N809AL
Registered owner: ZIPLINE INTERNATIONAL INC, CA (owner ≠ operator)
Operators of this aircraft
Who operated this tail, and how firmly we know it.
No operator established for this aircraft.
Accident & incident history
No NTSB accidents or incidents on file for this aircraft.
Maintenance disclosures
Service Difficulty Reports filed with the FAA for this airframe. Filing is largely voluntary — the number of reports is not a measure of reliability. To verify a report, search its control number at the FAA SDRS site.
108 reports on file, 1995-03-08 – 2003-03-07.
Part: WINDSHIELD — CRACKED (COCKPIT)
THE CAPTAIN'S FORWARD WINDSHIELD CRACKED WHILE CRUISING AT FL350. AN EMERGENCY WAS DECLARED. THE AIRCRAFT RETURNED TO HNL AND LANDED WITH NO FURTHER INCIDENT. MAINTENANCE REPLACED THE CAPTAINS FORWARD WINDSHIELD. GROUND OPERATIONAL AND PRESSURIZATION CHECKS WERE GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE. (M)
Earlier reports · 1995–2001 · 107 reports
2001
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED LEFT OVERWING IDENT BATTERY PACKS DUE TO INOPERATIVE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT — INOPERATIVE (CABIN)
REPLACED AFT SERVICE DOOR EMERGENCY LIGHT ASSEMBLY DUE TO INOPERATIVE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — INOPERATIVE (CABIN)
REPLACED NR 6 EMERGENCY FLOOR BATTERY PACKS DUE TO INOPERATIVE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — INOPERATIVE (CABIN)
REPLACED NR 3 EMERGENCY FLOOR BATTERY PACKS DUE TO INOPERATIVE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — DENTED (FUSELAGE)
DENT AT FUSELAGE SKIN AT BS 360-BS400, STRINGER 17L. REMOVED DAMAGED AREA, HFEC INSPECTION COMPLETED NO DEFECTS NOTED AROUND CUTOUT AREA, INSTALLED 7075-T6 CREASE BEAM, INSTALLED .071 INCH FILLER 2024-T3 INSTALLED .032 INCH DOUBLER 2024-T3, INSTALLED .050 INCH TRIPLER 2024-T6, AND CLEAN AND TREATED ALL BARE SURFACES IAW ECO 3186 OPTION 1. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED FORWARD ENTRY IDENT LIGHT ASSEMBLY DUE TO BEING INOPERATIVE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED FORWARD SERVICE EMERGENCY EXIT IDENT AND RIGHT CENTER EXIT IDENT BATTERY PACKS. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
2000
Part: BATTERY PACK — INOPERATIVE (PAX CABIN)
REPLACED NR 3 AND NR 5 FLOOR PROXIMITY BATTERY PACK DUE TO UNIT FAILS BATTERY TEST. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: FRAME — CORRODED (FUSELAGE)
REMOVED CORROSION FROM INNER CHORD AT BS 1088 STRINGER 17 AND INSTALLED REPAIR ANGLES IAW ECO 3178. AIRCRAFT RETURNED TO SERVICE. (M)
Part: KEELBEAM — CORRODED (FUSELAGE)
REPAIRED FUSELAGE SECTION 46, BS 727 KEEL BEAM AREA SKIN AND DOUBLER DUE TO CORROSION. REMOVED CORROSION AND INSTALLED .063 INCH AND .050 INCH FILLER AND .063 INCH DOUBLER IAW ECO 2454. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — INOPERATIVE (CABIN)
REPLACED NR 2 AND NR 5 FLOOR PROXIMITY BATTERY PACK DUE TO UNIT FAILS BATTERY TEST. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT — INOPERATIVE (CABIN)
REPLACED FORWARD SERVICE DOOR EXIT IDENTIFIER LIGHT ASSEMBLY. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT — INOPERATIVE (CABIN)
REPLACED NR 2 FLOOR EMERGENCY LIGHT ASSEMBLY. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — INOPERATIVE (CABIN)
REPLACED NR 4 FLOOR PROXIMITY BATTERY PACK DUE TO UNIT FAILS BATTERY TEST. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — INOPERATIVE (CABIN)
