N804DE

Part: SEAT TRACK — CORRODED (BS 891)

DURING 4C+12A+150M CHECK IN TPE, FOUND CORROSION AT M/D CABIN SEAT TRACK STA 891 LT SIDE NR 2 SEAT TRACK. REPAIRED THE DAMAGED AREA FOR SEAT TRACK AT STA891 LT NR 2 SEAT TRACK PER MD-11 SRM 53-70-00 VOL.1 REV38 FIG 1. JOB COMPLETED AND CONDITION CHECK NORMAL.

Part: SEAT TRACK — CORRODED (BS 891)

DURING 4C+12A+150M CHECK IN TPE, FOUND CORROSION AT MID CABIN SEAT TRACK STA 891 LT SIDE NR 1 SEAT TRACK. REPAIRED THE DAMAGED AREA FOR SEAT TRACK AT STA 891 LT NR 1 SEAT TRACK PER MD-11 SRM 53-70-00 VOL 1 REV 38 FIG 1. JOB COMPLETED AND CONDITION CHECK NORMAL.

Part: SEAT TRACK — CORRODED (BS 891)

DURING 4C+12A+150M CHECK IN TPE FOUND CORROSION AT M/D CABIN SEAT TRACK STA 891 RIGHT SIDE NR 7 AND NR 8 SEAT TRACK (R2 DOOR LAV D). RPR THE DAMAGED AREA FOR SEAT TRACK AT BS 891 RT NR 7 AND 8 SEAT TRACK PER MD-11 SRM 53-70-00 VOL 1 REV 38 FIG 1. JOB COMPLETED AND CONDITION CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (EMERGENCY LIGHT)

L4 OVERWING EMERGENCY BATTERY PACK TEST LOW, REMOVED AND REPLACED WITH A NEW BATTERY S/N#1037,OP'S CHECK GOOD.

Part: FAN — FAILED (CABIN AIR)

CABIN SMOKE LEFT SIDE ROWS 38-46 ABOUT 4 HOURS INTO FLIGHT. ODOR COMING FROM AIR SYSTEM E=EYE BALL VENTS. FOUND 3 PHASE C/B OF PASS AIR OUTLETS FAN AT 2R DOOR PANEL POPPED. REMOVED AND REPLACED PAX AIR OUTLET FAN ASSY AT FS 769, SYSTEM OPS CHECK GOOD.

Part: SKIN — DENTED (FUSELAGE) · airframe 51,308 hrs · 6,154 cycles

THE FUSELAGE SKIN AT THE AFT EDGE OF THE C2 CARGO DOOR CUTOUT WAS FOUND WITH A DENT AND GOUGE IN AN EXISTING SRM REPAIR DOUBLER. THE DOUBLER WAS REMOVED AND UNDERLYING STRUCTURE INSPECTED. ALL EXISTING AND NEW DAMAGE WAS REMOVED WITH A 14.5 X 6 INCH CUTOUT IN THE SKIN AND UNDERLYING DOUBLERS. THE CUTOUT WAS REPAIRED WITH 3 EXTERNAL ALUMINUM REPAIR DOUBLER PER ER/A 087661-14, REV B.

Part: MODULE — LOOSE (CREW REST) · airframe 51,119 hrs · 6,139 cycles

COULD NOT STOW CREW REST MODULE, L1 DOOR BLOCKED. FOUND LOOSE SCREW ON TRACK ASSY CAUSING INTERFERENCE WITH TRACK. TIGHTENED SAME. CREW REST MODULE OPEN/CLOSE AND LOCK/UNLOCK FUNCTIONS CHECKS OKAY.

Part: WARNING LIGHT — ILLUMINATED (LAVATORY) · airframe 49,243 hrs · 5,940 cycles

LAV SMOKE MSG ILLUMINATED WITH CORRESPONDING PILOT LIGHT. LIGHT INSPECTED LAV AND TESTED WARNING SYSTEM.

Part: CONNECTOR — DIRTY (SMOKE DETECTOR) · airframe 47,559 hrs · 5,702 cycles

LAV SMOKE LIGHT ILLUMINATED ON ADVISORY PANEL. DETECTOR IN FWD/CONDO AREA WAS ACTIVATED WITH NO INDICATION OF ASSOCIATED SMOKE. INTAKE OF SENSOR WAS COVERED AND ALARM CEASED. WHEN SENSOR UNCOVERED SYSTEM OPERATED NORMALLY. ALARM REOCCURED SEVERAL TIMES. ALL PACK OPERATION ON GROUND NORMAL. NO SMOKE OR ODOR NOTED IN CREW REST MODULE. CLEAN AND RESEAT CREW REST SMOKE DETECTOR CONNECTOR. PERFORMED SMOKE DETECTOR TEST PER CRM SUPP MTC MANUAL. TEST OKAY.

