N805AL

Part: BRAKE — INOPERATIVE (MLG PARKING) · airframe 51,207 hrs · 77,487 cycles

PILOTS OBSERVED BOTH ANTI-SKID LIGHTS CAME ON IN FLIGHT ONLY WHEN THE LANDING GEAR IS IN THE (OFF) POSITION; LANDED WITH NO DIFFICULTIES. REMOVED AND REPLACED PARKING BRAKE SHUTOFF VALVE ASSEMBLY. MAINTENANCE ALSO FOUND A BAD NR 4 TRANSDUCER AND CURRENTLY WAITING FOR AN ANTI-SKID CONTROL UNIT TO BE REPLACED.

Part: CONNECTOR — DAMAGED (FIRE LOOP)

FLT 942, HNL-KOA: (NON-ETOPS) AFTER ENGINES WERE STARTED, THE NR 2 ENGINE FIRE WARNING SWITCH AND BELL CAME ON. FOLLOWED THE QRH AND SHUT DOWN THE ENGINE. REPLACED THE HERMETIC CONNECTORS ON THE NR 2 ENGINE LOWER FIRE DETECTION LOOP. ACCOMPLISHED HIGH POWER ENGINE RUN WITH NO FIRE WARNING INDICATIONS NOTED. AIRCRAFT RETURNED TO SERVICE.

Part: FIRE LOOP — MALFUNCTIONED (NR 2 ENGINE)

FLT 922, (NON-ETOPS) HAD ENGINE NR 2 FIRE INDICATION ON CLIMBOUT. SHUTDOWN ENGINE NR 2 AND FIRED BOTH ENGINE FIRE EXTINGUISHER BOTTLES. RETURNED TO HNL. REPLACED THE NR 2 ENGINE LOWER FIRE DETECTION LOOP. SYSTEM CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: HYDRAULIC SYSTEM — CONTAMINATED (B SYSTEM) · airframe 49,850 hrs · 74,309 cycles

NON-ETOPS CARGO FLIGHT 909, HNL-LIH: ON CLIMB-OUT PASSING 1500 FT THE FEEL DIFFERENTIAL PRESSURE LIGHT ILLUMINATED. RETURNED TO HNL. REPLACED THE B HYDRAULIC SYSTEM RETURN FILTER AND CASE DRAIN FILTERS DUE TO CONTAMINATION, OPS CHECK GOOD. REPLACED THE A SYSTEM RETURN FILTER AND DRAINED/RE-SERVICED THE A SYSTEM HYDRAULIC RESERVOIR, OPS CHECK GOOD. CHECKED ELEVATOR PITOT SYSTEM FOR LEAKS IAW AMM 27-31-22, NO DEFECTS NOTED. AIRCRAFT RETURNED TO SERVICE

Part: WARNING LIGHT — ILLUMINATED (COCKPIT) · airframe 49,850 hrs · 74,309 cycles

NON-ETOPS CARGO FLIGHT 909, HNL-LIH, ON CLIMB-OUT PASSING 2000-3000 FT, THE FEEL DIFFERENTIAL PRESSURE LIGHT CAME ON. RETURNED TO HNL. BLEW OUT ELEVATOR PITOT TUBES, PITOT TUBES CLEAR. AIRCRAFT RETURNED TO SERVICE.

Part: CONTROL CABLE — OUT OF ADJUST (TE FLAPS) · airframe 49,717 hrs · 73,988 cycles

AT 34,000 FT DURING CRUISE THE L/E FLAP TRANSIT LIGHT CAME ON, AUTO-PILOT KICKED OFF AND ON DESCENT THE CONFIGURATION HORN CAME ON. RETURNED TO HNL. ADJUST FLAP CABLE WFA & WFB TENSION IAW AMM 27-51-01 AS ADDRESSED BY BOEING SERVICE LETTER 27-040. OPS CHECK OK, AIRCRAFT RETURNED TO SERVICE.

Part: DOOR FRAME — CRACKED (FUSELAGE)

FOUND CRACK ON LOWER INBOARD CORNER OF FORWARD CARGO DOOR FRAME. TRIMMED OUT DAMAGED AREA. VERIFIED CRACK REMOVED USING HFEC INSPECTION. FABRICATED A REPAIR ANGLE, ALODINED, AND PRIMED. INSTLALED REPAIR PARTS. REPAIR COMPLETED IAW ECO 1763. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SHUTOFF VALVE — DEFECTIVE (NR 2 ENGINE)

FLT 952 - HNL-ITO, NR 2 ENGINE COWL ENGINE ICE LIGHT REMAINS ON IN TRANSITION (BRIGHT BLUE). RETURNED TO HNL FOR UNEVENTFUL LANDING. REMOVED AND REPLACED THE NR 2 ENIGNE COWL VALVE. OPS CHECKED GOOD IAW AMM 75-11-0. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (PAX CABIN)

REPLACED FORWARD ENTRY EMERGENCY EXIT LIGHT BATTERY PACK DUE TO INOPERATIVE. OP CHECK OK. AIRCAFT RETURNED TO SERVICE. (M)

Part: SWITCH — INOPERATIVE (ENG OIL BYPASS)

DURING CLIMB, THE NR 1 ENGINE OIL FILTER BYPASS LIGHT ILLUMINATED. THE NR 1 ENGINE WAS SHUTDOWN IAW THE QRH. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LANDED IN HNL WITH NO FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE NR 1 ENGINE OIL BYPASS SWITCH AND THE OIL FILTER ELEMENT. THE NR 1 ENGINE OIL TANK WAS DRAINED AND SERVICED. GROUND OPERATIONAL AND LEAK CHECKS WERE GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — CORRODED (FUSELAGE)

TRIMMED OUT DAMAGE SKIN AT BS 947.5 ABOVE STRINGER 25L. HFEC INSPECTED THE EDGE OF THE TRIM. ENLARGED TRIM BY .040 INCH INSURANCE CUT. NDT INSPECTED THE OUTE ROW OF FASTENER HOLES COMMON TO REMOVED EXISTING REPAIR USING .030 NOTCH ROTARY AND SURFACE PROBE INSPECTIONS. FABRICATED A .032 INCH DOUBLER, .050 INCH TRIPLER AND TWO .071 INCH FILLERS FROM 2024-T3 CLAD SHEET. FINISHED ALL BARE ALUMINUM WITH ALODINE AND TWO COATS OF BVMS 10-79 TYPE III PRIMER. INSTLALED REPAIR PARTS WITH FASTENERS AND HI-LOKS WET WITH BMS 5-95 SEALANT IN TRANSITION FIT HOLES. APPLIED A FILLET SEAL OF BMS 5-95 SEALANT AROUND THE EDGES. APPLIED CORROSOIN INHIBITING COMPOUND TO THE INTERNAL AND EXTERNAL SURFACES OF THE REPAIR AREA.

