABRICATED ANGLE DOUBLER, LOCATED, DRILLED, DEBURRED, TREATED, PRIMED AND INSTALLED PER SRM 51-40-3, 51-10-2 AND MM 51-20-11.

Part: RETRACT MECH — OUT OF RIG (NLG DOORS)

THE NOSE GEAR DOORS CAME OPEN ACCOMPANIED BY ILLUMINATION OF THE RED NOSE GEAR DOORS LIGHT WITH THE GEAR HANDLE IN UP OR OFF POSITION WHILE AT CRUISE. VIBRATION WAS FELT AND NOISE LEVEL HAD INCREASED. MAINTENANCE FOUND THE NOSE GEAR DOORS OUT OF RIG. THE DOORS WERE RIGGED IAW MM 32-22-1 AND OPERATION CHECKED GOOD.

Part: HARNESS — CHAFED (FLUSH TIMER)

FIRE AND SMOKE OCCURRED IN THE LT AFT LAV WHILE EN ROUTE. A FIRE EXTINGUISHER WAS USED TO PUT OUT THE FIRE. THE ACFT LANDED AT IAH WITHOUT FURTHER INCIDENT. THE FIRE WAS CONTAINED WITHIN THE LAV. PRELIMINARY FINDINGS REVEALED THE WIRING TO THE LAV FLUSH TIMER IN THE LT AFT LAV BURNED. THE DAMAGED WIRING WILL BE REPLACED. *S/D* THE WIRE HARNESS SUPPLYING POWER TO THE TOILET FLUSH TIMER WAS CHAFED AT BOTH CLAMP POSITIONS ON THE AFT WALL OF THE LAV. ONE WIRE SHORTED TO GROUND AT THE LOWER CLAMP POSITION.

Part: ANGLE — CRACKED (LT LE RIB)

INSPECTION FOUND A .5 AND 1 INCH CRACK AT FASTENERS IN CURVED ANGLE INSIDE LEFT WING LEADING EDGE RIB OUTBOARD SIDE AT SLAT STA 0 (AFT OF NR 4 SLAT INBOARD MOST END). THE ANGLE WAS REMOVED. A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-10-1 AND 51-30-2.

Part: SKIN — DENTED (LT WING)

INSPECTION FOUND LEFT WING INBOARD LEADING EDGE SKIN DENTED BETWEEN INBOARD LANDING LIGHT AND NR 3 LEADING EDGE FLAP AREA. THE DENT WAS REWORKED IAW ECRA 5750-01352.

Part: SKIN — DENTED (BS 1333)

INSPECTION FOUND LEFT FUSELAGE SKIN DENTED AT STA 1333 JUST ABOVE AIRSTAIR. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 51-30-2 AND 53-30-03.

Part: SKIN — CRACKED (LT WING)

INSPECTION FOUND A .375 CRACK AT LEFT WING FIXED LEADING EDGE SKIN ABOVE NR 4 SLAT INBOARD TRACK. THE CRACK WAS STOP DRILLED. A REPAIR DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 57-30-05.

Part: BATTERY CHARGER — FAILED (CARGO COMPT)

AFT CARGO DOOR EMERGENCY LIGHT OUT. REPLACED BATTERY CHARGER.

Part: HYD HOSE — LEAKING (TAIL SECTION)

THE AIRCRAFT LOST A-SYSTEM HYDRAULIC PRESSURE AND QUANTITY AFTER TAKEOFF. THE AIRCRAFT WAS RETURNED TO PTY WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND HYDRAULIC FLEX HOSE IN TAIL SECTION OF AIRCRAFT LEAKING. THE HYDRAULIC FLEX LINE WAS REMOVED AND REPLACED. IN ADDITION, BOTH THE NR 1 AND NR 2 ENGINE DRIVEN HYDRAULIC PUMPS WERE REMOVED AND REPLACED. THE HYDRAULIC SYSTEM WAS SERVICED. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: PANEL — CORRODED (FUSELAGE)

INSPECTION FOUND AREA AROUND AFT LAVATORY SERVICE PANEL FILL AND DRAIN PIPE BULGED WITH CORROSION. THE PAN AND DOUBLER WERE REMOVED, A REPLACEMENT DOUBLER AND ANGLE WERE FABRICATED AND INSTALLED IAW SRM 51-10-2, 51-10-6, 51-20-2 AND 51-30-2.

Part: RIB — CRACKED (NR 8 LE SLAT)

INSPECTION FOUND A .5 INCH CRACK IN RT WING NR 8 SLAT RIB, JUST INBOARD OF ANTI-ICE DUCT. THE CRACK WAS ROUTED OUT AND A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 57-50-3, FIGURE 9.