REPLACED NR 5 FLOOR PROXIMITY BATTERY PACK DUE TO UNIT FAILS BATTERY TEST. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BEAM — CORRODED (CABIN)
BS 520 FLOORBEAM WEB AT RBL 24.75 CRACKED. REPAIRED IAW ECO 3111. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CORRODED (RT WING)
RIGHT WING UPPER SKIN AT WS 170.75 CORRODED. REPAIRED IAW ECO 3090. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CORRODED (RT WING)
RIGHT WING SKIN LOWER SURFACE CORRODED. REPAIRED IAW ECO 3091R1. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SPAR — CORRODED (RT WING)
RIGHT WING FORWARD SPAR LOWER CHORD AND WEB AT FSS 108 AND WBL 355 CORRODED. REPAIRED IAW ECO 3090. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BEAM — CORRODED (TAIL)
HORIZONTAL STABILIZER UPPER AND LOWER TRAILING EDGE BEAM FOUND CORRODED. REPAIRED IAW ECO 1979 R4. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — INOPERATIVE (CABIN)
REPLACED NR 1 FLOOR PROXIMITY BATTERY PACK DUE TO UNIT FAILS BATTERY TEST. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SPAR — GOUGED (HORIZ STAB)
IDENTIFIED .035 INCH GOUGE AT RIGHT HORIZONTAL STABILIZER CENTER SECTION REAR SPAR UPPER CHORD AFT UPPER CLEVIS LUG DURING SSIP INSPECTION. REPAIRED BY 20:1 RATION BLEND OUT, CONFIRMED HFEC INSPECTION NO DEFECTS NOTED, CLEAN AND TREATED AFFECTED AREA. IAW ECO 3201. RECEIVED 8110-3 APPROVAL. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CRACKED (BS 787)
FUSELAGE SKIN CRACK FOUND AT BS 787, STRINGER 18L, 1.75INCH LONG. REPAIRED PER SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)
1999
Part: LIGHT — INOPERATIVE (CABIN)
REPLACED FORWARD ENTRY DOOR IDENTIFIER LIGHT ASSY DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARAGED (CABIN)
REPLACED FORWARD SERVICE AND ENTRY DOOR OUTSIDE EMERGENCY LIGHT BATTERY PACKS DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED EMERGENCY FLOOR BATTERY PACKS FOR POSITIONS 3 AND 5 DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (PAX CABIN)
REPLACED FORWARD ENTRY AND SERVICE DOOR SLIDE LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT ASSY — BROKEN (CABIN)
REPLACED AFT ENTRY EXIT IDENTIFIER LIGHT ASSY DUE TO BEING BROKEN AND CRACKED. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED NR 6 FLOOR PROXIMITY EMERGENCY LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (PAX CABIN)
REPLACED NR 4 FLOOR EMERGENCY BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED NR 6 FLOOR EMERGENCY BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CORRODED (WS 157)
EXFOLIATION FOUND ON UNDERSIDE OF RIGHT INBOARD WING LOWER SKIN AT STATION 157 AT REAR SPAR. REPAIRED CORRODED AREA IAW ECO 1684R10. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED NR 2 FLOOR PROXIMITY EMERGENCY LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: ACCESSORY UNIT — DEFECTIVE (TR UNIT)
HNL/ITO - FLT 404 - TAKEOFF WARNING HORN SOUNDED DURING TAKEOFF. TAKEOFF ABORTED AT ABOUT 30 KNOTS. RETURNED TO GATE. REMOVED AND REPLACED ENGINE ACCESSORY UNIT. OPS CHECK OK IAW MM 78-34-91. AIRCRAFT RETURNED TO SERVICE. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED POSITIONS 1 AND 4 EMERGENCY FLOOR LIGHT BATTERY PACKS DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED POSITIONS 3, 5 AND 6 EMERGENCY FLOOR LIGHT BATTERY PACKS DUE TO LOW VOLTAGE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT — INOPERATIVE (SERVICE DOOR)