Part: SKIN — CORRODED (FUSELAGE)

TRIMMED OUT DAMAGE SKIN AT BS 918 ABOVE STRINGER 25R. HFEC INSPECTED THE EDGE OF THE TRIM. ENLARGED TRIM BY .04 INCH INSURANCE CUT. NDT INSPECTED THE OUTER ROW OF FASTENER HOLES COMMON TO REMOVED EXISTING LAP REPAIR USING ROTARY AND SURFACE PROBLE INSPECTIONS. FABRICATED A .032 INCH DOUBLER, .050 INCH TRIPLER AND TWO .071 INCH FILLERS FROM 2024-T3 CLAD SHEET. FINISHED ALL BARE ALUMINUM WITH ALODINE AND TWO COATS OF BVMS 10-79 TYPE III PRIMER. INSTALLED REPAIR PARTS WITH FASTENERS IDENTIFIED. APPLIED A FILLET SEAL OF BMS 5-95 SEALANT AROUND THE EDGES. APPLIED CORROSION INHIBITING COMPOUND TO THE INTERNAL AND EXTERNAL SURFACES OF THE REPAIR AREA. VERIFIED 8110-3 RECEIVED. REPAIR COMPLETED IAW SRM 53-30-

Part: SKIN — CORRODED (FUSELAGE)

REMOVED DAMAGED SKIN AND STRINGERS 26L, 27L, AND 27R BETWEEN BS 908 AND BS 1016. REPLACED SKIN PANEL PER PRODUCTION DRAWINGS 65-45776-55 AND 65-45776-56. INSTALLED PRODUCTION PANEL USING FASTENERS IDENTIFIED IN DRAWINGS. FINISHED ALL BARE ALUMINUM WITH ALODINE AND TWO COATS OF BMS 10-79 TYPE III PRIMER. APPLIED A FILLET SEAL OF BMS 5-95 SEALANT AROUND THE EDGES. APPLIED CORROSION INHIBITING COMPOUND TO THE INTERNAL AND EXTERNAL SURFACES OF THE REPAIR AREA. REPAIR COMPLETED IAW ECO 3334 PART 1. (M)

Part: STRINGER — CRACKED (FUSELAGE)

EXTERIOR 1 INCH FUSELAGE CRACK AT BS 375 AT STRINGER 15L. TRIMMED OUT DAMAGE. HFEC INSPECTED THE EDGE OF THE TRIM. ENLARGED TRIMMED AREA BY .040 INCH INSURANCE CUT. HFEC ROTARY AND SURFACE PROBLE INSPECTED FASTENER HOLES ALONG STRINGER 15R UNDER THE REPAIR COMMON TO LAP MODIFICATION. REPAIR COMPLETED IAW ECO 33360 AND BOEING SB 737-53A1177. (M)

Part: STRINGER — CORRODED (FUSELAGE)

TRIMMED OUT DAMAGE STRINGER SECTION. FABRICATED A .090 INCH THICK J AND U-CHANNEL FROM 7075-T6. ALODINED AND APPLIED TWO COATS PRIMER TO ALL BARE ALUMINUM. INSTALLED REPAIR PARTS USING FASTENERS IDENTIFIED IN FIGURE 2. SEALED FAYING SURFACE WITH BMS 5-95 SEALANT. APPLIED CORROSION INHIBITING COMPOUND TO REPAIR AREA. VERIFIED 8110-3 RECEIVED. REPAIR SPLICE COMPLETED IAW ECO 2599, FIGURE 2. (M)

Part: SKIN — CRACKED (FUSELAGE)

EXTERIOR 1 INCH CRACK BETWEEN BS 440 AND BS 460 AT BL 0. TRIMMED OUT DAMAGED AREA ON LOWER LOBE ANTENNA CUT OUT. PERFORMED NDT INSPECTION OF CUTOUT, SKIN AND SATELLITE HOLES USING HFEC, NO DEFECTS NOTED. FABRICATED A .063 INCH THICK FILLER AND .071 INCH THICK REPAIR DOUBLER FORM 2024-T3 CLAD SHEET. ALODINED AND PRIMED REPAIR PARTS AND BARE SURFACES WITH MIL-C-5541 AND BMS 10-11 TYPE 1. INSTALLED REPAIR PARTS USING RIVETS, WASHERS AND BOLT IDENTIFIED IN FASTENER CODE TABLE. REPAIR COMPLETED IAW ECO 3329. (M)

Part: STRINGER — CRACKED (FUSELAGE)

TWO RIVETS SHOW CRACK INDICATIONS USING LFEC AT BS 227.8 STRINGER 27R. REMOVED ADJACENT FASTENERS AND STRINGER. USING HFEC CONFIRMED NO CRACK INDICATION USING ROTARY PROBE IAW BOEING TELEX ALO-HNL-03-0031H. (M)

Part: BRACKET — CRACKED (THRUST REVERSER)

THE NUMBER ONE REVERSER UNLOCK LIGHT ILLUMINATED IN-FLIGHT. THE AIRCRAFT RETURNED TO AND LANDED AT AIRPORT WITH NO FURTHER INCIDENT. MAINTENANCE FOUND THE UPPER LOCK ACTUATOR SENSOR BRACKET CRACKED. MAINTENANCE REPLACED THE SENSOR BRACKET AND AS A PRECAUTIONARY BOTH UPPER AND LOWER PROXIMITY SENSOR CIRCUIT CARDS. GROUND OPERATIONAL CHECKS WERE GOOD AND THE AIRCRAFT RETURNED TO SERVICE.

Part: PITOT TUBE — OBSTRUCTED (PITOT/STATIC SYS)

FLT 930 - HNL-OGG - DURING THE CLIMB-OUT OF HNL, THE FIRST OFFICERS AIR SPEED INDICATOR WAS INDICATING 40 KNOTS SLOWER THAN THE CAPTAIN'S INDICATOR. THE AIRCRAFT RETURNED TO AND LANDED AT HNL WITH NO FURTHER INCIDENT. MAINTENANCE PERSONNEL REMOVED FOD FROM THE FIRST OFFICERS PITOT TUBE. THE PITOT/STATIC SYSTEM TEST AND CHECKED GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (FUSELAGE)

RT BS 1129 AND BS 1138 FUSELAGE SKIN CRACKS LOCATED AT S5R AND S12R. TRIMMED OUT CRACKS MAINTAINING A MINIMUM TRIM OUT CORNER RADIUS .050 INCHES AT A SURFACE FINISH OF 63 RMS OR SMOOTHER. PERFORMED HFEC INSPECTION AROUND TRIMOUT AREA, NO DEFECTS NOTED. FABRICATED AND INSTALLED .063 INCHES 2024T3 REPAIR DOUBLER, TWO .056 INCHES 2024T3 FILLERS AND A 2024T3 CLAD ALUMINUM TAPER SHIM WITH APPROVED FASTENERS WET WITH CORROSION INHIBITOR TO A REPAIR PARTS. APPLIED BMS 5-95 SEALANT TO ALL FAYING SURFACES IAW ECO. RECEIVED 8110-3 APPROVAL. AIRCRAFT RETURNED TO SERVICE.