Part: WEB — CRACKED (RT WING)

INSPECTION FOUND A 1 INCH CRACK IN RT WING FALSE SPAR WEB LOWER AREA, JUST INBOARD OF NR 5 FLAP TRACK. THE CRACKED AREA OF WEB WAS CUT OUT, A WEB REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-2.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND THE SECOND FROM FRONT AISLE CEILING EMERGENCY LIGHT INOPERATIVE. THE BATTERY PACK WAS REMOVED, SERVICED AND REINSTALLED.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND THE AFT AISLE FLOOR EMERGENCY LIGHT BETWEEN REAR LAVATORIES INOPERATIVE. THE BATTERY PACK WAS REMOVED, SERVICED AND REINSTALLED.

Part: ANGLE — CRACKED (WING)

INSPECTION FOUND A 2.6 INCH CRACK AT ANGLE BELOW INBOARD STOP FITTING AT NR 3 SLAT. THE CRACK WAS STOP DRILLED, AN EXTRUDED ANGLE REPAIR WAS FABRICATED AND INSTALLED IAW SRM 51-40-4.

Part: RIB — CRACKED (NR 5 SLAT ACT)

INSPECTION FOUND A 1 INCH CRACK IN RT WING NR 5 SLAT ACTUATOR OUTBOARD ATTACH RIB AND A .5 INCH CRACK IN INBOARD ATTACH RIB OF NR 5 SLAT ACTUATOR. THE CRACKS WERE STOP DRILLED, ANGLE REPAIRS WERE FABRICATED AND INSTALLED IAW SRM 51-40-3.

Part: DOUBLER — CRACKED (RT WING TIP)

INSPECTION FOUND A .75 INCH CRACK IN RT WING TIP TRAILING EDGE LOWER DOUBLER. THE DOUBLER WAS REMOVED AND A REPLACEMENT WAS FABRICATED AND INSTALLED IAW SRM 51-40-2.

Part: SKIN — PUNCTURED (RT ELEVATOR)

INSPECTION FOUND RT ELEVATOR UPPER SKIN HAD A HOLE AND LOOSE RIVETS JUST FORWARD OF INBOARD CONTROL TAB. A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 55-20-3.

Part: SKIN — DELAMINATED (LT ELEV TAB)

INSPECTION FOUND LT ELEVATOR CONTROL TAB UPPER SKIN DELAMINATED. A FIBERGLASS OVERLAY REPAIR WAS ACCOMPLISHED IAW SRM 51-40-6.

Part: SKIN — CRACKED (LT WING)

INSPECTION FOUND A .75 INCH CRACK IN LT WING FIXED LEADING EDGE AT CUTOUT WHERE NR 3 SLAT OUTBOARD TRACK INSERTS. THE CRACK WAS STOP DRILLED, A DOUBLER WAS FABRICATED AND INSTALLED IAW SRM 57-30-4.

Part: RIB — CRACKED (NR 6 SLAT ACT)

INSPECTION FOUND A .5 INCH CRACK IN RT WING NR 6 SLAT OUTBOARD TRACK INBOARD ATTACH RIB AND A .5 INCH CRACK IN INBOARD TRACK OUTBOARD ATTACH RIB OF NR 6 SLAT. THE CRACKS WERE STOP DRILLED, DOUBLERS WERE FABRICATED AND INSTALLED IAW SRM 51-40-3.

Part: LIGHT — INOPERATIVE (CABIN)

THE EMERGENCY EXIT LIGHT AT ROW 8 WAS FOUND INOPERATIVE. THE EMERGENCY EXIT LIGHT ASSEMBLY WAS REMOVED AND REPLACED.

Part: ACTUATOR — LEAKING (RUDDER)

AIRCRAFT LOST ALL B-SYSTEM HYDRAULIC QUANTITY AND PRESSURE AFTER TAKEOFF FROM IAH. THE HYDRAULIC LOSS CHECKLIST WAS COMPLIED WITH AND THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE UPPER RUDDER ACTUATOR SOLENOID O-RING PLATE LEAKING. THE O-RING PLATE WAS REMOVED AND REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD.

Part: BATTERY PACK — DISCHARGED (AFT AIRSTAIR)

FLT NR 232 - EWR - THE EMERGENCY OVERHEAD LIGHTING IN AFT AIRSTAIR WAS FOUND INOPERATIVE. THE BATTERY PACK WAS REMOVED AND REPLACED AND OPERATION OF THE LIGHTING WAS RESTORED. (M)

Part: RETRACT MECH — JAMMED (TE FLAPS)

FLT NR 0294 - EWR - DURING LANDING, FLAPS JAMMED AT 5 DEGREES, HANDLE SET AT 25 DEGREES HAD SPLIT INDICATION. PERFORMED ONE GO AROUND 'NO EMERGENCY DECLARED'. (M)

Part: TRANSDUCER — INOPERATIVE (ANTI-SKID SYSTEM)