REPLACED FORWARD SERVICE DOOR EMERGENCY LGIHT BATTERY PACK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CRACK (BS 831-838)
WHILE PERFORMING THE EXTERIOR LOW FREQUENCY EDDY CURRENT INSPECTION REQUIRED BY AD 97-22-07 (AD 94-25-05 SUPERSEDED AD) A CRACK WAS DISCOVERED ON STRINGER 10R LAP JOINT AT BS 831 THROUGH 838. THE LAP JOINT WAS REPAIRED IAW 737 SRM 53-30-03 FIG 42. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CRACKED (BS 831-838)
FOUND CRACK NOTED ON STRINGER 10R LAP JOINT AT BS 831 THROUGH 838. THE LAP JOINT WAS REPAIRED IAW 737 SRM 53-30-03 FIG 42. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED AFT CONTROL MODULE BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT — INOPERATIVE (CABIN)
REPLACED FORWARD ENTRY DOOR EMERGENCY LIGHT ASSY DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT — INOPERATIVE (CABIN)
REPLACED FORWARD SERVICE DOOR EMERGENCY LIGHT ASSEMBLY DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: PRESSURE WEB — CRACKED (NLG WW)
NOSE LANDING GEAR WHEELWELL RIGHT HAND FORWARD PRESSURE PANEL CUT-OUT HAS 2.5 INCH CRACK AT LOWER EDGE BETWEEN RIVETS. REPAIRED NOSE LANDING GEAR WHEELWELL RIGHT HAND FORWARD PRESSURE PANEL CUT-OUT PER ECO 2935. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: PANEL — CORRODED (RUDDER)
CORROSION ON RUDDER LEADING EDGE COVER PANEL, RUDDER STA 92.92. REPLACED EXISTING PANEL PER ECO 2938. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: BRACKET — CRACKED (BS 500)
CRACK NOTED ON Z-CHANNEL AND ATTACH BRACKET AT BS 500A STR 25L IN FORWARD CARGO PIT. REMOVED AND REPLACED ATTACHING BRACKET PER SRM 51-10-1. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: SKIN — CRACKED (LT ELEV TAB)
LOWER LEFT HAND ELEVATOR TRIM TAB CRACKED AT HINGE CUT-OUT AREA ELEVATOR STA 39.02. REPAIRED PER SRM 51-40-7. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: SPAR — CORRODED (VERT STABILIZER)
POSSIBLE REAR SPAR CORROSION AT APPROXIMATELY RS 156.00 VERTICAL STABILIZER RIGHT HAND SIDE. REPAIRED PER ECO 2509R5 PART 2. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: PANEL — CORRODED (RUDDER)
CORROSION ON RUDDER LEADING EDGE COVER PANEL, RUDDER STA 201.91. REPLACED EXISTING PANEL PER ECO 2938. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: SPAR — CORRODED (VERT STABILIZER)
POSSIBLE REAR SPAR CORROSION AT APPROXIMATELY RS 136.00 VERTICAL STABILIZER RIGHT HAND SIDE. REPAIRED PER ECO 2509R5 PART 2. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: BRACKET — CRACKED (BS 380)
CRACK NOTED AT BS 380 STR 25L AT Z-CHANNEL IN FORWARD CARGO PIT. REPLACED BRACKET PER SRM 53-10-10. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: FLOORBEAM — CRACKED (BS 500)
FLOORBEAM IN FORWARD CARGO PIT CRACKED A BS 500 STR 26L. REPLACED SPLICED CRACKED SECTION OF CARGO FLOORBEAM PER SRM 53-10-2. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: FLOORBEAM — CORRODED (BS 294)
UPON FLOORBOARDS REMOVAL, SCATTERED CORROSION SPOTTED ALONG UPPER SECTION, MAIN DECK BS 294.5 FLOORBEAM AS EVIDENT. REPAIRED PER SRM 53-10-9. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: BRACKET — CRACKED (BS 500)
SUSPECTED CRACK AT BS 500A STRINGER 25R AT Z-CHANNEL IN FORWARD CARGO PIT. REPLACED BRACKET AS PER SRM 53-10-10. (M)
Part: FRAME — CRACKED (BS 400)
CRACK NOTED IN FORWARD CARGO PIT ON FRAME BS 400 STR 25L. REPAIRED CRACK PER SRM 51-40-3. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: STRINGER — CORRODED (BS 939)