Part: WINDOW FRAME — CRACKED (FUSELAGE)

RT SIDE WINDOW FRAME CORNER FASTENER HOLE CRACK AT BS 727B. VERIFIED CRACK ON WINDOW FRAME ASSY BY UTILIZING HFEC ROTAR PROBE METHOD, REAMED WINDOW FRAME FASTENER HOLE UNTIL REMOVAL OF CRACK. VERIFIED CRACK REMOVAL BY HFEC ROTARY METHOD, ENLARGED AND INSTALLED FREEZE PLUG TO FASTENER HOLE TO MAINTAIN FREEZE PLUG WALL THICKNESS OF .050 IN PER SRM 51-10-9. FAB AND INSTALL .032 IN FILLER A .050 INCH FILLER, A .071 IN FILLER AND A .063 IN DOUBLER FROM 2024-T3 CLAD ALUM WITH APPRVD FASTENERS, APPLIED TO ALL FAYING SURFACES. BMS 3-23 CORROSION INHIBITING COMPOUND APPLIED TO INTERNAL SURFACES OF REPAIR AREA IAW ECO. A/C RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE)

TEAR STRAP FASTENER HOLE CRACK AT BS 777, S-20L. REMOVED FASTENER AND VERIFIED CRACK UTILIZING HFEC ROTARY HOLE PROBE METHOD IAW WITH NDT, REMOVED DAMAGED AREA AND HFEC INSPECTION COMPLETED NO DEFECTS NOTED. FABRICATED AND INSTALLED .032 IN 2024-T3 CLAD REPAIR FILLERS AND DOUBLERS WITH APPROVED FASTENERS, APPLIED ALODINE AND BMS 10-79 TYPE II PRIMER TO ALL REPAIR PARTS AND BARE SURFACES. APPLIED BMS 5-95 SEALANT TO ALL FAYING SURFACES. REPAIR COMPLETED IAW SRM. AIRCRAFT RETURNED TO SERVICE.

Part: WINDOW FRAME — CRACKED (FUSELAGE)

RT SIDE WINDOW FRAME CORNER FASTENER HOLE CRACK AT BS 380. CRACK ON WINDOW FRAME ASSY BY UTILIZING HFEC ROTARY PROBE METHOD, REAMED WINDOW FRAME FASTENER HOLE UNTIL REMOVAL OF CRACK, CRACK REMOVAL BY HFEC ROTARY METHOD, ENLARGED, INSTALLED FREEZE PLUG TO FASTENER HOLE TO MAINTAIN FREEZE PLUG WALL THICKNESS OF .050 INCH PER SRM. FAB AND INSTALL .032 INCH FILLER, A .050 INCH FILLER, A .071 INCH FILLER AND .063 INCH DOUBLER FROM 2024-T3 CLAD ALUM WITH APPROVED FASTENERS, ALODINE AND TWO COATS OF BMS 10-11 TYPE 1 PRIMER TO EXPOSED SURFACES. BMS 5-95 SEALANT APPLIED TO ALL FAYING SURFACES. BMS-3-23 CORROSION INHIBITING COMPOUND APPLIED TO INTERNAL SURFACES OF REPAIR AREA IAW ECO. A/C RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE)

CRACK LOCATED AT BS 807, S-14L. CUT AND REMOVED DAMAGED AREA, VERIFIED CRACK REMOVAL UTILIZING HFEC METHOD NO DEFECTS NOTED, FABRICATED AND INSTALLED REPAIR ANGLES AND FILLER FROM .063 IN 2075-T6 IAW APPROVED FASTENERS WENT WITH BMS 5-95 SEALANT PER TABLE I AND TABLE V IAW SRM. APPLIED ALODINE COATING AND ONE COAT OF BMS 10-11, TYPE 1 PRIMER TO ALL REPAIR PARTS AND BARE SURFACES AND BMS 5-95 SEALANT APPLIED TO ALL FAYING SURFACES. REPAIR COMPLETED IAW SRM. AIRCRAFT RETURNED TO SERVICE.

Part: STIFFENER — CRACKED (LT WING)

LT WING FRONT SPAR STIFFENER CRACK AT FSS 473.31 AND FSS 475.55. REMOVED, FABRICATED AND INSTALLED STIFFENERS. NEW STIFFENERS FABRICATED FROM 7178-T6511 EXTRUSION AND NEW SHIMS FABRICATED FROM 2024-T3, APPLIED ALODINE AND BMS 10-11 TYPE 1 PRIMER AND BMS 10-11 TYPE 2 ENAMEL TO ALL EXPOSED SURFACES, BMS 5-26 SEALANT APPLIED TO ALL FAYING SURFACES. INSTALLED .0312 INCH OVERSIZED TENSION PROTRUDING HEAD HEX DRIVE BOLTS AT EXISTING RIVET LOCATIONS AND .0156 OVERSIZED TENSION PROTRUDING HEAD HEX DRIVE BOLTS AT EXISTING LOCK BOLT LOCATIONS WET WITH BMS 5-26 SEALANT. REPAIR COMPLETED IAW ECO. AIRCRAFT RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE)

REPAIRED RIGHT OUTBOARD CHORD AT BS727, S18A DUE TO FASTENER HOLE CRACK. UTILIZED HIGH FREQUENCY EDDY CURRENT AND ULTRASONIC METHODS. REMOVED AND INSTALLED CHORD ASSEMBLY, REASSEMBLED AND INSTALLED ALL COMPONENTS AND FASTENERS, APPLIED BMS 5-95, TYPE I SEALANT TO ALL FAYING SURFACES, CLEAN AND TREATED ALL BARE SURFACES IAW ECO. AIRCRAFT RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE)

