N826AL

Part: ENGINE — POWER LOSS (NR 2) · airframe 57,192 hrs · 68,119 cycles

DURING TAKEOFF/CLIMB AT APPROXIMATELY 400 FEET, NR 2 ENGINE FAILURE/LOSS OF POWER WITH HEAVY VIBRATION. COMPLETED ENGINE FAILURE AND SHUTDOWN CHECKLIST. INFLIGHT EMERGENCY DECLARED. REPLACED NR 2 ENGINE. OPS AND LEAK CHECK GOOD.

Part: FRAME — CRACKED (BS 927) · airframe 57,075 hrs · 67,858 cycles

CRACK APPROX 2.6250 FOUND AT BS 927, STRINGER 23L. REPAIR COMPLIED WITH IAW SRM 53-30-3, FIG 48, DETAIL XI.

Part: FRAME — CRACKED (BS 907) · airframe 56,334 hrs · 66,237 cycles

AFT PIT CRACKED, FRAME LOWER CHORD AT BS 907 AND STRINGER 26R.

Part: SEAT TRACK — CRACKED (ZONE 200) · airframe 56,334 hrs · 66,237 cycles

MAIN CABIN SEAT TRACK UPPER FLANGE CRACKED STATION 727B AT RBL 24.75

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

CORROSION UNDER TIE DOWN AT STRINGER 26R AT SHEAR TIE FLOORBOARD SUPPORT AT BODY STATION 384.

Part: SILL — CORRODED (ZONE 900) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

FORWARD CABIN FLOOR STURCTURE AT BODY STATION 312 TO 344 AT MOP SILL HAS CORROSION AROUND FASTNER HOLES.

Part: THRESHOLD — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

FORWARD FUSELAGE FLOOR STRUCTURE AT L1 DOOR CENTER THRESHOLD AREA HAS LIGHT CORROSION ON UPPER SURFACE STRUCTURE AND UNDER NUTPLATES

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT FUSELAGE FLOOR STRUCTURE HAS CORROSION AT FLOOR SUPPORT BODY STA 957 BETWEEN RT SIDE OF SEAT TRACKS AT RBL 24 AND 45.

Part: FLOOR SUPPORT — CORRODED (ZONE 200) · airframe 56,334 hrs · 66,237 cycles

AFT FUSELAGE CABIN FLOOR STURCTURE AT BODY STA 947 TO 967 AT LBL 12 HAS EVIDENCE OF CORROSION.

Part: BEAM — ELONGATED (ZONE 700) · airframe 56,334 hrs · 66,237 cycles

DURING THE ACCOMPLISHMENT OF ECO 3731 SB 737-57A-1266 INSPECTION OF THE MAIN LANDING GEAR BEAM TO WING ATTACH FITTINGS IT WAS DISCOVERED THAT THE MLG BEAM PIN RETAINER LOCK BOLT FITTING IS ELONGATED ON BOTH LT AND RT MLG BEAM.

Part: INTERCOSTAL — CORRODED (ZONE 100) · airframe 56,334 hrs · 66,237 cycles

AFT BAGGAGE COMPARTMENT INTERCOSTAL UPPER FLANGE CORRODED OUT OF LIMITS BETWEEN BODY STATION 767 AND 787 AT STRINGER 25R

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

UPPER FUSELAGE FLOOR STRUCTURE HEAVY AMOUNT OF CORROSION UNDER NUTLPLATE ON LOWER CHORD OF FLOORBEAM AT BS 787 AT RBL 24

Part: SKIN — CRACKED (FUSELAGE) · airframe 56,334 hrs · 66,237 cycles

DURING THE ACCOMPLISHMENT OF ECO 3735, FORWARD ENTRY AND FORWARD GALLEY SERVICE DOORWAY UPPER AND LOWER HINGE CUTOUT INSPECTION, IT WAS DETERMINED THAT THE FORWARD ENTRY DOOR, LOWER HINGE CUTOUT HAS 1 EACH CRACKED FASTENER HOLE. CRACK IS IN THE LOWER B-5 HOLE, DETERMINED BY EDDY CURRENT.

Part: FLOOR SUPPORT — CORRODED (ZONE 200) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

FORWARD CABIN FLOOR STRUCTURE HAS CORROSION ON FLOOR SUPPORT AT LBL 6 BETWEEN BODY STATION 294.5 AND 312.0.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT FUSELAGE HAS EVIDENCE PILLOWING (CORROSION) AT BODY STA 1016 AT STR 25L AND 24L AROUND FASTENERS.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT BAGGAGE COMPARTMENT AT BODY STA 947.6, STRINGER 26L, HAS CORROSION OUT OF LIMITS.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT FUISELAGE BODY STA 976.6 AT STRINGER 25L, EDGE OF WATER SERVICING DOOR HAS EVIDENCE OF CORROSION.

