N803DE

Part: BUSS — SPARKS (GALLEY)

SPARKS/FUMES AFT OF MID GALLEY PARTITION AT FLOOR CABIN BUSS. SPARKS CEASED 1 HOUR REMAINING IN FLIGHT. PULLED ALL BREAKERS TO POWER SEATS & LAPTOPS AND TRANSFERRED ITEM TO DMI M25JL1905-139 CAT 'D' PER MEL 25-22-1, ITEM DUE ON 11/16/05.

Part: FITTING — CRACKED (BRAKE ASSY) · airframe 50,067 hrs · 6,476 cycles

FOUND DURING D1 LTR CHECK- P/N ABH7269-509 FITTING CRACKED THRU FASTENER HOLES. REPLACED WITH A -521 FITTING. THIS IS THE LT SIDE FITTING FOR THE BRAKE PEDAL TORQUE TUBE ASSY REF NR297.

Part: SMOKE DETECTOR — MALFUNCTIONED (CREW REST MODULE) · airframe 48,554 hrs · 6,243 cycles

DURING CRUISE AT FL 380, THE SMOKE ALARM SOUNDED IN THE CREW REST FACILITY WITH ASSOCIATED LAV SMOKE EAD ALERT. AFTER APPROXIMATELY ONE MINUTE THE ALARM AND ALERTS EXTINGUISHED. PACK NR 1 TEMP WENT TO 50 DEG WHILE 2 AND 3 AT 26 DEF F. CYCLED AIR CONTROLLER AND PACK 1 BACK TO 26 DEG F. ACC-1 NO CURRENT FAULTS. LAST FLT FAULTS RAM AIR DR ACT. ACC-1 RTS PASS. CLEAN AND RESEAT CRM SMOKE DET ELEC CONN. CRM SMOKE DETECTOR TEST PASS PER CRM SUPP M/M. RAN ENG PER PFHB AND PACK 1 TEMP NORMAL. NO ODOR NOTED IN COCKPIT OR CREW REST MODULE.

Part: RELIEF VALVE — OPEN (EMERGENCY EXIT) · airframe 46,233 hrs · 5,877 cycles

ON TRIP CHECK, FOUND L1 DOOR EMERGENCY EXIT N2 RESERVOIR PRESSURE READING 0 PSI. FOUND PRESSURE RELIEF VALVE OPEN. REPLACED PRESS RELIEF VALVE PER M/M. CHARGED N2 PRESSURE AND PRESSURE CHECKS OKAY PER M/M.

Part: CONTROLLER — FAILED (RT WING) · airframe 45,465 hrs · 5,779 cycles

TANK 1 FUEL QTY WENT AMBER WITH FSC IN AUTO. REPLACED FSC.

Part: LIGHT — DEFECTIVE (CABIN) · airframe 45,336 hrs · 5,761 cycles

SEAT 35B READING LIGHT WOULD NOT TURN OFF AND SMOKED FOR FEW MINUTES. SMOKE CEASED BEFORE C/B WAS PULLED. REPLACED LAMP ASSY.

Part: FAN — FAILED (LAVATORY) · airframe 44,974 hrs · 5,715 cycles

LIGHT ELECTRICAL FUMES IN 2R LAV. REPLACED 2R LAV VENT FAN.

Part: CONTROLLER — FAILED (E/E BAY) · airframe 44,974 hrs · 5,715 cycles

LEFT WINDSHIELD HEAT FAIL LEVEL 1 ALERT SMELLED FUMES TURNED HEAT OFF. REMOVED AND REPLACED LEFT WINDSHIELD ANTI-ICE CONTROLLER PER M/M CHECKS GOOD. NO ODORS OR DEFECTS NOTED.

Part: STRUCTURE — CORRODED (HORIZ STAB) · airframe 44,935 hrs · 5,707 cycles

CORROSION FOUND IN THE HORIZONTAL STABILIZER ATTACH BOLT BARREL NUT BORES. REPAIRED ER/A 398116-14.

Part: BATTERY — DISCHARGED (LAVATORY) · airframe 43,827 hrs · 5,570 cycles

LAV 1L SMOKE DETECTOR WILL NOT TURN OFF. REPLACED BATTERY.