FOUND CRACK ON THE FRAME AT BS 480 ABOVE STRINGER 17R. CUT OUT AND REMOVED DAMAGED PORTION OF FORMED SECTION. VERIFIED CUTOUT WITH HFEC. DETERMINED FROM TABLES III, IV, AND V, THE NUMBER OF FASTENERS AND FASTENER ROWS REQUIRED. FABRICATED REPAIR PARTS FROM MATERIALS SPECIFIED IN TABLE 1. APPLIED ALODINE AND BMS10-11 TYPE 1 PRIMER TO ALL BARE ALUMINUM. INSTALLED REPAIR PARTS MAKING A FRAYING SURFACE SEAL AND FASTENERS WET WITH BMS 5-95 SEALANT. REPAIR COMPLETED IAW WITH SRM. AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — CRACKED (FUSELAGE)

REPAIRED FUSELAGE SKIN CRACK AT BS 727B, S-17. CUT OUT DAMAGED AREA AND PERFORMED HFEC INSPECTION AROUND CUT OUT, PERFORMED INSURANCE CUT OF .040 INCH, FABRICATED AND INSTALLED REPAIR DOUBLER AND TEAR STRAP. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED LEFT OVERWING EMERGENCY LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (FUSELAGE)

FOUND 3 INCH CRACK ON THE FUSELAGE SKIN AT BS 887 ALONG STRINGER 24R. CUT OUT DAMAGED PORTION OF SKIN. VERIFIED CRACK REMOVED USING HFEC. FABRICATED AND INSTALLED REPAIR PARTS IAW SRM 53-30-3 FIGURE 1. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SPAR — CRACKED (VERTICAL STAB)

FOUND CRACK IN THE VERTICAL STABILIZER IN SPAR WEB ON THE VERTICAL STABILIZER. TRIMMED OUT CRACK IAW FIGURE 2. FABRICATED A REPAIR DOUBLER AND A FILLER AS SHOWN IN FIGURE 2. INSTALLED REPAIR PARTS AND VERIFIED 8110-3 RECEIVED IAW ECO 3276. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CORRODED (VERTICAL STAB)

FOUND SKIN BULGE ON RIGHT SIDE VERTICAL FIN RIGHT SPAR AT FWL 112.356. FABRICATED REPAIR ANGLE, EXTERNAL DOUBLER, TWO FS 173.10 IN SPAR RIB CLIPS, REPLACEMENT FIN REAR SPAR WEB, SOLID SINGLE GUSSET, SKIN TRIM POUT FILLER AND FLAT FILLERS IAW FIGURES 2A THROUGH 2E. INSTALL ALL REPAIR PARTS AND SHIM GAPS TO .003 INCH MAXIMUM IAW ECO 2509. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SPAR — NICKED (HORIZONTAL STAB)

FOUND NICKS ON CENTER SECTION REAR SPAR UPPER FORWARD SIDE FITTING. REMOVED NICKS/DAMAGED MATERIAL TO A MAXIMUM OF .01 INCH AND TAPERED. APPLIED A CHEMICAL CONVERSION COATING AND REFINISHED THE REWORKED SURFACE IAW SRM 55-10-1 FIGURE 6, DETAIL IX. AIRCRAFT RETURNED TO SERVICE. (M)

Part: ATTACH FITTING — GOUGED (HORIZONTAL STAB)

FOUND GOUGE MARKS ON LEFT HORIZONTAL STABILIZER CENTER SECTION LUG, UPPER FORWARD FITTING. REMOVED GOUGE / DAMAGED MATERIAL TO A MINIMUM WIDTH OF .10 INCH AND RADIUS OF 1 INCH AND TAPERED. APPLIED A CHEMICAL CONVERSION COATING AND REFINISHED THE REWORKED SURFACE IAW SRM 55-10-1 FIGURE 6, DETAIL II, VI, AND VII. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED NR 5 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OP CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FIRE WARNING — FALSE ACTIVATION (APU)

FLT - 117 - HNL-LIH - ON SHORT FINAL LANDING IN LIHUE, HI, THE APU WAS STARTED AND FOLLOWED BY AN ILLUMINATION OF THE APU FIRE WARNING HANDLE, THE SOUNDING OF THE FIRE WARNING BELL, AND ILLUMINATION OF THE GLARE SHIELD FIRE WARNING LIGHTS. THE APU FIRE HANDLE WAS PULLED AND THE APU SWITCH WAS POSITIONED TO OFF. THE FIRE WARNING LIGHT REMAINED ILLUMINATED. THE APU FIRE BOTTLE WAS DISCHARGED. NO SMOKE OR FIRE DETECTED BY THE ATC TOWER. INSPECTED THE APU AREA FOR DAMAGE. NO DAMAGE FOUND. DEFERRED THE APU ASSEMBLY PER MEL 49-1 AND APU FIRE DETECTION SYSTEM PER MEL 26-8-1. (M)

Part: SPAR — CORRODED (FS 476-481.7)

FOUND CORROSION DURING HEAVY CHECK AT RIGHT WING FRONT SPAR LOWER CHORD FORWARD FLANGE LOWER SURFACE AT FSS 476.0 THROUGH FSS 481.7. (M)

Part: BEAR STRAP — CORRODED (FUSELAGE)

DISCOVERED CORROSION AT FORWARD CARGO DOOR BEAR STRAP (AFT UPPER CORNER). (M)

Part: SKIN — CRACKED (RT WING)

FOUND .62 INCH CRACK DURING HEAVY CHECK AT RIGHT UPPER WING SKIN AFT EDGE BETWEEN WBL 157 AND WBL 183.4. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 FLOOR EMERGENCY LIGHT BATTERY PACK FOR BEING LOW. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLAED NR 2 FLOOR EMERGENCY LIGHT BATTERY PACK FOR BEING LOW. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FRAME — CRACKED (FUSELAGE)

FOUND IDENTIFIED CRACK AT BS 727, STRINGER 18L UPPER CHORD BY UTILIZING HFEC METHOD. (M)

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED NR 4 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE, OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 2 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FRAME — CRACKED (FUSELAGE)

PREVENTIVE MODIFICATION INCORPORATED INCONJUNCTION WITH CRACK REPAIR AT BS 480 INNER FRAME FLANGE. REPAIR INCLUDED TRIM OUT OF CRACK, HFEC INSPECTION OF TRIM OUT. INSTALLED .040 INCH 7075-T6 FILLER AND INSTALLATION OF .050 INCH DOUBLER. IAW AD 2000-04-08, SB 737-53A1220R1 AND ECO 3078R2. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SEAL — WORN (NR 1 ENGINE)