Part: BYPASS VALVE — MALFUNCTIONED (A/C BAY) · airframe 46,980 hrs · 5,588 cycles

LAV SMOKE WITH RESIDUAL SMELL IN CREW REST AREA AND HOT SMELL IN COCKPIT LASTED A FEW MINUTES. RAN ENGINES PER PFHB AT HIGH PWR SETTINGS. ISOLATED PACKS, NO SMOKE OR UNUSUAL HEAT NOTICED IN CREW REST MODULE. REMOVED AND REPLACED PACK 1 TURBINE BYPASS VALVE AND WATER SEPARATOR BAG AS PER MM. REMOVED AND REPLACED PACK 1 RAM AIR DOOR ACTUATOR AS PER MM. REPLACED ALL 3 PACK WATER SEPARATOR BAGS. INSPECTED E/E AND AVIONICS COOLING FANS. NO DEFECTS NOTED. ALL 3 PACK INDICATIONS NORMAL.

Part: VALVE — FAULTY (CABIN) · airframe 46,938 hrs · 5,576 cycles

DURING CLIMBOUT OF DFW COCKPIT CREW SMELLED SMOKE. SUBSEQUENTLY HAD AN LAVATORY SMOKE EAD ALERT. SMOKE PERSISTED FOR 3-4 MIN, THEN WENT OUT. F/A'S REPORT DENSE SMOKE ESCAPE FROM CREW REST MODULE WHEN DOOR WAS OPENED AFTER LANDING. RETURNED TO DFW. REPLACED FWD CABIN TRIM AIR VALVE. PERFORMED AIR CONDITION PACK AND DISTRIBUTION DUCT CLEANING PER M/M. RAN ENGINES, OPERATIONAL CHECK NORMAL. DURING PACK AND DISTRIBUTION DUCT CLEAN FOUND NR 3 TURBINE BYPASS VALVE INOP. REPLACED SAME.

Part: ODOR — DETECTED (CABIN) · airframe 46,399 hrs · 5,486 cycles

APPROX 11 HRT INTO FLIGHT F/A IN AFT GALLEY AREA SMELLED. BURNING PLASTIC SMELL AT 4L AREA. SMELL DISSIPATED QUICKLY. OVENS WERE OFF AND LAVS WERE EMPTY AND PANELS NOT WARM. CEILING ABOVE F/A 4L JUMPSEAT IS SOOTED AROUND AIRVENT. CHECKED AFT C/B PANEL IN CEILING. NO C/B WERE POPPED. INSP AFT GALLEY CEILING PANELS AND O/H EQUIP ABOVE CEILING. INSP 4L LAV UNDERSINK AND TRASH CONTAINER AREA. HEAT IND AND FIRE BOTTLES NORM. REMOVED 4L PA STANCHION AND INSP OK. ALL GALLEY EQUIP OPS NORMAL. ALL LIGHTS OP OK. SOOT AT AIRVENT IS DUST. CLEAN SAME. NO SMELL NOTED.

Part: SOCKET — DEFECTIVE (CABIN) · airframe 46,386 hrs · 5,485 cycles

EMERGENCY LIGHTS IN FIRST CLASS DO NOT COME ON DURING TEST. REMOVED AND REPLACED 1 BATTERY IN COCKPIT PER M/M. NO HELP. FOUND TROUBLE TO BE IN SEAT 1J AND H REMOVED AND REPLACED LIGHT SOCKET AT 1J/H. FIRST CLASS EMERGENCY LIGHTING CKS GOOD.

Part: WIRE HARNESS — DAMAGED (CABIN) · airframe 46,155 hrs · 5,454 cycles

EMERGENCY LIGHTS ON SEATS IN FWD BUSINESS CLASS WILL NOT STAY ON. FLASH ON AND OFF EVERY FEW MINUTES. FOUND DAMAGED WIRE HARNESS UNDER SEAT 1H. REPLACED WIRE HARNESS. OPN CKS GOOD.

Part: LIGHT — DEFECTIVE (REST MODULE) · airframe 45,594 hrs · 5,388 cycles

CREW REST MODULE READING LIGHT IN BOTTOM BUNK BEGAN TO SMOKE AND WAS TURNED OFF. REPLACED READING LIGHT BULB.