Part: PROJECTOR — OVERHEATED (NR 2) · airframe 43,052 hrs · 5,465 cycles

NR 2 PROJECTOR OVERHEATED AND EMITTED FUMES BEFORE DEPARTURE - REPLACED SAME

Part: COFFEEMAKER — SHORTED (MID GALLEY) · airframe 43,027 hrs · 5,461 cycles

MID GALLEY COFEEMAKER SHORTED OUT. (283) VISIBLE SPARKS FLEW, C/B POPPED. REPLACED COFFEEMAKER

Part: FAN — OVERHEATED (PAX OUTLET FAN) · airframe 42,754 hrs · 5,429 cycles

DIVERTED INTO CDB FOR SMOKE SMELL IN CABIN. WITH CABIN BUSES OFF SMELL DIMINISED. FOUND PAX OUTLET FAN AT FAULT. DEACTIVATED SAME. FAN R/R IN ANC ON LOG PAGE 379080001. FAN P/N 605457-8 S/N 18-7444

Part: CIRCUIT BREAKER — FAILED (MID E/E BAY) · airframe 41,776 hrs · 5,323 cycles

BUS AC AND DC GROUND OFF LEVEL ONE ALERT. WITH MTC APPR RESET POPPED C/B C-14 UPPER MAINT PANEL POPPED AGAIN IN 4 MINUTES. DIVERTED TO PDX. REPLACED RCCB B1-1347 AGSTR CONTROL EPCU BITE THRU CFDS NO FAULTS R-T-S- NML.

Part: SWITCH — INTERMITTENT (NR3 ENGINE) · airframe 41,372 hrs · 5,279 cycles

ON CLIMBOUT GOT RED REVERSER UNLOCKED MESSAGE FOR NR3 ENGINE. FOUND LOWER RT STOW SWITCH INTERMITTENT. REPLACED SAME.

Part: B-NUT — FAILED (ACTUATOR) · airframe 41,069 hrs · 5,248 cycles

NR 3 HYD FAILURE ON TAXI IN. FOUND B-NUT LOOSE ON DOWNLOCK ACTUATOR. TIGHTEN NUT AND REMOVED 4 ENG FILTERS, FOUND ALL 4 CLEAN. RE-INSTALLED NEW FILTERS AND MOTORED ENG. LEAK CK OK. RAN ENG AT IDLE AND CHECKED THAT PUMPS SWITCHED OVER AND ARMED. SERVICED NR 3 HYD SYSTEM.

Part: GENERATOR — DISCHARGED (OXYGEN) · airframe 39,500 hrs · 5,088 cycles

THE 4R AFT JUMPSEAT OXYGEN GENERATOR FOUND DISCHARGED. REPLACED O2 GENERATOR PER M/M.

Part: MASK — LEAKING (COCKPIT) · airframe 38,335 hrs · 4,958 cycles

SECOND OBSERVERS MASK HAS O2 LEAK. REPLACED SAME.

Part: TRANSDUCER — LEAKING (HYD SYSTEM)

TWENTY MIN AFTER T/O, HYD 2 OFF ALERT CAME ON. HYD QTY WAS 2.5 GAL AND HOLDING. HYD IN AUTO. NR 2 HYD PUMPS WERE OFF. WHEN SLATS WERE EXTENDED NR 2 HYD QTY WENT TO 1.0 GAL AND HYD 2 FAIL ALERT CAME ON. REPLACED PRESSURE TRANSDUCER.

Part: WINDSHIELD — SHATTERED (COCKPIT)

AT 25,000 FT, CAPT OUTER WINDSHIELD CRACKED. ON INSP, TOTAL AREA FOUND TO BE SHATTERED AT OUTER PANE. REPLACED WINDSHIELD AND CONTROLLER.

Part: CADA — MALFUNCTION (NR 2)

DURING CLIMB-OUT CADC2 SHOWED PLUS 100 KTS WITH OVERSPEED WARNING. REPLACED NR 2 CADC. OP CKS NORMAL.

Part: WHEEL — DAMAGED (CTR MLG)

DURING LANDING ROLL ACFT ENTERED OVERRUN AREA, REMAINED ON PAVEMENT. REPLACED TWO CENTER MAIN WHEEL ASSYS, NO OTHER DAMAGE.