FLT 286 - OGG-ITO - FLIGHT CREW EXPERIENCED A LEFT WING BODY OVERHEAT LIGHT ON. LIGHT WENT OUT AFTER LEFT BLEED SWITCH WAS TURNED OFF AND ISOLATION VALVE CLOSED. CREW RETURNED TO OGG AFTER CONFERRING WITH DISPATCH THAT THER WAS NO MAINTENANCE SUPPORT AVAILABLE IN ITO. AIRCRAFT LANDED UNEVENTFULLY IN OGG. REPLACED CLAMP AND RUBBER SEALS FROM NR 1 ENGIEN AIRFILTER TO PURGE VALVE AIR DUCT. VERIFIED OPERATIONS AND LEAK CHECK OK. AIRCRAFT RETURNED TO SERVICE. REF TSAA0026160. (M)

Part: CLAMP — WORN (NR 1 ENGINE)

FLT - 286 - OGG-ITO - FLIGHT CREW EXPERIENCED A LEFT WING-BODY OVERHEAT LIGHT ON. LIGHT WETN OUT AFTER LEFT BLEED SWITCH WAS TURNED OFF AND ISOLATION VALVE CLOSED. CREW RETURNED TO OGG AFTER CONFERRING WITH DISPATCH THAT THERE WAS NO MAINTENANCE SUPPORT AVAILABLE IN ITO. AIRCRAFT LANDED UNEVENTFULLY IN OGG. REPLACED CLAMP AND RUBBER SEALS FROM NR 1 ENGINE AIRFILTER TO PURGE VALVE AIR DUCT. VERIFIED OPERATIONS AND LEAK CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED NR 3 AND NR 6 FLOOR EMERGENCY LIGHT BATTERY POWER PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (SERVICE DOOR)

REPLACED FORWARD SERVICE DOOR EMERGENCY EXIT IDENTIFIER POWER PACK. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: STRINGER — CRACKED (FUSELAGE)

REPAIRED 1.75 INCH CRACK AT STRINGER 16L APPROX 4 INCHES AFT OF BS 727 AND 2 INCH CRACK AT STRINGER 17L APPROX 7 INCHES AFT OF BS 727 CONFIRMED BY USING HIGH FREQUENCY EDDY CURRENT METHOD. REPAIRED BY USING ONE DOUBLER FOR BOTH CRACKS IAW SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (OVERWING)

REPLACED FORWARD OVERHEAD EXIT IDENTIFIER BATTERY. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (RT OVERWING)

REPLACED RIGHT OVERWING EXIT IDENTIFIER AND BATTERY. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED NR 3 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FITTING — CRACKED (NLG ACTUATOR)

NLG UPPER ACTUATOR ATTACH FITTING, CRACKED AT ATTACH BRACKET FORWARD RIGHT HI-LOCK. REPAIRED IAW ECO 3122 PART II. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED FORWARD ENTRY EXIT IDENTIFIER LIGHT BATTERY PACK DUE TO INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: LIGHT — INOPERATIVE (CABIN)

REPLACED FORWARD ENTRY EXIT IDENTIFIER LIGHT ASSY DUE TO INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED NR 3 FLOOR PROXIMITY LIGHT BATTERY PACK DUE TO NO TEST. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 6 FLOOR EMERGENCY LIGHT BATTERY PACK FOR BEING LOW. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 5 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO LOW VOLTAGE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 4 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO LOW VOLTAGE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 2 FLOOR EMERGENCY LIGHT BATTERY PACK FOR BEING LOW. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 5 FLOOR EMERGENCY LIGHT BATTERY PACK FOR BEING LOW. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (FUSELAGE)

FOUND 2 INCH CRACK ON RIGHT FUSELAGE AFT OF WINGS BELOW WINDOW. HFEC AROUND CUT COMPLIED WITH. REPAIRED PER SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT ASSY — INOPERATIVE (EMER EXIT)

REPLACED FORWARD SERVICE DOOR EMERGENCY EXIT LIGHT ASSY DUE INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 FLOOR EMERGENCY LIGHT BATTERY PACK FOR BEING LOW. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M

Part: BEARING — WORN (NR 1 GEARBOX)

FLT 63 - OGG-HNL - DURING CLIMB, THE NR 1 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED. OIL PRESSURE ON NR 1 GAUGE WAS FALLING RAPIDLY AND OIL TEMPERATURE WAS RISING. ENGINE WAS SHUTDOWN IAW THE CHECKLIST. EMERGENCY WAS DECLARED. UNEVENTFUL LANDING WAS MADE IN HONOLULU. REMOVED AND REPLACED NR 1 ENGINE IAW FORM M-211, M-213, M-212, M-214, M-215, M-209, AND M-224. GEARBOX JY1963 WAS TORE DOWN AND ROLLER BEARING P/N PWA 446746 (INSTALLED ON OIL PUMP BEVEL GEAR) WAS FOUND WORN. THE WORN BEARING CAUSED SLIPPAGE OF THE OIL PUMP AND CAUSED IT TO FAIL. ENGINE RUN OK. A/C RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (BS 774)

FOUND .875 INCH SKIN CRACK NOTED AT BS 774 STRINGER 17L. HFEC CONFIRMED ENDS OF CRACK. REPAIRED CRACK PER SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED FORWARD SERVICE, FORWARD PASSENGER, RIGHT OVERWING, AND LEFT OVERWING SLIDE LIGHT BATTERY PACKS DUE TO INOP. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (SERVICE DOOR)

REPLACED AFT SERVICE DOOR EMERGENCY SLIDE LIGHT ASSY DUE TO BEING INOPERATIVE. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (SERVICE DOOR)

REPLACED AFT SERVICE DOOR EMERGENCY SLIDE LIGHT ASSY DUE TO BEING INOPERATIVE. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 6 EMERGENCY FLOOR PROXIMITY LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 POSITION BATTERY PACK FOR FLOOR PROXIMITY LIGHT ASSY DUE INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

NR 2 SEAT EMERGENCY LIGHT ASSY BATTERY INOPERATIVE. REMOVED AND REPLACED NR 2 SEAT EMERGENCY LIGHT BATTERY PACK, OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (PAX DOOR)

REMOVED AND REPLACED AFT ENTRY EXIT IDENTIFIER LIGHT ASSY DUE TO RECEIVES ONLY 1 TRANSMITTER. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

REMOVED AND REPLACED FORWARD ENTRY DOOR EMERGENCY LIGHT DUE TO BEING INOP. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REMOVED AND REPLACED FORWARD ENTRY DOOR EMERGENCY LIGHT BATTERY PACK DUE TO LOW VOLTAGE. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: INTERCOSTAL — DENT (BS 857)