Part: START VALVE — MALFUNCTIONED (NR 3 ENGINE) · airframe 45,255 hrs · 5,344 cycles

ATB FOR NUMBER 3 ENG START VALVE LIGHT FLICKERING DURING FLIGHT. REPLACED NR 3 START VALVE AND PRESSURE SWITCH.

Part: FLUSH MOTOR — FAULTY (LAVATORY) · airframe 45,246 hrs · 5,343 cycles

LAV SMOKE WARNING ILLUMINATED. FLT ATTN FOUND NO SMOKE BUT ODOR L4 LAV. FOUND L4 TOILET VALVE MOTOR SMOKING. REPLACED TOILET ASSY.

Part: STRUCTURE — CORRODED (HORIZ STAB) · airframe 45,242 hrs · 5,340 cycles

CORROSION WAS FOUND IN THE BORES OF THE UPPER SURFACE BARREL NUT HOLES AT 49 LOCATIONS ON THE HORIZONTAL STABILIZER. REPAIRED PER ER/A 412361-14.

Part: SKIN — CORRODED (FUSELAGE) · airframe 45,242 hrs · 5,340 cycles

AT OVERHAUL, DAMAGE WAS FOUND TO THE EXISTING REPAIR DOUBLERS AT STA 1937 AND 1959 AT THE AFT LAV EXHAUST PORTS. REPAIRED PER ER/A 360655-14 REV C.

Part: SMOKE DETECTOR — DAMAGED (LAVATORY) · airframe 43,735 hrs · 5,148 cycles

SMOKE ALARM AFT TOILET CAPT SIDE BATT LOW. DETECTOR DAMAGED. REMOVED AND REPLACED SAME. OPS OK.

Part: OVEN — DIRTY (GALLEY) · airframe 43,735 hrs · 5,148 cycles

AFT MOST OVEN ON F/O SIDE OF A/C HAD BURNING SMELL WHEN ON. TURNED OFF, SMELL WENT AWAY. FOUND REMNANTS OF MELTED PLASTIC BAG IN AFT RT OVEN. CLEANED OVEN. INSPECTED OVEN HARNESS AND CONNECTOR. REINSTALLED, OPS OK. NO ABNORMAL SMELL NOTED. HARNESS AND CONNECTOR OK.

Part: ACTUATOR — MALFUNCTIONED (A/C PACK) · airframe 43,431 hrs · 5,106 cycles

CLIMBING THROUGH 10,000 MSL ON TAKEOFF, A SMOKE DETECTOR IN THE CREW REST FACILITY ACTIVATED. WITH THE DOOR OPEN FROM THE COCKPIT COULD SMELL A HOT ODOR. RETURNED TO KENNEDY. UNEVENTFUL LANDING. INSPECTED A/C FOR EVIDENCE OF ANY FIRE, NONE FOUND. SUSPECT PAC O/HEAT ON CLIMBOUT AND ALT ALERT HORN WENT OFF IN CREW REST AREA AND ODOR FROM O/HEATED PAC IN CABIN. BIT CK ACC-1. FAULTED PK1 RAD ACT. REPLACED ACT AND COALESCER SOCKS. OPERATED PAC. NO ODOR AND PAC, OPS NORMAL.

Part: BATTERY PACK — DISCHARGED (COCKPIT) · airframe 43,224 hrs · 5,081 cycles

NR 1 EMERGENCY LIGHT BATTERY FAILED TEST. REPLACED SAME.

Part: O-RING — LEAKING (NR 1 ENGINE) · airframe 43,039 hrs · 5,055 cycles

NR ONE ENGINE LOSING OIL. QTY DOWN TO ONE. FOUND O-RING AT BOTTOM OF OIL PRESSURE TRANSMITTER TO BE LEAKING. REPLACED O-RING. REPLACED TRANSMITTER AS PRECAUTION.

Part: SLIDE — UNSERVICEABLE (R4 DOOR) · airframe 42,335 hrs · 4,975 cycles

PER SERVICE CK NR 3 INSPECTION INDICATED SLIDE AT R4 DOOR ABOVE GIRT BAR, THE CORDS WERE LOOSE AND THE SAFETY BROKEN ON THE PIN. REMOVED AND REPLACED R4 DOOR SLIDE. SN ON 0303 SN OFF 0430 DELTA PN 250007930.

