N824AL

Part: SENSOR — FAILED (TEMP) · airframe 54,817 hrs · 60,868 cycles

NON-ETOPS FLIGHT 63 HNL-LIH, DURING CLIMB, THE CREW NOTED LOUD NOISE AND ICE EMANATING FROM THE AIR CONDITIONING SYSTEM. THE CREW ATTEMPTED TO CONTROL THE NOISE AND ICE BY SELECTING A WARMER TEMPERATURE WITH NO CHANGE IN CONDITION. THE NOISE WAS DISRUPTIVE TO THE CREW AND THEY ELECTED TO RETURN TO HNL. THE AIRCRAFT LANDED IN HNL WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE 35º TEMPERATURE SENSOR AND THE 35º TEMPERATURE CONTROL PER AMM 21-51-0 WITH ALL CHECKS NORMAL.

Part: CONTROL VALVE — FAILED (NR 1 ENGINE) · airframe 53,684 hrs · 58,313 cycles

FLT 206 HNL-OGG: DURING TAKEOFF ROLL, NR 1 ENGINE EPR WOULD NOT INCREASE ABOVE 1.53 WITH MORE THAN A TWO THROTTLE KNOB WIDTH SPLIT AND EGT RISING TO 580 DEGREES. NR 2 ENGINE STABILIZED AT 1.89 EPR AND EGT AROUND 530 DEGREES. TAKEOFF WAS ABORTED AROUND 80 KNOTS. AIRCRAFT RETURNED TO GATE WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED THE NR 1 ENGINE PRESSURE RATIO BLEED CONTROL IAW AMM 75-31-11. OPERATIONAL AND LEAK CHECK WAS PERFORMED WITH NO DEFECTS NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: UPLOCK — DIRTY (MLG) · airframe 53,565 hrs · 58,040 cycles

AFTER TAKEOFF, THE RT MLG DID NOT RETRACT. CREW CYCLED THE LANDING GEAR LEVER AND WAS ABLE TO RETRACT THE GEAR. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE CLEANED THE RT MLG UPLOCK SENSOR AND PERFORMED THE MAIN LANDING GEAR EXTENSION AND RETRACTION TEST IAW AMM 32-32-0. NO DEFECTS WERE NOTED. MAINTENANCE REPLACED THE RT MLG UPLOCK SENSOR AS PRECAUTIONARY. AIRCRAFT WAS RETURNED TO SERVICE.

Part: NOSE BULLET — LOOSE (NR 1 ENGINE) · airframe 53,494 hrs · 57,884 cycles

NON-ETOPS FLT 281: CLIMBING THRU 16,000 FEET WITH THE ENGINE ANTI-ICE ON, THE CREW HEARD A LOUD BANGING SOUND COMING FROM THE LT SIDE OF THE AIRCRAFT. ENGINE INDICATIONS WERE NORMAL. THE CREW RETARDED THE NR 1 ENGINE THRUST LEVER AND THE BANGING STOPPED. THE CREW TRIED TO ADVANCE THE NR 1 THRUST LEVER AGAIN, BUT THE ENGINE WOULD BEGIN TO STALL. HNL TOWER WAS NOTIFIED AND THE CREW DID DECLARE AN EMERGENCY. THE AIRCRAFT LANDED IN HNL WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND THE NR 1 ENGINE NOSE CONE AND STUDS SEPARATED FROM THE FRONT ACCESSORY DRIVE SUPPORT ASSEMBLY.

Part: HOSE — FAILED (A HYD SYSTEM) · airframe 53,022 hrs · 56,823 cycles

NON-ETOPS FLT 77 ITO-HNL: DURING LANDING ROLLOUT, THE AIRCRAFT EXPERIENCED SYSTEM ‘A’ HYDRAULIC FAILURE. THE CREW BROUGHT THE AIRCRAFT TO A STOP, NOTIFIED TOWER, AND PERFORMED THEIR QRH CHECK LIST. THE AIRCRAFT WAS TOWED BY MAINTENANCE TO THE GATE. R & R NOSE LANDING GEAR ACTUATOR DOWN LINE. MAINTENANCE ALSO REPLACED NR 1 AND NR 2 ENGINE CASE DRAIN FILTERS TO CHECK FOR ANY CONTAMINATION IN HYDRAULIC SYSTEM. NO DEFECTS WERE NOTED. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SLIDE — OUT OF POSITION (SERVICE DOOR) · airframe 52,731 hrs · 56,149 cycles