DENT NOTED AROUND RIVET AT BS 857 ALONG STRINGER 19R A/Y RATIO =.75/.048=15625. INSTALLED FABRICATED INTERCOSTAL AND REPAIRED IAW SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SPAR — CORRODED (HORIZ STABILIZER)

HORIZONTAL STAB UPPER RIGHT FRONT SPAR CHORD EXFOLIATED. REPAIRED PER ECO 2201R1. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SPAR — CORRODED (VERTICAL STAB)

VERTICAL STABILIZER REAR SPAR SKIN BULGING DUE TO CORROSION. REPAIR PER ECO 2509 R5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SPAR — CORRODED (VERTICAL STAB)

VERTICAL STABILIZER REAR SPAR SHOWS SIGNS OF EXFOLIATION. REPAIRED PER ECO 2509 R5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: DOOR FRAME — CRACKED (FUSELAGE)

AFT CARGO DOOR FRAME CRACKED. REPLACED AFT CARGO DOOR IAW BOEING MM 52-31-0. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 POSITION EMERGENCY LIGHT ASSY BATTERY PACK DUE TO BEING INOPERABLE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. TAT: 40,564.9 HOURS. TAC: 52,457. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 2 POSITION EMERGENCY LIGHT ASSY BATTERY PACK DUE TO CONDITION LED'S INOP. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 3 POSITION EMERGENCY LIGHT ASSY BATTERY PACK DUE TO CONDITION LED'S INOP. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 POSITION EMERGENCY LIGHT ASSY BATTERY PACK DUE TO CONDITION LED'S INOP. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 4 POSITION EMERGENCY LIGHT ASSY BATTERY PACK DUE TO CONDITION LED'S INOP. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 2 POSITION EMERGENCY LIGHT ASSY BATTERY PACK DUE TO FAILING CHECK. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: CONNECTOR — LOOSE (NR 2 FIRELOOP)

FIRE WARNING WENT OFF MOMENTARILY IN FLIGHT NR 2 ENGINE AND APU FIRE DETECTION SYSTEM WOULD NOT TEST THEREAFTER. INSPECTED NR 2 ENGINE AND FOUND LOOSE CONNECTOR ON LOWER FIRE LOOP. SECURED AND SAFETY-TIED CONNECTOR. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REMOVED AND REPLACED NR 3 SEAT LIGHT ASSY BATTERY PACK DUE TO FAILING CHECK. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

FORWARD PASSENGER EXIT DOOR LIGHT COVER BROKEN. REPLACED FORWARD EXIT IDENTIFIER EMERGENCY LIGHT. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING SERVICE CHECK, FOUND NR 3 POSITION EMERGENCY FLOOR LIGHT INOPERABLE. REPLACED BATTERY PACK. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

DURNIG SERVICE CHECK, FOUND NR 6 POSITION EMERGENCY FLOOR LIGHT INOP. REPLACED BATTERY PACK. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SIGN — INOP (CABIN)

REPLACED RIGHT FORWARD SERVICE DOOR EMERGENCY LIGHT IDENTIFIER DUE TO 'ALL'S WELL' LIGHT NOT ILLUMINATING. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

ON SERVICE CHECK, FOUND POSITION NR 1 EMERGENCY FLOOR LIGHT INOPERABLE. REPLACED BATTERY PACK. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 39,502:35 HOURS. TAC: 50,012. (X)

Part: CROSSBEAM — CRACKED (CARGO DOOR)

FORWARD CARGO DORO CROSSBEAM CRACKED. REPAIRED AREA PER ECO 2875 R1 (WEB). REPAIRED LOWER FRAME CORNER PER SRM 51-10-1. (M)

Part: PANEL — CORRODED (WING)

DURING CPC CHECK, FOUND CORROSION AT WING LOWER SKIN PANEL, FUEL ACCESS DOOR CUTOUT LIP NR 9 RT. CORROSION IS LEVEL 2. REPAIRED PER ECO 2871. (M)

Part: SKIN — CRACKED (TE FLAP)

DURING CPC CHECK, FOUND SKIN CRACK ON UNDERSIDE OF INBOARD AFT TRAILING EDGE FLAP AT WLB 157. REPAIRED PER SRM 57-50-4. (M)

Part: SILL — CORRODED (CARGO DOOR)

DURING CPC CHECK, FOUND CORRODED CHORD ON AFT CARGO PIT DOOR SILL, TOP OF FRAME. REPAIRED DAMAGE BY REPLACING CHORD PER SRM 51-10-1. (M)

Part: SKIN — CORRODED (LT MAIN WING BOX)

DURING CPCP CHECK, FOUND CORROSION AT NR 6 RT AND NR 7 LEFT MAIN WING BOX LOWER SKIN ACCESS PANEL CUTOUT LIP. REPAIRED PER ECO 2869. (M)

Part: TRACK — CORRODED (CARGO COMPT)

DURING CPC CHECK, FOUND CORROSION ON RIGHT OUTBOARD TRACK AT DOOR SILL (AFT CARGO PIT). REPAIRED DAMAGE BY REPLACING TRACK PER SRM 51-10-1. (M)

Part: SKIN — CRACKED (HORIZ STAB)

DURING CPC CHECK, FOUND CRACKS AT HORIZONTAL STABILIZER LOWER SKIN ACCESS PANEL AT STATION 99.1 RT SIDE. REPAIRED PER ECO 2870 R2. (M)

Part: BULKHEAD — CORRODED (BS 294)

DURING CPCP CHECK, FOUND EXFOLIATION CORROSION ON INTERIOR FUSELAGE LOWER LOBE BULKHEAD STATION 294, STRINGER 26L. CORROSION IS LEVEL 2, CUTOUT DAMAGED AREA AND REPAIRED PER SRM 53-10-31 AND FASTENERS PER SRM 51-30-02. (M)

Part: FRAME — CRACKED (CARGO DOORWAY)

DURING CPC CHECK, FOUND AFT CARGO DOOR INBOARD DOOR SILL FRAME CRACKED. REPAIRED PER ECO 1700 R-4. (M)

Part: FLOORBEAM — CORRODED (BS 867)

DURING CPC CHECK, FOUND CORROSION AT SECTION 43 AND 46 FLOORBEAM LOWER CHORD AT BS 867, LBL 18.6 AND BS 480, RBL 50-55. REPAIRED PER EO 2874. (M)

Part: STRINGERS — CUT (FUSELAGE)

CUT STRINGERS 23 AND 24R TO FACILITATE AFT OUTFLOW VALVE DOUBLER INSTALLATION. REPAIRS STRINGERS PER SRM 53-10-3 USING NEW DOULBER. (M)

Part: LIGHT ASSY — INOPERATIVE (CABIN)

ON SERVICE CHECK, FOUND NR 1 POSITION EMERGENCY FLOOR LIGHTING INOP. REPLACED FLOOR LIGHT ASSEMBLY. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

ON SERVICE CHECK, FOUND NR 4 POSITION EMERGENCY FLOOR LIGHTING INOP. REPLACED BATTERY PACK. OPS CHECK GOOD. AIRCRAFT RETURNED TO ERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

ON SERVICE CHECK, FOUND NR 3 POSITION EMERGENCY FLOOR LIGHTING INOPERABLE. REPLACED BATTERY PACK, OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 39,245:49 HOURS. TAC: 49,426.