Part: FAN — MALFUNCTIONED (GALLEY) · airframe 42,281 hrs · 4,969 cycles

IR- AFTER LANDING LAV SMOKE ANNUNCIATES FOR 10 SECONDS WITH HIGH PITCED TONE IN 4R LAV. INSPECTED 4R LAV. NO EVIDENCE OF SMOKE. HIGH PITCHED WHINE FOUND TO BE AFT GALLEY CHILLER VENT FAN. PULLED AND COLLARD C/B FWD TO MCO AND PLACARDED.

Part: POWER SUPPLY — DISCHARGED (COCKPIT) · airframe 42,029 hrs · 4,939 cycles

ON PREFLIGHT CHECK, EMERGENCY LIGHTS TEST FAILED. EMER LIGHT BATT 1 LO MSG ON SYN DISPLAY. REPLACED NR 1 EMERGENCY LIGHT POWER SUPPLY UNIT PER M/M. EMERGENCY LIGHTS TEST PASS.

Part: FMC — FAILED (FWD E/E BAY) · airframe 42,013 hrs · 4,936 cycles

IN CRUISE LAV SMOKE AND CREW REST SMOKE DETECTORS TRIPPED. ELECTRICAL SMELL NOTED IN COCKPIT FWD AND MID CABINS. SMOKE ALSO NOTED IN CREW REST AREA. T/S FOUND FMC 2 INOP. FOUND EVIDENCE OF ELECTRICAL SMOKE ON TOP OF UNIT. REMOVED AND REPLACED UNIT RTS PASSED RAN ALL GALLEY EQUIP AND IFE NO SMOKE/SMELL NOTED CHECKED GOOD.

Part: OVEN — SMOKE (GALLEY) · airframe 41,837 hrs · 4,916 cycles

OVEN MID GALLEY RIGHT SIDE PRODUCES HEAVY SMOKE-MAYBE SPILLED FOOD. CABIN SERVICE CLEANED SPILLED FOOD FROM INTERIOR OF OVEN HEATED OVEN 15 MIN. NO SMOKE

Part: OVEN — OVERHEATED (GALLEY) · airframe 41,625 hrs · 4,894 cycles

BULKHEAD NEXT TO G-7 GALLEY IS CHARRED, OTHER AREAS SHOW BURN DAMAGE. VISUAL INSPECTED AFT GALLEY AREA FOUND OVEN 327 AND 328 DUAL OVEN SHOWED BURN. OTHER AREA NO ABNORMALITY OBSERVED. SUSPECT OVEN PROBLEM. OVEN 327 AND 328 REPLACED.

Part: CONTROL PANEL — FAILED (COCKPIT) · airframe 39,766 hrs · 4,714 cycles

MULTIPLE COMMUNICATION SYSTEMS FAILURE. DIVERT TO PDX. REPLACED OBSERVER''S AUDIO CONTROL PANEL.

Part: ACTUATOR — LOOSE (SPOILER) · airframe 39,722 hrs · 4,710 cycles

SHIMS MIGRATING NR 12 SPOILER ACTUATOR ILB LWR ATTACH BOLT. REPLACED SHIMS AND C/W MM 57-42-0 PG 804.

Part: UNKNOWN — ODOR (AFT GALLEY) · airframe 39,529 hrs · 4,691 cycles

STRONG ODOR DETECTED IN AFT GALLEY AREA. REMOVED CARGO AND THOROUGHLY INSPECTED AIRCRAFT. UNABLE TO DUPLICATE.

Part: STRINGER — CRACKED (WING) · airframe 37,675 hrs · 4,493 cycles

STRINGER 9 ON THE UPPER SURFACE OF THE CENTER WING WAS FOUND WITH A 9 INCH CRACK IN UPPER HORIZONTAL FLANGE OF THE STRINGER BETWEEN LBL 46 & 55. THE STRINGER FORMS THE UPPER CAP OF THE XCW 46.5 BULKHEAD. THE CRACK WAS STOP DRILLED AND REPAIRED WITH ALUMINUM REPAIR ANGLES PER ER/A 377244-14, REV A.

Part: CONTROLLER — MALFUNCTIONED (E/E BAY) · airframe 37,464 hrs · 4,472 cycles

RT MLG UNSAFE IND WITH GEAR UP ON BOTH SYNOPTIC AND PANEL LIGHT. REPLACED UNIT.