Part: OVEN — SMOKING (GALLEY)

OVEN LOC 281 OVERHEATS SMOKES DURING OPERATION. OVEN WIRE HARNESS ELECT GENERAL INSPECTED, NO DAMAGE NOTED. REPLACED OVEN.

Part: BATTERY — DISCHARGED (CABIN)

ON S/C, EMERGENCY LIGHTS TEST BATTERY 3 AND 4 LOW MESSAGE ILLUMINATED. REPLACED NR 3 AND NR 4 BATTERIES, EMERGENCY LIGHT TEST PASS.

Part: BATTERY PACK — DISCHARGED (CABIN)

ON LAYOVER CHECK, EMERGENCY LIGHTS BATTERY PACK 3 AND 4 FAILED TEST. REPLACED SAME.

Part: FAN — FAILED (CABIN)

ELECTRICAL SMELL IN FORWARD PART OF PLANE, FAIRLY NOTICEABLY. TURNED OFF CABIN BUSS AND SITUATION IMPROVED. ISOLATED SOURCE TO NR 1 RECIRC FAN. REPLACED SAME.

Part: LIGHT — INOPERATIVE (GALLEY)

EMERGENCY LIGHTS INOP AT GALLEY 8A. FOUND DURING LAYOVER MTC CHECK. REPLACED LIGHT ASSY, CHECKS OK.

Part: PROJECTOR — FAILED (CABIN)

MIDWAY DURING FLT STRONG ELEC FUMES WERE DETECTED FROM THE FWD Y CLASS CABIN, PROJECTOR APPEARS TO HAVE OVERHEATED. PULLED C/BS FOR VIDEO SYSTEM AND FUMES APPEARED TO DISSIPATE AFTER VIDEO PROJECTOR WAS SHUTDOWN. REMOVED CEILING PANELS THROUGHT CABIN, INSPECTED WIRING AND COMPARTMENT, NO PROBLEM FOUND. INSPECTED CEILING LIGHTS, NO DEFECTS NOTED. FOUND Y CLASS PROJECTOR AT FAULT WITH BLACK SOOT INSIDE PROJECTOR. REMOVED CANNON PLUG FROM PROJECTOR AND PULLED RELATED C/B IN AFT CABIN BETWEEN 4L AND 4R DOORS. FWD TO MCO AND PLAC PER MEL 25-22-01.

Part: AIR DIST — ODOR (COCKPIT)

ELEC SMOKE SMELL IN COCKPIT. VERIFIED BY FLIGHT ATTENDANTS AS THEY WALKED UP TO COCKPIT. RAN ENGINES AT POWER FOR 30 MIN. PRESSURIZED AIRCRAFT OPERATED ALL GALLEY EQUIPMENT, CKD AFT GALLEY FEEDER CABLES AND GALLEY GCU'S FOR SECURITY. REPLACED OVEN 108 AND COALESCER BAGS PRECAUTIONARY. PERFORMED SMOKE AND ODOR CHECK PER MM 21-53-00-7. INSPECTED OVERHEAD CIRCUIT BREAKER PANELS AND ABOVE FWD PASSENGER DOORS AND FWD AVIONICS EQUIPMENT RACKS. ALL CHECKS NORMAL. NO DISCREPANCIES NOTED.

Part: LIGHT — INOPERATIVE (CABIN)

JUMPSEAT 2L FWD FLASHLIGHT RED LIGHT NOT FLASHING. REPLACED FLASHLIGHT AND BATTERY. INDICATOR OPS NORMAL.

Part: VALVE — FAILED (RUDDER CONTL)

DURING FLIGHT, ACFT LOST NR 3 HYDRAULIC PRESSURE, RETURNED TO KATL. DURING INSPECTION FOUND RUDDER SHUTOFF VALVE LEAKING EXCESSIVELY. REMOVED AND REPLACED RUDDER SHUTOFF VALVE PER MM (P/N AV24E1162) DELTA NUMBER 290001011. SYSTEMS CHECK AND LEAK CHECKED GOOD.

Part: BATTERY — DISCHARGED (CABIN)

DURING EMERGENCY LIGHT TEST BATTERY -3 AND BATTERY -4 LOW MESSAGES ILLUMINATED. REPLACED BATTERY -3 AND BATTERY -4. EMERGENCY LIGHTS CHECK NORMAL WITH NO ASSOCIATED MESSAGES.