BULGE AT BS 939 STR 27L, POSSIBLE CORROSION UNDER SKIN. REMOVED, CLEANED, AND TREATED PER SRM 51-10-6. INSTALLED FUSELAGE STRINGER REPAIR PER SRM 53-10-3 PAGE 10. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: SPAR — CORRODED (LT WING)
LEFT WING FRONT SPAR LOWER CHORD AT NR 2 SLAT ACTUATOR HAS EXFOLIATION CORROSION. CLEANED AND TREATED PER SRM 51-10-6. REPAIRED PER ECO 2135R2. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: FRAME — CRACKED (BS 480)
CRACK NOTED AT BS 480 STR 22L ON FRAME IN FORWARD CARGO PIT. SPLICED FRAME FROM STR 20L TO STR 25L ON STA 480 PER SRM 51-40-3. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: FLOORBEAM — CORRODED (BS 312)
UPON FLOORBOARDS REMOVAL, SCATTERED CORROSION SPOTTED ALONG UPPER SECTION, MAIN DECK BS 312 FLOORBEAM AS EVIDENT. CUT OUT CORRODED FLOORBEAM AND REPAIRED PER SRM 53-10-9. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: RETAINER — CORRODED (BS 312-328)
FLOORBOARD RETAINER DAMAGE AT STA 312 - STA 328. REPAIRED PER ECO 2942. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: FRAME — CRACKED (BS 420)
FRAME CRACKED AT BS 420 ABOVE STR 25L. REPAIRED FRAME AT BS 430 IAW SRM 51-40-3. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: FRAME — CRACKED (BS 480)
CRACK NOTED ON FRAME AT BS 480 STR 20L IN FORWARD CARGO PIT. SPLICED FRAME FROM STR 20L TO STR 25L ON STA 480 PER SRM 51-40-3. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: CHANNEL — CRACKED (BS 440)
CRACK NOTED AT BS 440 STR 25L AT Z-CHANNEL IN FORWARD CARGO PIT. REMOVED AND REPLACED ATTACHING BRACKET PER SRM 51-10-1. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: LINK — CORRODED (LT MLG)
LEFT HAND LANDING GEAR BEAM INBOARD ATTACH LINK HAS CORROSION; ALSO, HARDWARE HAS CORROSION AND DEEP PITTING. REPLACED LEFT HAND LINK ASSY IAW 57-15-0 AND SB 737-53-1038, AND REPLACED ALL HARDWARE. (X)
Part: LINK — CORRODED (RT MLG)
RIGHT HAND LANDING GEAR BEAM INBOARD ATTACH LINK HAS CORROSION; ALSO, HARDWARE HAS CORROSION AND DEEP PITTING. REPLACED RT LINK ASSY IAW MM 57-15-0 AND SB 737-53-1038, AND REPLACED ALL HARDWARE. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: SKIN — CORRODED (VERT STABILIZER)
EXFOLIATION CORROSION NOTED ON VERTICAL FIN AT FS 60.0 LEFT HAND SIDE. REPAIRED PER ECO 2509 PART 2. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
Part: BRACKET — CRACKED (NLG WW)
NOSE LANDING GEAR ACTUATOR SUPPORT ANGLE HAS 2 INCH CRACK, HFEC CONFIRMED. REMOVED AND REPLACED WITH NEW SUPPORT ANGLE PER SRM 51-30-2 AND BOEING DRAWING 65-45819. TAT: 47,785.0 HOURS. TAC: 63,219. (X)
1998
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED BATTERY IN NR 4 POSITION FLOOR PROXIMITY LIGHT ASSY DUE TO BEING INOP. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY PACK — DISCHARGED (CABIN)
REPLACED BATTERY IN NR 2 POSITION FLOOR PROXIMITY LIGHT ASSY DUE TO BEING INOPERABLE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERIVCE. TAT: 47,255.7 HOURS. TAC: 62,000. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
DURING SERVICE CHECK, POSITIONS NR 1, NR 2, AND NR 3 EMERGENCY FLOOR LIGHTS WERE FOUND INOPERATIVE. REPLACED BATTERY PACK FOR POSITION NR 1. ALL POSITIONS OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAC: 59,963. (X)
Part: KEEL BEAM — CORRODED (BS 727)
DURING A CPC VISIT, CORROSION WAS FOUND AT BS 727 KEEL BEAM AREA. REPAIR ACCOMPLISHED PER ALOHA ECO 2454. AIRCRAFT RETURNED TO SERVICE. TAT: 46,314:38 HOURS. TAC: 59,862.