Part: COFFEEMAKER — MALFUNCTIONED (GALLEY)

MID GALLEY COFFEMAKER WIRE BURNED THROUGH, BUT DID NOT OPEN CIRCUIT BREAKER. VERIFIED WITH FLITE CREW AND CABIN CREW AND NO SMOKE DETECTED. FOUND C/B POP AT COFFEEMAKER. VERIFIED A/C CIRCUIT BREAKER ON CONTROL PANEL DID NOT OPEN, INSPECTED AIRCRAFT WIRING. NO DEFECTS NOTED, PULLED AND CLAMPED CIRCUIT BREAKER NR 3 ON CONTROL PANEL COFFEEMAKER (S/N 3300) AND REMOVED FROM A/C SHIP TO ATL T/NPJG284.

Part: UNKNOWN — SMOKE (CABIN)

CREW REPORTED SMOKE IN CABIN AND TRACES OF SMOKE IN COCKPIT. CREW TURNED OFF CABIN BUS AND DIVERTED TO RDU. INSPECTED AIRCRAFT, CLEANED DUCTS AND NO TROUBLE FOUND.

Part: BULB — FAILED (ROW 38B)

OVERHEAD READING LIGHT AT SEAT 38B SHORTED OUT. WHEN BULB REPLACED, IT BEGAN TO PRODUCE SMOKE. LIGHTS TURNED OFF FOR REMAINDER OF FLT. REPLACED BULB.

Part: BATTERY PACK — DISCHARGED (CABIN)

BATTERY PACKS NR 5 AND 6 FAILED EMER LTS TEST: FAIL MSGS WERE BATT NR 5 LO AND BATT NR 6 LO. REPLACED BOTH BATTERY PACKS IN NR 5 AND 6 CHARGERS, OPERATION NORMAL.

Part: BATTERY CHARGER — FAILED (CABIN)

DURING EMERGENCY LIGHT TEST, THE NR 5 AND NR 6 BATTERY LOW LIGHTS ILLUM ON EAD. REMOVED AND REPLACED BOTH BATTERY CHARGERS AND BATTERIES. SYS CHK OK.

Part: SKIN — GOUGED (BS 1781)

THE RT SIDE FUSELAGE SKIN WAS DAMAGED BY GROUND EQUIPMENT AFT OF THE C2 DOOR ABOVE LONGERON 41. REPAIRED PER DELTA ER/A 362932-14, REV A.

Part: ACM — FAILED (NR 1)

SMOKE IN COCKPIT AND CABIN AFTER TAKEOFF. RETURNED TO CVG. ACCOMPLISHED ABNORMAL PROCEDURES, SMOKE CLEARED. SMOKE RETURNED AFTER LANDING. INSPECTED ALL THREE PACKS AND COALESCER BAGS. REPLACED NR 1 PACK BAG AND NR 1 ACM.

Part: LIGHT — INOPERATIVE (CABIN)

NUMEROUS EMERGENCY FLOOR TRACK LIGHT OUT. REPLACED ALL EMERGENCY FLOOR TRACK LIGHTS THAT WERE OUT.

Part: TRIM CYLINDER — MALFUNCTIONED (RT MLG)

ON FLIGHT 15 OUT OF FRA, ACFT EXPERIENCED AN UNSAFE RT MLG INDICATION WHICH EXTINGUISHED ITSELF AFTER 30 SEC. ON LANDING FOUND DAMAGE TO THE RT GEAR WHEEL WELL. FOUND THE RT GEAR TRIM CYLINDER OUT OF ADJ PER THE CMM. THIS COMPONENT WAS REPLACED ON THE 10TH OF MAY 1996, WITH A HISTORY OF RT GEAR UNSAFE FOLLOWING THAT REPLACEMENT.

Part: DUCT CLAMP — LOOSE (NR 3 ENGINE)

NR 3 ENG FIRE WARNING AT 13,500 FT ON CLIMBOUT, APPROX 1.36 EPR. FIRE WARNING EXT WHEN THROTTLE PLACED AT IDLE. REPAIRED PNEU LEAK AT PRSOV AND REPLACED BOTH LOWER LOOPS. RAN ENG, NO HELP. FOUND BLEED AIR DUCT LEAKING AT CLAMP AT 12 O'CLOCK POSITION. REPLACED CLAMP, CKS GOOD.

Part: TRACK — SHORTED (CABIN)

EMERGENCY LIGHT TRACK SHORTED. REPLACED TRACK, OPS CHECK GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING INSPECTION, CABIN EMERGENCY LIGHTS FAIL TO TEST. REPLACED BATTERY PACK, OPERATION NORMAL.