NON-ETOPS: FLT 206 HNL - OGG: ON THE GROUND, FWD SVC DOOR EMERGENCY SLIDE ACCIDENTALLY DISLODGED FROM THE DOOR BUT DID NOT INFLATE. REMOVED AND REPLACED FORWARD SERVICE DOOR SLIDE CHUTE ASSEMBLY. AIRCRAFT RETURNED TO SERVICE.

Part: SKIN PANEL — CRACKED (BS370, BL-0) · airframe 51,873 hrs · 54,201 cycles

FUSELAGE SKIN CRACK LOWER BL-0, BETWEEN S-28L AND R AT BS 370. TWO 1/2 INCH FUSELAGE SKIN CRACKS LOWER BL-0, BETWEEN S-28L AND R AT BS370 AND BS380. MAINTENANCE REPAIRED WITH APPROXIMATELY 40" X 20" SKIN PATCH, FABRICATED DOUBLER )1002024-T3). REPAIR COMPLETED IAW ECO 3245R2.

Part: TIRE — FAILED (NOSEWHEEL)

DURING TAXI AFTER LANDING, CREW HEARD A LOAD POP FOLLOWED BY VIBRATION FROM THE NOSEWHEEL AND STEERING DIFFICULTY. CREW STOPPED AIRCRAFT ON TAXIWAY. MAINTENANCE FOUND HOLE IN LT NOSEWHEEL AND BOTH TIRES FLAT. REMOVED AND REPLACED BOTH NOSEWHEEL TIRES, INSPECTED AND FOUND NO OTHER DEFECTS. RETURNED THE AIRCRAFT TO SERVICE.

Part: ANTI-SKID SYS — DEACTIVATED (MLG)

ON CLIMB OUT, PILOT OBSERVED THE LT ANTI-SKID LIGHT ON AND STAYED AND RETURNED BACK TO DEPARTURE. THE ANTI-SKID SYSTEM WAS MEL’D WAITING FOR AN ANTI-SKID CONTROL BOX. THE ANTI-SKID SYSTEM AND ANTI-SKID BRAKES WERE DEACTIVATED.

Part: WARNING LIGHT — FALSE INDICATION (CARGO DOOR)

FLT 211, OGG-HNL, FORWARD CARGO DOOR LIGHT CAME ON DURING TAKEOFF ROLL. ABORTED TAKEOFF PRIOR TO 80 KTS. RETURNED TO GATE. MAINTENANCE OPENED AND CLOSED THE FORWARD CARGO DOOR AND CHECKED LOCKS FOR SECURITY. OPS CHECK OK AND LIGHTS CHECK GOOD. IN HNL, FWD CARGO DOOR LIGHT ON T/O. DEFERRED PER MEL 52-3-1, FWD CARGO DOOR LIGHT COMING ON. INSPECTED DOOR AFTER CLOSING. AIRCRAFT RETURNED TO SERVICE.

Part: SENSOR — DEFECTIVE (NR 4 SLAT)

FLT 278, HNL-KOA: ON INITIAL TAKEOFF ROLL, THE LEADING EDGE FLAP TRANSIT LIGHT ILLUMINATED (NR 4 SLAT) WITH THE CONFIGURATION WARNING HORN. ABORTED TAKEOFF AND RETURNED TO GATE. REMOVED AND REPLACED THE NR 4 LEADING EDGE FLAP EXTEND SENSOR. OPS CHECK OK PER MM 27-88-44. AIRCRAFT RETURNED TO SERVICE.

Part: INDICATOR — INOPERATIVE (AIRSPEED)

FLT 220, HNL-OGG: FIRST OFFICE AIRSPEED INDICATOR INOP. RETURNED TO HNL, UNEVENTFUL LANDING. REMOVED AND REPLACED THE MACH AIR SPEED INDICATOR. OPS CHECK OKAY. AIRCRAFT RETURNED TO SERVICE.