Part: BATTERY PACK — DISCHARGED (CABIN)

ON SERVICE CHECK, FOUND NR 1 POSITION EMERGENCY FLOOR LIGHTING INOPERABLE. REPLACED BATTERY PACK, OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 39,245:49 HOURS. TAC: 49,426. (X)

Part: SKIN — CRACKED (BS 755)

ON SERVICE CHECK, FOUND A FUSELAGE SKIN CRACK AT BS 755, .50 INCH ABOVE STR 16L, APPROXIMATELY 1 INCH LONG. REPAIRED PER SRM 53-30-3, FIG 6. AIRCRAFT RETURNED TO SERVICE. TAT: 38,201:03 HOURS. TAC: 49,317. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

ON SERVICE CHECK, FOUND POSITION NR 1 EMERGENCY FLOOR LIGHTING INOP. REPLACED BATTERY PACK. OP CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — DISCHARGED (CABIN)

DURING OVERNIGHT CHECK, REPLACED BATTERIES FOR ROWS 1 AND 4 EMERGENCY FLOOR PROXIMITY LIGHT ASSY DUE TO INOPERABLE. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERIVCE. TAT: 38,922:36 HOURS. TAC: 48,687. (X)

Part: BATTERY — DISCHARGED (CABIN)

DURING OVERNIGHT CHECK, REPLACED BATTERY PACK FOR ROW 12 EMERGENCY FLOOR PROX LIGHT ASSY DUE TO INOP. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

ON SERVICE CHECK, FOUND POSITION NR 6 EMERGENCY FLOOR LIGHT INOP. REPLACED BATTERY PACK. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — DISCHARGED (CABIN)

DURING OVERNIGHT CHECK, REPLACED ROW 5 EMERGENCY FLOOR PROX LIGHT ASSEMBLY BATTERY DUE TO LIGHT INOP. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (BS 727)

DURING OVERNIGHT CHECK, FOUND FUSELAGE SKIN CRACK 1 INCH AT BS 727B PLUS 16 AND STRINGER 17L. CONFIRMED WITH HFEC. REPAIRED PER SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — DISCHARGED (CABIN)

DURING SERVICE CHECK, REPLACED BATTERY FOR ROW 4 FLOOR PROX LIGHT ASSY DUE TO BEING INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. TAT: 38,062:33 HOURS. TAC: 46,719. (X)

Part: SKIN — CRACKED (BS 747/750)

DURING OVERNIGHT CHECK, FOUND TWO EACH FUSELAGE SKIN CRACKS AT BS 747 STR 17L APPROXIMATELY 1 INCH IN LENGTH, AND AT BS 750 STR 17L APPROXIMATELY 2.3750 INCHES IN LENGTH. REPAIRED PER SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. TAT: 37,944:39 HOURS. TAC: 46,442. (X)

Part: SMOKE DETECTOR — ACTIVATED (CARGO COMPT)

HNL/KOA - FLT 36 - PILOT REPORT, FORWARD CARGO SMOKE DETECTOR ILLUMINATED WITH BELL IN-FLIGHT. REPLACED BULB. (X)

Part: SKIN — CORRODED (LT WING)

DURING HEAVY MAINTENANCE VISIT, CORROSION FOUND SCATTERED ALONG LEFT UNDERWING SKIN PANEL BTW WBL 204.4 AND 198.6 OUTBOARD OF ENGINE PYLON. REPAIRED PER ECO1684R7. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SPAR CHORD — CORRODED (RT WING)

DURING HEAVY MAINTENANCE VISIT, EXFOLIATION CORROSION FOUND ON RIGHT WING LEADING EDGE OUTBOARD OF NR 5 SLAT ACTUATOR. REPAIRED PER ECO NR 1803 R3-WING FRONT SPAR LOWER CHORD FORWARD HORIZONTAL FLANGE LOWER SURFACE CORROSION REPAIR. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CORRODED (WS 531)

DURING HEAVY MAINTENANCE VISIT, FOUND SURFACE CORROSION AROUND LEFT WING OUTBOARD SUMP DRAIN VALVE, WS 531. REPAIRED PER ECO 1684R7. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — TORN (CARGO DOORWAY)

DURING HEAVY MAINTENANCE VISIT, ACCOMPLISHED PERMANENT REPAIR TO .5 INCH TEAR ON OUTER SKIN APPROXIMATE 10 INCHES FROM FORWARD BOTTOM CORNER OF MAIN CARGO DOOR. FABRICATED FILLER FROM 2024 T3 CLAD AND DOUBLER FROM .056 INCH 2024 T3 CLAD. REPAIRED PER ECO 2788. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CORRODED (WS 515)

DURING HEAVY MAINTENANCE VISIT, FOUND SURFACE CORROSION IN FRONT OF LEFT AILERON LOWER INBOARD FALSE PANEL WS 515. REPAIRED PER ECO 1684R7. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FRONT SPAR — CORRODED (HORIZ STABILIZER)

DURING HEAVY MAINTENANCE VISIT, FOUND LEFT HORIZONTAL STABILIZER CENTER SECTION FWD FITTING CLEVIS CORRODED AROUND BUSHING LOWER CLEVIS AFT FACE. REPAIRED PER ECO 2792. AIRCRAFT RETURNED TO SERVICE. BORE WAS OVERSIZED AND AFT FACE SPOTFACED TO REMOVE CORROSION. (M)

Part: SKIN — CRUSHED (WING)

DURING HEAVY MAINTENANCE VISIT, FOUND WING LEADING EDGE SKIN BELOW NR 1 SLAT INBOARD STOP CRUSHED INWARD. REPAIRED PER ECO 2159 R4. (M)

Part: SMOKE DETECTOR — MALFUNCTIONED (CARGO COMPT)