Part: SKIN — CORRODED (WING)
DURING A CPC VISIT, CORROSION WAS FOUND ON THE OUTBOARD WING MAIN WING BOX LOWER SKIN. CORRECT REWORK ACCOMPLISHED PER ALOHA ECO 1684. AIRCRAFT RETURNED TO SERVICE. TAT: 46,314:38 HOURS. TAC: 59,862. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
ON SERVICE CHECK, FOUND POSITION NR 4 EMERGENCY FLOOR LIGHT INOPERABLE. REPLACED BATTERY PACK. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 46,104:23 HOURS. TAC: 59,386. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
ON SERVICE CHECK, FOUND POSITION NR 3 EMERGENCY FLOOR LIGHT INOPERABLE. REPLACED BATTERY PACK. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 46,104:23 HOURS. TAC: 59,386. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
ON SERVICE CHECK, FOUND POSITION NR 5 EMERGENCY FLOOR LIGHT INOPERABLE. REPLACED BATTERY PACK. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 46,104:23 HOURS. TAC: 59,386. (X)
1997
Part: SIGN — INOPERATIVE (CABIN)
ON SERVICE CHECK, FOUND RT OVERWING EXIT LIGHT INOPERATIVE. REPLACED OVERWING EXIT LIGHT IDENTIFIER ASSY, OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 45,977:16 HOURS. TAC: 59,092. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
ON SERVICE CHECK, FOUND POSITION NR 6 INOPERABLE. REPLACED BATTERY PACK. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. TAT: 45,977:16 HOURS. TAC: 59,092. (X)
Part: BATTERY PACK — DISCHARGED (CABIN)
ON SERVICE CHECK, FOUND NR 6 POSITION EMERGENCY FLOOR LIGHT INOP. REPLACED BATTERY PACK. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY — DISCHARGED (CABIN)
DURING OVERNIGHT CHECK, REPLACED BATTERY FOR ROW 8 EMERGENCY FLOOR PROX LIGHT ASSY DUE TO INOP. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: BATTERY — DISCHARGED (CABIN)
DURING OVERNIGHT CHECK, REPLACED BATTERY FOR ROW 12 EMERGENCY FLOOR PROX LIGHT ASSY DUE TO INOP. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CRACKED (BS 727)
DURING OVERNIGHT CHECK, DISCOVERED FUSELAGE SKIN CRACK APROXIMATELY 2 INCHES IN LENGTH ABOVE STR 16L, BETWEEN BS 727A AND BS 727B. VERIFIED CRACK BY HFEC. REPAIRED PER SRM 53-30-3, FIG 1. AIRCRAFT RETURNED TO SERVICE. TAT: 45,695:05 HOURS. TAC: 58,451. MATERIAL USED: DOUBLER - 204T3 .063 INCH. (X)
Part: BATTERY — DISCHARGED (CABIN)
DURING OVERNIGHT CHECK, REPLACED BATTERY FOR ROW 17 EMERGENCY FLOOR PROXIMITY LIGHT ASSY DUE TO INOPERABLE. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. TAT: 45,588:48 HOURS. TAC: 58,211. (X)