Part: BLEED AIR SYS — MALFUNCTIONED (RIGHT) · airframe 49,793 hrs · 49,525 cycles

FLIGHT 280, HNL-KOA: PASSING THROUGH 8000 FT ON CLIMB-OUT, THE RT DUCT PRESSURE WAS OBSERVED AT ABOUT 40PSIG WITH THE ISOLATION VALVE CLOSED AND THE RT BLEED & RT PACK OFF. THE PRESSURE THEN DECREASED TO 14 PSIG, AND THEN DECREASED FURTHER WHEN POWER WAS REDUCED. RETURNED TO HNL. OPS AND LEAK CHECKED THE ISOLATION VALVE AND NR 2 ENGINE BLEED VALVE, CLEARED PRESSURE REGULATOR VENT HOLE. RAN ENGINES IAW AMM 71-00, OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — CORRODED (RT WING)

FOUND RIGHT UPPER WING SURFACE CORROSION BETWEEN THE FRONT AND REAR SPAR IDENTIFIED ON FIGURES 1 THROUGH 5 AS NR 1 TO NR 15 AT THE FOLLOWING LOCATIONS, NR 1 AT WBL 92.5, NR 2, 3, 4, 5 AND 6 BETWEEN WBL 198.6 AND WBL 227.0, NR 7 AND 8 AT WBL 157, NR 9 AND 10 BETWEEN WS 442 AND WS 453, NR 11, 12 AND 13 AT WS 505, NR 14 AT WS 472, NR 15 AT WBL 227. REMOVED CORROSION, FLAT PEEN, ALODINED AND SEALED. REMOVED AND REPLACED FASTENERS WITHIN BLEND OUT AREA PER SRM 57-30-1. REPAIR COMPLETED IAW ECO 3399. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CORRODED (LT WING)

FOUND LT UPPER WING SURFACE CORRODED BETWEEN FRONT & REAR SPAR IDENTIFIED ON FIGURES 1 THROUGH 6 AS NR 1 - 19 AT LOCATIONS, NR 1, 2, & 3 AT WBL 227, NR 4 AT WLB 228, NR 5 AT WBL 254, NR 6 AT WBL 264, NR 7 AT WBL 268, NR 8 AT WBL 234, NR 9 AT WBL 236, NR 10 AT WBL 309.5, NR 11 AT WBL 555, NR 13 AT WBL 355, NR 18 AT WBL 580, AND NR 19 AT REAR SPAR WS 571. REMOVED CORROSION, FLAT PEEN, ALODINED, & SEALED. R & R FASTENERS WITHIN BLEND OUT AREA PER SRM. NR 12 AT WBL 555 FABRICATED & INSTALLED AN INTERNAL STRAP. NR 14, 15, 16 & 17 AT OVERWING REFUELING PORT WS 442 FABRICATED & INSTALLED REPAIR STRAPS AND FILLERS IAW SRM. REPAIRS COMPLETED IAW ECO 3400. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (FUSELAGE)

CLEANED OUTER SKIN AT EACH MOUNTING HOLE. OVER-DRILLED ELONGATED HOLES TO RESTORE HOLES TO CIRCULAR SHAPE. TRIMMED OUT CRACK DAMAGED HOLE LARGE ENOUGH TO REMOVE CRACK TO RECTANGULAR SHAPE. HFEC VERIFIED HOLES CRACK FREE. FABRICATED CIRCULAR AND RECTANGULAR DOUBLERS FROM .25 INCH THICK, MIL-T-9046, CONDITION ANNEALED TYPE III, COM C TITANIUM SHEET. WET INSTALLED DOUBLERS WITH MBS 5-63 SEALANT AND 5/32 MONEL RIVETS. REPAIR COMPLETED IAW ECO 3302. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FLOORBEAM — CRACKED (FUSELAGE)