EWR - FLT 0293 - LOW SPEED TAKEOFF ABORT. SUPPLEMENT - TAKEOFF WAS ABORTED DUE TO A LOUD POPPING NOISE FOLLOWED BY A JOLT. THE ANTI-SKID SYSTEM WAS TROUBLESHOT AND ALL ANTI-SKID VALVES CHECKED GOOD. MAINTENANCE FOUND THE RT ANTI-SKID TRANSDUCER CONNECTOR PINS PULLED. THE CONNECTOR WAS RE-PINNED. THE LT INBD ANTI-SKID TRANSDUCER HAD PIN NR 4 PUSHED BACK. THE PIN WAS RE-SECURED. THE ANTI-SKID SYSTEM FUNCTIONED NORMALLY. (X)

Part: ACM — MALFUNCTIONED (RIGHT)

MIA - FLT 0702 - THE LT PACK TRIP-OFF LIGHT ILLUMINATED FOLLOWED BY LOSS OF CABIN PRESSURE WHILE EN ROUTE FROM SDQ TO EWR. THE CREW WAS UNABLE TO REGAIN CONTROL OF CABIN PRESSURE. ACFT DESCENDED TO FL 190 AND OXYGEN MASKS DROPPED. ACFT WAS DIVERTED TO MIA WHERE IT LANDED WITHOUT INCIDENT. RT ACM WAS REMOVED AND REPLACED. IN ADDITION, LT TURBO INLET OVHT SWITCH, LT COMPRESSOR DISCHARGE OVHT SWITCH, LT CONTROL CABIN DUCT OVHT SWITCH, AND LT PACK TRIP RELAY WERE ALL REMOVED AND REPLACED AS A PRECAUTIONARY MEASURE. LEAK AND OPERATIONAL CHECKS WERE NORMAL. MAINTENANCE FOUND ALL OXYGEN MASKS IN CABIN AND LAVATORIES HAD DEPLOYED. ALL OXYGEN BOTTLES CHECKED GOOD. (X)

Part: COFFEEMAKER — SMOKING (GALLEY)

FLT NR 0538 - EWR - SMOKE WAS OBSERVED COMING FROM THE VICINITY OF THE AFT GALLEY COFFEEMAKER WHILE IN FLIGHT. THE COFFEEMAKER WAS TURNED OFF AND THE SMOKE CEASED. MAINTENANCE FOUND BURNT PAPER AT THE BACK OF THE COFFEEMAKER. THE AREA WAS CLEANED FREE OF THE DEBRIS. THERE WAS NO TROUBLE FOUND WITH THE COFFEEMAKER.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

FLT NR 0279 - EWR - A FORWARD SECTION OF EMERGENCY TRACK LIGHTING ILLUMINATED WHEN TESTED, BUT WENT DIM SHORTLY AFTER. THE FORWARD BATTERY PACK WAS REMOVED AND REPLACED AND OPERATION OF THE EMERGENCY TRACK LIGHTING WAS RESTORED. (W)

Part: CONTROL CABLE — CORRODED (NLG DOOR)

EWR - FLT 0232 - NOSE GEAR DOOR OPEN LIGHT ON FORWARD PANEL AND SECOND OFFICER'S PANEL REMAINED ILLUMINATED AFTER RAISING THE LANDING GEAR ON TAKEOFF FROM EWR. CYCLING GEAR DID NOT HELP. CREW CONFIRMED DOOR WAS OPEN BY VISUAL INSPECTION THROUGH THE VIEW PORT. AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NOSE GEAR DOOR CABLES WITH ZERO TENSION AND BOTH CABLES STRETCHED AND CORRODED. CABLE PIVOT QUADRANT WAS WORN IN CABLE GROOVE AND CORRODED. CABLES AND QUADRANT WERE REMOVED AND REPLACED. AN ADJUSTMENT/TEST WAS PERFORMED IAW MM 32-22-1, PAGE 501. NOSE GEAR WAS SWUNG SEVERAL TIMES WITH ALL OPERATION AND INDICATIONS CHECKING GOOD. REF CONTL NR 95ZZZX426. (X)

Part: CONTROL CABLE — CORRODED (NLG DOOR)

EWR - FLT 0232 - NOSE GEAR DOOR OPEN LIGHT ON FORWARD PANEL AND SECOND OFFICER'S PANEL REMAINED ILLUMINATED AFTER RAISING THE LANDING GEAR ON TAKEOFF FROM EWR. CYCLING GEAR DID NOT HELP. CREW CONFIRMED DOOR WAS OPEN BY VISUAL INSPECTION THROUGH THE VIEW PORT. AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NOSE GEAR DOOR CABLES WITH ZERO TENSION AND BOTH CABLES STRETCHED AND CORRODED. CABLE PIVOT QUADRANT WAS WORN IN CABLE GROOVE AND CORRODED. CABLES AND QUADRANT WERE REMOVED AND REPLACED. AN ADJUSTMENT/TEST WAS PERFORMED IAW MM 32-22-1, PAGE 501. NOSE GEAR WAS SWUNG SEVERAL TIMES WITH ALL OPERATION AND INDICATIONS CHECKING GOOD. REF CONTL NR CAL95-0013.