Part: SAFETY VALVE — INOPERATIVE (CABIN)
FLT 404 - HNL-ITO - UNABLE TO CONTROL CABIN PRESSURIZATION, NO AUTO FAIL, SWITCH TO STANDBY, NO RESPONSE, SELECTED MANUAL, CABIN STILL CONTINUED CLIMB. ACCOMPLISHED CHECKLIST. RETURNED TO HNL. REMOVED AND REPLACED CABIN PRESSURIZATION SAFETY VALVE DUE TO LEAKAGE. LEAK CHECK OK. (M)
Part: BATTERY — DISCHARGED (CABIN)
DURING OVERNIGHT CHECK, REPLACED BATTERIES FOR ROW 1 AND 4 EMERGENCY FLOOR PROX LIGHT ASSY DUE TO INOP. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)
Part: LIGHT — INOPERABLE (CABIN)
DURING OVERNIGHT CHECK, REPLACED FORWARD SERVICE DOOR EMERGENCY LIGHT ASSY DUE TO INOPERABLE. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. TAT: 45,140:41 HOURS. TAC: 57,208. (X)
Part: SKIN — CRACKED (BS 927)
DURING OVERNIGHT CHECK, DISCOVERED FUSELAGE SKIN CRACK APPROXIMATELY 2.5 INCHES AT BS 927 PLUS 18 INCHES AT STR 24R. HFEC CONFIRMED. REPAIRED PER SRM 5330-3, FIGURE 1. AIRCRAFT RETURNED TO SERVICE. TAT: 44,902:35 HOURS. TAC: 56,652. (X)
Part: SPAR WEB — CRACKED (CENTER WING)
DISCREPANCIES FOUND DURING C AND CP1 VISIT, CRACK IN WING CENTER SECTION FRONT SPAR WEB AT RBL 44. REPAIRED CRACKED CENTER SECTION FRONT SPAR AS FOLLOWS 1) CUTOUT CRACKED PORTION OF WEB. (2) CONFIRM CRACK REMOVAL BY HFEC INSPECTION. 3) FABRICATED 2024T3 .063 DOUBLER TO FILL OUT MILLED OUT POCKET IN WEB. (M)
Part: FIRE WIRE — CHAFED (NR 2 ENGINE)
FLT 100 - PPG-CHC - NR 2 ENGINE FIRE WARNING ON TOUCHDOWN, ALL OTHER INDICATIONS NORMAL. FOLLOWING NORMAL ENGINE FIRE PROCEDURES, FIRED RIGHT BOTTLE. NO EVIDENCE OF FIRE, RECTIFICATION TO OCCUR ON ANZ NRWC 412735, 412734, AND 412733 (AIRCRAFT IN FOR C-CHECK). DEFECT TRACED TO A BADLY CHAFED FIRE WIRE IN A CLAMP AT THE TOP FORWARD POSITION OF THE ENGINE. FIRE WIRES REPLACED, FIRE BOTTLE REPLACE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)
Part: KEEL BEAM — CORRODED (BS 535)
DISCREPANCIES FOUND DURING C AND CP1 VISIT. BS 6.3 LEFT KEEL BEAM LOWER CHORD CORRODED AND CRACKED AT BS 535. BLENDED CORROSION, OUTSIDE SRM LIMITS. FLAP PEENED PER SRM 51-10-8, FABRICATED REPAIR DOUBLER FROM 7075-T6 EXTRUSION, FILLERS FROM 707T6 INSTALLED. BOEING 8110-3 APPROVAL. (M)
Part: BEAR STRAP — CORRODED (CARGO DOORWAY)
DISCREPANCIES FOUND DURING C AND CP1 VISIT, FORWARD CARGO DOOR FRAME BEAR STRAP INNER SURFACE CORRODED. BLENDED OUT CORROSION. CONFIRMED ALL CORROSION REMOVED BY FPI. FLAP PEEN REWORKED AREA. FILLED BLEND VOIDS WITH BMS 5-95 SEALANT TO RESTORE ORIGINAL CONTOUR. FABRICATED AND INSTALLED REPAIR DOUBLER FROM .063 2024T3. FABRICATED AND INSTALLED A REPAIR FILLER FROM .071 2024T3. BOEING 8110-3 APPROVAL. (M)