REMOVED EXISTING FASTENERS, STIFFENERS, ANGLE AND A SECTION OF THE WEB. REMOVED AND DISCARDED REINFORCING ANGLE, DOUBLER AND A SECTION OF THE WEB. DRILL AND COLD WORKED THE HOLES IN THE CHORD. INSTALLED SPLICE ANGLE AND STIFFENERS WITH FASTENERS SHOWN IN SECTION A-A. INSTALLED THE ANGLE, REINFORCING ANGLE, FILLER DOUBLER, SPLICE PLATES AND THE WEB WITH FASTENERS FROM THE KIT. APPLIED ALODINE, BMS 10-11 TYPE 1 PRIMER AND TYPE 11 ENAMEL TO ANY BARE SURFACE. COMPLETED REPAIR IAW ECO 2223, FIGURES 4 AND 9. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LAP JOINT — DAMAGED (FUSELAGE)

TRIMMED BONDED DOUBLER ABOVE EXISTING FASTENER PATTERN LEAVING ED FOR FINAL FASTENER INSTALL. OPENED DISCREPANT COUNTERSINK HOLE TO .75 INCH DIAMETER. VERIFIED CRACK FREE USING HFEC. HOLE OPENED UP TO 1 INCH INSURANCE CUT. FABBED .032/.036 INCH THICK CIRCULAR FILLER, .040 INCH THICK TEAR STRAP SPLICE-STRAP, .036/.040 INCH THICK FILLER FOR BONDED DOUBLER, TWO .40 INCH THICK TAPERED FILLERS FROM 2024 T-3 CLAD ALUMINUM. ALODINED, PRIMED ALL BARE EDGES AND REPAIR PARTS WITH BMS 10-11 TYPE 1 PRIMER. INSTALL FILLERS AS SHOWN IN FIGURE 1 AND REPAIR PARTS IAW SB 737-53A1177, REV 6 REQUIREMENTS MAINTAINING A 2 INCH MINIMUM RADIUS AND .5 INCH MAXIMUM EXTERNAL RADIUS ON DOUBLER, TRIPLER. AC RETURNED TO SERVICE. (M)

Part: SKIN — DENTED (EMPENNANGE)

CUT OUT DAMAGED AREA. FABRICATED REPAIR .063 DOUBLER AND .040 FILLER FROM 2024 T3 CLAD. INSTALLED REPAIR PARTS AND FASTENERS WET WITH MBS 5-95 SEALANT. REPAIR COMPLETED IAW SRM 55-10-1 FIGURE 2. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — GOUGED (FUSELAGE)

CUT AND REMOVED GOUGE AREA. FABRICATED REPAIR .063 DOUBLER AND .040 FILLER FROM 2024 T3 CLAD. INSTALLED REPAIR PARTS AND FASTENERS WET WITH MBS 5-95 SEALANT. REPAIR COMPLETED IAW SRM 55-10-1 FIGURE 2. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — GOUGED (HORIZONTAL STAB)

CUT OUT DAMAGED AREA. FABRICATED REPAIR .063 DOUBLER AND .040 FILLER FROM 2024 T3 CLAD. INSTALLED REPAIR PARTS AND FASTENERS WET WITH MBS 5-95 SEALANT. REPAIR COMPLETED IAW SRM 55-10-1 FIGURE 2. AIRCRAFT RETURNED TO SERVICE. (M)

Part: PRESSURE PANEL — DAMAGED (FUSELAGE)

PERFORMED MODIFICATION TO THE WEB AND DOUBLER OF THE MAIN WHEEL WELL PRESSURE FLOOR TRANSVERSE BEAM BETWEEN BS 650 AND BS 727 AND BETWEEN RT AND LT BBL 45. FABRICATED WEB FILLER AND REPAIR DOUBLER IAW FIGURE 7. REPLACED ANGLE, CHANNEL AND DOUBLER WITH PARTS FABRICATED PER FIGURE 3. VERIFIED 8110-3 RECEIVED. COMPLETED MODIFICATION IAW ECO 2299, FIGURE 3/7. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BEAM — DAMAGED (RT WING)