Part: FLOOR SUPPORT — CORRODED (ZONE 900) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT FUSELAGE FLOOR STRUCTURE AT LT LAVATORY WALL, FLOOR IS CORRODED AT BODY STATION 947 TO 967.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT BAGAGGE COMPARTMENT FLOOR SUPPORTS AT BODY STATION 770 AT SPLICE STRAP ATTACHED HAS SIGNS OF CORROSION

Part: TRANSITION PANEL — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT PIT TRANSITION PANEL CORRODED JUST AFT OF CARGO DOOR ON THE RT SIDE AT BODY STATION 887.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT BAGGAGE COMPARTMENT FLOOR SUPPORT SPLICE PLATE HAS SIGNS OF CORROSION ON BOTTOM SIDE AT BODY STA 770.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

FORWARD CABIN FLOOR STRUCTURE (FRAME) HAS CORROSION AT BODY STA 312 BETWEEN RBL 24 AND RBL 45.

Part: STRUCTURE — CORRODED (BS 464) · corrosion level 2 · airframe 5,634 hrs · 66,237 cycles

CORROSION UNDER FLOORBOARD SPLICE AT STA 464 BETWEEN STRINGER 27R AND 26R IN FORWARD PIT.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT PIT FLOOR SUPPORT AT BODY STATION 770 HAS CORROSION AND WAS FOUND TO BE OUT OF LIMITS AT SPLICE STRAP

Part: ANGLE — CORRODED (ZONE 900) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT FUSELAGE FLOOR STRUCTURE AT AFT LAVATORY FORWARD WALL AS CORROSION AT ATTACH ANGLE AT INBD FASTENER HOLE.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT BAGGAGE COMPARTMENT FLOOR SUPORT AT RBL 8" HAS CORROSION THAT IS OUT OF LIMITS AT SPLICE STRAP BODY STA 770.

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT FUSELAGE FLOOR STRUCTURE HAS CORROSION ON FLOOR SUPPORT AT BODY STATION 955 INBD OF SEAT TRACK AT RBL 24.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT PIT AT STATION 907 TO 929 AT STRINGER 26R HAS CORROSION AROUND FASTENER. FASTENERS ARE PULLING THROUGH.

Part: SKIN — CORRODED (ZONE 100) · airframe 56,334 hrs · 66,237 cycles

PILLOWING CORROSION AROUND FASTENERS AT BODY STA 787, STRINGER 27R.

Part: SKIN — CORRODED (ZONE 500) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

CORROSION AROUND FASTNERS AT LT LOWER SURFACE OF WING AT STATION WRL 167 BEHIND FUEL ACCESS PANEL NR 7204.

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

FUSELAGE LOWER LOBE AT BODY STATION 807 TO 827 AT STRINGER 26R TO 27R HAS EVIDENCE OF PILLOWING (CORROSION).

Part: ACCESS PANEL — CORRODED (ZONE 100) · corrosion level 2 · airframe 56,334 hrs · 66,237 cycles

AFT FUSELAGE AT POTABLE WATER SERVICING PANEL HAS EVIDENCE OF CORROSION AROUND PANEL.

Part: SKIN — CORRODED (BS 807-827) · airframe 56,334 hrs · 66,237 cycles

FUSELAGE LOWER LOBE BETWEEN STA 827 AND 807 AT STRINGER 27R AND 26R HAS POSSIBLE PILLOWING AROUND FASTENERS (CORROSION).

Part: SKIN — CRACKED (BS 574) · airframe 56,334 hrs · 66,237 cycles

2.5 INCH CRACK DISCOVERED AT BS 574 ABOVE STRINGER 18R. REPAIR COMPLIED WITH IAW SRM 53-30-3 DETAIL XI AND XIX FIGURE 48.

Part: CONNECTOR — SHORTED (FIRE WARNING) · airframe 56,198 hrs · 65,951 cycles

DURING CRUSE FLIGHT, THE CREW NOTED THE NR1 ENGINE OVERHEAT WARNING LIGHT ILLUMINATED. THE CONDITION WAS INTERMITTENT AND EXTINGUISHED. THE CREW RETURNED TO HNL WITHOUT FURTHER INCIDENT. MX FOUND A SHORTED CONNECTOR IN THE LOWER FIRE AND OVERHEAT DETECTOR LOOP. THE SHORT WAS CORRECTED IAW THE SWPM 20-30-12. PERFORMED ENGINE HIGH POWER RUN FOR OPS CHECK IAW AMM 26-11-1. THE ACFT WAS RETURNED TO SERVICE.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 55,825 hrs · 65,178 cycles

NON-ETOPS CARGO FLIGHT 25. UPON ARRIVAL, AN ELECTRICAL ODOR WAS REPORTED BY THE PILOT IN THE COCKPIT. MX INSPECTED COCKPIT AND FOUND NO DEFECTS OR ODORS. MX INSPECTED THE E & E BAY AND FOUND WATER IN THE BAY. ACFT WAS TOWED TO HANGAR, DRIED OUT, AND RETURNED TO SERVICE.