Part: OVEN — FAILED (CABIN)

B/C GALLEY OVEN F/O SIDE DOUBLE OVEN ARCHED AND SHORTED WITH VISIBLE FLASH AND SPARKS WHEN TIMER WAS SET. POPPED C/B AND MOMENTARILY LIT ELECT WARNING IN COCKPIT. C/B WAS LEFT OUT. REPLACED OVEN ASSY.

Part: SEAT TRACK — CORRODED (BS 1781-1841)

SEAT TRACK CORRODED IN SEVERAL PLACES BETWEEN FS 1781 AND 1841 LBL 27. REPAIRED PER SRM 53-70-00 MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (BS 1771-1861)

SEAT TRACK CORRODED IN SEVERAL PLACES BETWEEN FS 1771 AND 1861 RBL 27. REPAIRED PER SRM 53-70-00 MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (BS 1305-1361)

SEAT TRACK CORRODED IN SEVERAL PLACES BETWEEN FS 1305 AND 1361 RBL 75. REPAIRED PER SRM 53-70-00 MAJOR REPAIR.

Part: WIRE — BROKEN (CABIN)

A/C LOST ELECTRICAL POWER AT GATE WITH PASSENGERS ON BOARD. RIGHT SIDE EMERGENCY LIGHTS AT ROW 30 TO 36 FLOOR LIGHTS INOPERATIVE. REPAIRED BROKEN WIRE FOUND IN FLOOR TRACK WIRING.

Part: SOLENOID — MALFUNCTIONED (NR 1 ENGINE)

AFTER T/O, PILOT NOTICED SLIGHTLY MORE THAN NORMAL AIRFRAME VIBRATION AND NOISE. DURING CLIMB F/A AT DOOR 3L COMPLAINED OF VIBS IN FLOOR. FOUND NR 1 ENGINE LEFT HALF THRUST REVERSER DAMAGED DUE TO UNSCHEDULED OPENING OF 2.9 STABILITY BLEED VALVE. REPLACED 2.9 BLEED VALVE SOLENOID.

Part: LIGHT — FAILED (CABIN)

EMERGENCY FLOOR TRACK LIGHTS INOP FWD OF SEAT 30C AND RT SIDE OF FIRST CLASS GALLEY. CLEANED SOCKETS AND RELAMPED, CHECKS OK.

Part: EEL PWR PACK — FAILED (NR 5)

EEL BATTERY NR 5, LOW MSG ON EEL TEST. REPLACED NR 5 BATTERY POWER PACK.

Part: FILTER — DIRTY (CABIN)

DURING CRUISE HAS STRONG ELECTRICAL BURNING SMELL THROUGHOUT CABIN. DEACTIVATED RECIRC FAN, SMELL DISSIPATED. FOUND NR 1 RECIRC FAN MOTOR HOT TO TOUCH AND ADJACENT RECIRC FILTER VERY DIRTY. REPLACED FILTER, FAN OPERATION NORMAL.

Part: EEL LAMP — BROKEN (CABIN)

DURING MAINT TESTING OF EMERGENCY FLOOR TRACK LIGHTING, FOUND LAMP MODULE AT 2L DOOR DEFECTIVE. REPLACED FLOOR TRACK LAMP MODULE DAL (P/N 330201571), OPERATIONAL TEST NOW OK.

Part: EEL BULB — FAILED (CABIN)

SEVERAL EMERGENCY FLOOR TRACK LIGHTS ARE NOT LIGHTING UP. RELAMPED LIGHTS, CKS GOOD.

Part: EEL BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY LIGHTS AFT OF SEAT 46 ARE STROBING. REPLACED AFT EMERGENCY BATTERY PACK. EMERGENCY LIGHTS AT 2AB, 3AB, 14G, 49AB, AFT 2 IN FWD GALLEY, RT SIDE ARE INOP. RELAMPED.

Part: COFFEE MAKER — SMOKING (GALLEY)

DURING CRUISE, BUSINESS CLASS GALLEY AFT COFFEE MAKER BEGAN TO SMOKE AND POP, THEN WATER STARTED TO LEAK. SHUT OFF POWER AND WATER TO MAKER. DISPENSER WAS INITIALY DEFERRED, THEN REPLACED AT PDX.