OVERSIZED 4 HOLES IN THE RIGHT MLG LOWER BEAM CHORD FLANGE. FABRICATED FOUR FREEZE PLUGS. FABRICATED FOUR 1 INCH DIAMETER RETAINING WASHERS. INSTALLED FREEZE PLUGS AND OPENED ID HOLES TO THE EXISTING .1875 INCH DIAMETER PANEL ATTACH BOLTS. INSTALLED RETAINING WASHERS UNDER THE NUT AND USED A LONGER BOLT TO THE RETAINING WASHER. VERIFIED 8110-3 RECEIVED. REPAIR COMPLETED IAW ECO 3307. AIRCRAFT RETURNED TO SERVICE. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

TRIMMED OUT THE DAMAGE OF THE HOLES TO A RECTANGULAR SHAPE. VERIFIED CRACK REMOVED USING HFEC. FABRICATED CIRCULAR DOUBLERS FOR EACH HOLE. REPAIR COMPLETED IAW ECO 3302. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FITTING — DAMAGED (T/E FLAP)

REMOVED DAMAGE FROM THE NR 2 AND NR 7 FLAP TRACK ATTACHMENT FITTING HOLE. FABRICATED A 'NEW' REPLACEMENT TUBE AND BUSHING INCREASING THE OUTSIDE DIAMETER .0015 TO .0020 INCH INTERFERENCE FIT ON THE FINISHED DIAMETER OF THE HOLE. INSTALLED NEW TUBE AND BUSHING. 8110-3 RECEIVED. REPAIR COMPLETED IAW BOEING DRAWING 65-46429 INSTRUCTIONS AND ECO 3308. AIRCRAFT RETURNED TO SERVICE. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

TRIM OUT ALL THREE HOLES IN THE DAMAGED ZONE. HFEC THE EDGE OF THE TRIM. FABRICATED A DOUBLER AND A TRIPLER. INSTALLED DOUBLER AND TRIPLER. REPAIR COMPLETED IAW ECO 3250, FIGURE 24. AIRCRAFT RETURNED TO SERVICE. (M)

Part: STRUCTURE — CORRODED (HORIZ STAB)

BLENDED THE DAMAGE ON THE LUG. SPOTFACED THE INBOARD AND OUTBOARD SURFACES. OVERSIZED THE TAPERED/ELONGATED HOLE OF THE INBOARD LUG ON THE ORIGINAL CENTERLINE TO OBTAIN A ROUND AND TRUE CONDITION. FABRICATED NEW REPAIR SLEEVE BUSHING TO FIT THE OVERSIZED INBOARD LUG BORE. FABRICATED TWO FINISHED WASHERS FOR EACH SIDE OF LUG SPOT FACED BONDED TO SPOTFACED SURFACE. COMPLETED FINAL INSIDE DIAMETER REAM OF THE REPAIR BUSHING PER DRAWING REQUIREMENTS. VERIFIED 8110-3 RECEIVED. REPAIR COMPLETED IAW ECO 3305. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 6, EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED FORWARD SERVICE DOOR EMERGENCY LIGHT BATTERY PACK DUE TO INOPERATIVE. OP CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 AND NR 3 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OP CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FIRE LOOP — DEFECTIVE (APU)

FLT 205 - HNL-LIH - EN ROUTE TO LIH, THE APU FIRE WARNING ILLUMINATED THOUGH THE APU WAS PREVIOUSLY MEL'D. THE APU FIRE BOTTLE WAS DISCHARGED AND THE AIRCRAFT RETURNED TO HNL WITHOUT FURTHER INCIDENT. THE AIRCRAFT WAS OPERATING UNDER MEL 49-1 FOR A PREVIOUS APU FIRE DETECTION TEST BEING INOPERABLE. MAINTENANCE INSPECTED AND REPLACED THE APU FIRE ELEMENT, AFT TAIL LOOP CONNECTORS, FIRE DETECTION UNIT AND FIRE BOTTLE. OPERATIONAL CHECKS WERE GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED LEFT OVERWING IDENT BATTERY PACKED DUE TO LOW VOLTAGE. OP CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BULKHEAD — CRACKED (FUSELAGE)

FOUND RIVET HOLES CRACKED AT BS 178 LEFT AND RIGHT LBL 9 WL 234. REMOVED CRACK PER SRM 53-10-11 PAGE 1, PROCEDURE 1. VERIFIED CRACK REMOVED USING HFEC. INSTALLED REPAIR DOUBLER IAW ECO 3138 PART 1. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — CORRODED (CABIN)