1996
Part: WEB — CRACKED (BS 706-714)
DURING SCHEDULED INSPECTION OF FUSELAGE DETECTED MULTIPLE CRACKS ON BL 24.5R WEBBING BETWEEN BS 706 AND 714, CRACKS ORIGINATE FROM RIVET HOLES. REPAIRED PER ECO 2763. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CRACKED (BS 882)
DISCOVERED FUSELAGE SKIN CRACK AT BS 882 AND STRINGER 24R. APPROXIMATELY 3.5 INCHES IN LENGTH. HFEC CONFIRMED CRACK. REPAIRED PER SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)
Part: SKIN — CRACKED (BS 767)
DISCOVERED FUSELAGE SKIN CRACK AT BS 767 AND STRINGER 19L, APPROXIMATELY 1.5 INCH IN LENGTH CONFIRMED BY HFEC. REPAIRED PER SRM 53-30-3. AIRCRAFT RETURNED TO SERVICE. (M)
1995
Part: FITTING — CORRODED (FSS 422)
DURING HEAVY MAINTENANCE VISIT, FOUND INTERGRANULAR CORROSION NEAR NR 5 L/E SLAT ACTUATOR ATTACH FITTING (FRONT SPAR) APPROXIMATELY FSS-422. REPAIRED PER ECO 2659. AIRCRAFT RETURNED TO SERVICE. (X)
Part: PANEL RECESS — CORRODED (AFT LAVATORY)
DURING HEAVY MAINTENANCE VISIT, FOUND AFT LAVATORY SERVICE PANEL HAS INTERGRANULAR CORROSION AROUND PANEL RECESS. REPAIRED PER ECO 1998, OPTION II. AIRCRAFT RETURNED TO SERVICE. (X)
Part: STRINGER — CORRODED (BS 907-927)
DURING HEAVY MAINTENANCE VISIT, AFT CARGO COMPARTMENT, CORROSION NOTED ON S27L BETWEEN BS 907 AND BS 927. REPAIRED PER ECO 2599. AIRCRAFT RETURNED TO SERVICE. (X)
Part: STRINGER — CORRODED (BS 907)
DURING HEAVY MAINTENANCE VISIT, AFT CARGO COMPARTMENT, CORROSION NOTED ON S27R AT BS 907. REPAIRED PER ECO 2599. AIRCRAFT RETURNED TO SERVICE. (X)
Part: DOOR HINGE — CORRODED (LT MLG)
DURING HEAVY MAINTENANCE VISIT, INTERGRANULAR CORROSION NOTED ON FIXED DOOR HINGE AREA, LT GEAR. CLEANED AND TREATED PER SRM 51-10-6. AIRCRAFT RETURNED TO SERVICE. (X)
Part: SKIN — CORRODED (WS 499.9)
DURING HEAVY MAINTENANCE VISIT, FOUND RT WING LOWER SURFACE HAS CORROSION AT WS 499.9 PLUS 11.50 INCH, AND WS 499.9 PLUS 17 INCH. REPAIRED PER ECO 2648. AIRCRAFT RETURNED TO SERVICE. (X)
Part: SKIN — CORRODED (VERT STAB)
DURING HEAVY MAINTENANCE VISIT, FOUND VERTICAL STABILIZER, LT SKIN EXFOLIATED APPROXIMATELY 2 INCHES BY .50 INCH JUST ABOVE AFT FUSELAGE TO STABILIZER MOUNT BOLT. REPAIRED PER ECO 2649. AIRCRAFT RETURNED TO SERVICE. (X)
Part: SPAR — CORRODED (FSS 286-321)