ON 10-31-96, FLIGHT NR 934, PIREP NR 2, FORWARD CARGO SMOKE WENT OFF INFLIGHT. WENT OUT WHEN RETURNED TO FIELD AFTER LANDING. INSPECTED CARGO COMPARTMENT, CHECK SMOKE DETECTORS. REPLACED DETECTOR BULBS IN A/B DETECTORS. SYSTEM CHECKED NORMAL AIRCRAFT RETURNED TO SERVICE. (M)

Part: FRAME — CRACKED (SERVICE DOOR)

DURING SCHEDULED INSPECTION OF FUSELAGE, FORWARD SERVICE DOORWAY AFT FRAME, DISCOVERED INTERCOSTAL S8A CRACKED. REPAIRED PER ECO 1475R4 PART 3 AND PER DRAWING 65C33436. AIRCRAFT RETURNED TO SERVICE. (M)

Part: AIR DISTRIBUTION — ODOR (COCKPIT)

FLT NR 950 - BURNING SMELL IN COCKPIT. DIVERTED AIRCRAFT TO OGG. VISUALLY INSPECTED AIRCRAFT SYSTEM, ELECTRICAL SYSTEM, AND ENGINE AND FOUND NO DEFECTS. OPERATED ENGINES AND AIRCRAFT SYSTEMS AND FOUND NO DEFECTS. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (BS 747)

DURING OVERNIGHT CHECK, DISCOVERED FUSELAGE SKIN CRACK 1 INCH IN LENGTH AT BS 747 PLUS 3 AT STR 17L. REPAIRED END OF CRACK WITH HFEC. REPAIRED PER SRM 53-30-3, FIGURE 25. AIRCRAFT RETURNED TO SERVICE. TAT: 35026.06 HRS. TAC: 39,796. (X)

Part: BEAM — CRACKED (BS 630)

DURING HEAVY MAINTENANCE VISIT, FUSELAGE BS 639 FLOOR STUB VERTICAL BEAM LOWER CHORD CRACKED LEFT SIDE. REPAIRED PER ECO1567. AIRCRAFT RETURNED TO SERVICE. (M)

Part: STOP — CRACKED (LE SLAT)

DURING HEAVY MAINTENANCE VISIT, NR 3 LEADING EDGE SLAT, CENTER UP STOP, AREA ON BOTH INBOARD AND OUTBOARD OF UP STOP CRACKED. REPAIRED PER ECO 2159R4, PT VI. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FRAME — CORRODED (BS 807)

DURING HEAVY MAINTENANCE VISIT, FOUND CORROSION ON FRAME LOWER FLANGE AT BS 807, STRINGER 27R. CLEANED AND TREATED PER SRM 51-10-6. AIRCRAFT RETURNED TO SERVICE. (M)

Part: INTERCOSTAL — CORRODED (BS 727)

DURING HEAVY MAINTENANCE VISIT, EXFOLIATION ON INTERCOSTAL BETWEEN 727A AND 727B ABOVE STRINGER 25L. REPLACED INTERCOSTAL PER SRM 51-10-1. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SEAT TRACK — WORN (BS 706)

DURING HEAVY MAINTENANCE VISIT, PASSENGER CABIN SEAT TRACK AT STATION 706, SECOND TRACK FROM THE RIGHT SIDE (SLOT WORN). REPAIRED PER SRM 53-10-5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SEAT TRACK — CORRODED (BS 747)

DURING HEAVY MAINTENANCE VISIT, PASSENGER CABIN SEAT TRACK AT STATION 747 EXFOLIATION CORROSION NOTED ON THE SECOND RIGHT TRACK FROM THE WALL. REPAIRED PER SRM 53-10-5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SEAT TRACK — CORRODED (BS 747)

DURING HEAVY MAINTENANCE VISIT, PASSENGER CABIN SEAT TRACK AT STATION 747 EXFOLIATION CORROSION NOTED ON THE THIRD LEFT TRACK FROM THE WALL. REPAIRED PER SRM 53-10-5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FRAME — CRACKED (BS 480)

DURING HEAVY MAINTENANCE VISIT, CRACK FOUND ON FRAME AT BS 480 BETWEEN STRINGER 21L AND 22L, LOWER LOBE COMPARTMENT AS EVIDENT. REPAIRED PER ECO 2275. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SEAT TRACK — CORRODED (BS 520)

DURING HEAVY MAINTENANCE VISIT, PASSENGER CABIN SEAT TRACK AT STATION 520 EXFOLIATION CORROSION NOTED THIRD RIGHT TRACK FROM THE WALL. REPAIRED PER SRM 53-10-5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FLOOR BEAM — CORRODED (BS 520)

DURING HEAVY MAINTENANCE VISIT, PASSENGER CABIN FLOOR BEAM CORRODED AT BS 520, LBL 4, 16, 21. REPAIRED PER ECO2641. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SEAT TRACK — CORRODED (BS 747)

DURING HEAVY MAINTENANCE VISIT, PASSENGER CABIN SEAT TRACK AT STATION 747 EXFOLIATION CORROSION NOTED ON THE SECOND LEFT TRACK FROM THE WALL. REPAIRED PER SRM 53-10-5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: CHORD — CRACKED (BS 727)

DURING HEAVY MAINTENANCE VISIT, BS 727 COMPRESSION CHORD CRACKED APPROXIMATELY 1.5 INCHES AT LBL 25. REPAIRED PER ECO 1528R2, PART III. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SEAT TRACK — CRACKED (BS 910)

DURING HEAVY MAINTENANCE VISIT, PASSENGER CABIN SEAT TRACK AT STATION 910 RIGHT SECOND TRACK FROM THE WALL CRACKED. REPAIRED PER SRM 53-10-5. AIRCRAFT RETURNED TO SERVICE. (M)

Part: ENGINE — FAILED (NR 2)

HUL - FLT 940 - P/R 1 - NR 2 ENGINE FAILED AT 1,000 FEET WITH THROTTLE VIBRATION. RETURNED FOR LANDING AFTER SOP. THE AIRCRAFT RETURNED TO HUL, AND AN UNEVENTFUL LANDING WAS ACCOMPLISHED. ACCOMPLISHED ENGINE MOUNT INSPECTION, PHASE 2, PER FORM M-148, AND NR 2 ENGINE ASSY REPLACED PER M-211, M-212, M-213, M-214, AND M-215. AIRCRAFT RETURNED TO SERVICE. ENGINE CYCLES, 28,632. (X)

Part: ADI — FAILED (NR 2)

FLT 201 - HNL-LIH - FIRST OFFICER ATTITUDE FAILED JUST AFTER TAKEOFF. RETURN TO HNL. REMOVED AND REPLACED NR 2 ADI. GROUND OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (Z)