AFT ENTRY DOOR EMEREGNCY IDENT LIGHT INOPERATIVE. REPLACED BATTERY PACK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — CORRODED (CABIN)

FOUND LEFT OVERWING EMERGENCY IDENT LIGHT INOPERATIVE. REPLACED BATTERY PACK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (PAX CABIN)

REPLACED NR 1 AND NR 4 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OP CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: FRAME — CRACKED (FUSELAGE)

IDENTIFIED A CRACK AT 2 PLACES ON THE RIGHT SIDE OF BS 1156 CHORD BETWEEN WL 281-269. STOP DRILLED ENDS OF CRACKS, REMOVED FASTENERS ON AFFECTED CHORD ASSEMBLY AND INSTALLED REPAIR STIFFENER ANGLE IAW ECO 1822. APPLIED ALODINE AND PRIMER BMS 10-11 TYPE 1 PRIMER TO ALL BARE SURFACES AND CORROSION INHIBITING COMPOUND. AIRCRAFT OK FOR SERVICE. (M)

Part: FRAME — CRACKED (FUSELAGE)

IDENTIFIED CRACK AT RIGHT UPPER CHORD BS 727, STRINGER 18A AFT HOLE BY UTILIZING HFEC AND ULTRASONIC METHOD. REMOVED AND REPLACED RIGHT UPPER CHORD ASSEMBLY CLEANED AND TREATED ALL EXPOSED AREAS AND APPLIED CORROSION INHIBITING COMPOUND IAW ECO 1785. AIRCRAFT RETURNED TO SERVICE.(M)

Part: FRAME — DENTED (FUSELAGE)

IDENTIFIED DENT ON FRAME ASSEMBLY 5 INCHES BY 7 INCHES AT BS 360-380 STRINGER 17L. (M)

Part: BATTERY PACK — INOPERATIVE (PAX CABIN)

REPLACED NR 1, NR 4 AND NR 5 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED POSITION 1 FLOOR PROXIMITY LIGHT ASSY BATTERY PACK DUE TO INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: VALVE — INOPERATIVE (MLG BRAKE)

HNL/ITO - FLT 108 - ON TAKOFF ROLL, PARKING BRAKE LIGHT AND ANTI-SKID INOPERABLE. INBOARD/OUTBAORD LIGHT REMAINED ILLUMINATED. PARKING BRAKE LEVER WAS IN RELEASED POSITION WITH NO BRAKE DRAG FELT. ABORTED TAKEOFF AND RETURNED TO RAMP. REMOVED AND REPLACED BRAKE SHUTOFF VALVE PER MM 32-44-21, PAGE 401. GROUND RUN AND TAXI CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED BATTERY PACK FOR CENTER AISLE EMERGENCY LIGHT DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNE TO SERVICE. (M)

Part: FRAME — CRACKED (PAX DOOR)

FORWARD ENTRY DOOR FRAME CORRODED AT LWR AFT CORNER ABOVE DOOR SILL. REPAIRED IAW ECO 2992. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BEAM — CORRODED (LT WING)

LEFT MLG BEAM CORRODED BEYOND LIMITS. REPLACED LEFT MLG BEAM (PERFORMED BY BOEING AOG TEAM). AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — DISCHARGED (CABIN)

REPLACED BATTERY PACKS FOR NR 2, NR 4 AND NR 5 EMERGENCY FLOOR LIGHT DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERABLE (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED BATTERY PACK IN AFT CONTROL MODULE DUE TO INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY — DISCHARGED (CABIN)

REPLACED BATTERY PACKS FOR FORWARD AISLE EMERGENCY LIGHT DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — DISCHARGED (CABIN)

REPLACED BATTERY PACKS FOR NR 3, NR 4, AND NR 6 FLOOR LIGHT DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SKIN — CRACKED (RT LE SLAT)