DURING HEAVY MAINTENANCE VISIT, NUMEROUS SPAR CORROSION NOTED BETWEEN FSS 286.9 - SS 45.9, AND FSS 321 - SS 80.1. REPAIRED PER ECO 2646. AIRCRAFT RETURNED TO SERVICE. (X)
Part: SKIN — CORRODED (WS 461)
DURING HEAVY MAINTENANCE VISIT, FOUND RT WING, TOP SURFACE, HAS SURFACE CORROSION. CLEANED AND TREATED PER SRM 51-10-6 AT FSS 461 PLUS 17 INCH AFT OF FRONT SPAR. REPAIRED PER ECO 1722R5. AIRCRAFT RETURNED TO SERVICE. (X)
Part: SPAR — CORRODED (FSS 286-321)
DURING HEAVY MAINTENANCE VISIT, OUTBOARD OF NR 3 ACTUATOR ATTACH POINT HAS SPAR CORROSION NEXT TO RIVET BETWEEN FSS 286.9 AND FSS 321.1. REPAIRED PER SRM 51-30-2. AIRCRAFT RETURNED TO SERVICE. (X)
Part: SPAR — CORRODED (FSS 326-359)
DURING HEAVY MAINTENANCE VISIT, FOUND RT LOWER FRONT SPAR HAS CORROSION AT FSS 321.6 INCH, FSS 359-3.5 INCH AND FSS 359 PLUS 18 INCH. REPAIRED PER ECO 2645. AIRCRAFT RETURNED TO SERVICE. (X)
Part: COFFEE JUG — SHORTED (NR 6)
FLT 30 - PIREP 1 - SMOKE IN GALLEY COMING FROM COFFEE/HOT JUG AT L1H. ISOLATED TROUBLE TO NR 6 COFFEE JUG, JUG REMOVED. CIRCUIT BREAKER PULLED AND SWITCHED TO OFF FOR NR 6 COFFEE JUG RECEPTACLE. AIRCRAFT AND LOG BOOK PLACARDED PER MEL 25-10. HNL - REPLACED POWER RECEPTACLE, AND OPS CHK ACCOMPLISHED. PLACARDS REMOVED AND AIRCRAFT RETURNED TO SERVICE. TAT: 41,488.23 HRS. TAC: 48,948. (X)
Part: DUCT ASSY — CRACKED (NR 2 ENGINE)
PILOT REPORT FLIGHT NR 30 - LIH-OGG - NR 2 ENGINE START VALVE OPEN LIGHT CAME ON AND STAYED ON INFLIGHT. SHUT DOWN ENGINE AND DIVERTED TO HNL. FOUND 13TH STAGE BLEED AIR DUCT BLOWN OUT OVER STARTER VALVE PRESSURE SWITCH. REPLACED DUCT, NO LEAKS NOTED. OPS CHECK START VALVE, CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (W)
Part: START VALVE — MALFUNCTIONED (NR 2 ENGINE)
PILOT REPORT FLIGHT 480 - HNL-KOA - NR 2 START VALVE OPEN LIGHT FLICKERED ON MOMENTARILY IN FLIGHT THEN EXTINGUISHED. DECLARED IN FLIGHT EMERGENCY. LANDED WITH NO INCIDENT IN KOA. CHECKED STARTER AND START VALVE AND CLEANED CANNON PLUG ON START VALVE. FUNCTIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE. (W)
Part: FUEL PUMP — SHAFT SHEARED (NR 1 ENGINE)
FLT NR 282 - HNL-KOA - DURING CLIMB UNABLE TO REDUCE EPR ON NR 1 ENGINE. NO RESPONSE TO THROTTLE. PRECAUTIONARY SHUTDOWN NR 1 ENGINE IN FLIGHT. RETURNED TO HNL. FOUND FUEL PUMP WITH SHEARED SHAFT. REPLACED NR 1 FCU (PRECAUTIONARY) AND FUEL PUMP IAW PWA MM 73-11-1 AND 73-21-2. JET CALIBRATED IAW FORM M-125. GROUND OPS AND LEAK CHECK OK. AIRCRAFT RETURNED TO SERVICE. (W)