WHILE PERFORMING THE WALKAROUND INSPECTION, A CRACK WAS DISCOVERED ON THE NR 3 SLAT. THE CRACK WAS ON THE LOWER SKIN INBOARD EDGE, 2 INCH FORWARD FROM THE AFT EDGE. THE CRACK WAS REPAIRED IAW ECO 2976 PART I. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED FORWARD SLIDE LIGHT BATTERY POWER SUPPLY DUE TO BEING INOPERATIVE. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED FORWARD AND SERVICE DOOR SLIDE LIGHTS DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — DISCHARGED (EMERG EXIT)

REPLACED BATTERY CARTRIDGE FOR OVERWING EMERGENCY EXIT LIGHT DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (PAX CABIN)

REPLACED POSITION 1, 4, AND 6 BATTERIES FOR PROXIMITY LIGHT ASSY DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED BATTERY IN POSITION NR 5 FLOOR PROXIMITY LIGHT ASSY DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

REPLACED NR 5 POSITION FLOOR PROXIMITY LIGHT ASSEMBLY DUE TO INOP. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 THROUGH NR 6 POSITION FLOOR EMERGENCY PROXIMITY LIGHT BATTERY PACK. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: POWER SUPPLY — FAILED (FUEL FLOW)

FLT 78 - LIH-HNL - ON TAKEOFF ROLL, APPROX 80 KTS, BOTH NR 1 AND NR 2 FUEL FLOW INDICATORS STARTED CYCLING BETWEEN 8,000 PPH DOWN TO 500 TO 1000 PH. ALL OTHER ENGINE PARAMETERS WERE NORMAL. ABORTED TAKEOFF AND RETURNED TO GATE. REMOVED AND REPLACED FUEL FLOW POWER SUPPLY. GROUND CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 AND NR 6 POSITION FLOOR EMERGENCY PROXIMITY LIGHT BATTERY PACK. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

REPLACED AFT SERVICE DOOR IDENTIFIER EMERGENCY LIGHT ASSY. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 5 POSITION EMERGENCY LIGHT BATTERY PACK. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 4 POSITION EMERGENCY LIGHT BATTERY PACK DUE TO NO TESTING. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (LT OVERWING)

RIGHT SIDE OVERWING EXIT IDENTIFIER (EMERGENCY LIGHT) STAYS ON. REPLACED LIGHT ASSY. SYSTEM OPS CHECKED GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SWITCH — FAILED (FLAP SYSTEM)

TAKEOFF CONFIGURATION WARNING HORN SOUNDS WHEN THRUST LEVERS ADVANCED TO TAKEOFF POWER. CHECKED CONDITION AND RESISTANCE CHECK NR 1 AND NR 4 EXT. PROXIMITY SWITCH OK. REPLACED FLAP/SLAT POSITION SWITCH UNIT MODULE. OPERATIONAL CHECK OK PER TAKEOFF WARNING. AIRRAFT RETURNED TO SERVICE. (M)

Part: SENSOR — FAILED (NR 1 TE FLAP)

TAKEOFF CONFIGURATION WARNING HORN CAME ON ON TAKEOFF ROLL. REPLACED NR 1 FLAP PROXIMITY SENSOR NR 1 POSITION. OPS CHECK OK PER MM 27-50-0. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 6 POSITION EMERGENCY EXIT BATTERY PACK DUE TO HAVING LOW VOLTAGE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: WIRE HARNESS — DAMAGED (INST PANEL)

FLT 205 - OVERHEAD MASTER CAUTION LIGHT WILL NOT EXTINGUISH. FOUND WIRE BUNDLE W038 PLUS W047 ABOVE P-5 PANEL CHAFED AND BURNED. REPLACED ALL WIRES, OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 2 POSITION EMERGENCY FLOOR PROXIMITY LIGHT BATTERY PACKS DUE TO BEING INOPERATIVE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 4 POSITION EMERGENCY FLOOR PROXIMITY LIGHT BATTERY PACKS DUE TO BEING INOPERATIVE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 5 POSITION EMERGENCY FLOOR PROXIMITY LIGHT BATTERY PACKS DUE TO BEING INOPERABLE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: LIGHT — INOPERATIVE (CABIN)

REPLACED EXIT IDENTIFICATION LIGHT ASSY FOR AFT SERVICE DOOR DUE TO BEING INOPERATIVE. OPS CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (X)