Part: STIFFENER — CORRODED (BS 612-630) · corrosion level 2 · airframe 55,701 hrs · 64,924 cycles

WING CTR SECTION LOWER BEAM AT RBL 40.875 IS CORRODED AT BS 612 AND BS 630. MAINTENANCE ACTION: REPLACED ANGLE IN ACCORDANCE WITH SRM 51-10-1. CLEANED AND TREATED AFFECTED AREA IN ACCORDANCE WITH SRM 51-10-6 AND FOUND WITHIN LIMITS.

Part: CIRCUIT BREAKER — FAILED (NR 2 XFER BUSS) · airframe 55,316 hrs · 64,110 cycles

DURING CLIMB, THE CREW NOTED THE NR 2 TRANSFER BUS CIRCUIT BREAKER POPPED. CREW ATTEMPTED TO RESET WITHOUT SUCCESS. CREW RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. MX R & R THE NR 2 TRANSFER BUS CIRCUIT BREAKER (C821) AND OPERATIONALLY CHECKED SATISFACTORY IAW AMM 24-21-0. THE ACFT WAS RETURNED TO SERVICE.

Part: RELAY — FAILED (TRANSFER BUSS) · airframe 55,314 hrs · 64,107 cycles

NON-ETOPS CARGO FLIGHT 16. DURING CLIMB THE ACFT EXPERIENCED A NR2 BUS POWER FAILURE CAUSING THE LOSS OF USE OF ALL INSTRUMENTS AND SYS POWERED BY THE NR 2 BUS. CREW ACCOMPLISHED APPROPRIATE CHECK LISTS LANDED WITHOUT FURTHER INCIDENT. MX R & R THE NR2 TRANSFER BUS RELAY IAW AMM 24-21-0 AND WDM 24-24-01. FUNCTION TESTED SATISFACTORY AND RETURNED THE ACFT TO SERVICE.

Part: TRANSMITTER — DEFECTIVE (NR 1 EPR) · airframe 54,334 hrs · 62,022 cycles

ON TAKEOFF, NR 1 EPR FROZE AT 1.14 WHILE SETTING TAKEOFF POWER. OTHER NR 1 INDICATIONS NORMAL. ABORTED TAKEOFF AT 70 KTS. RETURNED TO RAMP. MX: REMOVED AND REPLACED EPR INDICATOR, DID NOT FIX. REMOVED AND REPLACED EPR TRANSMITTER IAW AMM 77-11-21. OPS CHECK OF EPR TRANSMITTER GOOD. ACFT RETURNED TO SERVICE.

Part: UPLOCK SENSOR — DIRTY (MLG) · airframe 54,055 hrs · 61,402 cycles

FLT 11, HNL- LIH - NOSE GEAR RED LIGHT ILLUMINATED AFTER TAKEOFF. RETURNED TO HNL. ALL THREE GREEN LIGHTS ILLUMINATED WHEN LANDING GEAR EXTENDED. FLIGHT TERMINATED UNEVENTFUL. CLEANED UPLOCK SENSOR. TEST IAW 32-61-41. OPERATIONAL CHECK/GEAR SWING OKAY. AIRCRAFT RETURNED TO SERVICE.

Part: CONTROL CABLE — OUT OF ADJUST (GROUND SPOILER)

FLT 320: TEST FLIGHT, LANDING GEAR LEVER WOULD NOT GO UP AFTER TAKEOFF. WARNING HORN ON AFTER FLAP RETRACT. RETURNED TO SJO, UNEVENTFUL LANDING. PERFORMED ADJUSTMENT AND TEST FOR THE GROUND SPOILER INTERLOCK VALVE CABLE AS PER MM 27-62-51, PAR 2 AND 3. PERFORMED LANDING GEAR EXTENSION AND RETRACTION AS PER MM 32-32-0, PAR 3 TO 5. SATISFACTORY CONDITION. AIRCRAFT RETURNED TO SERVICE.

Part: SWITCH — OBSTRUCTED (CARGO DOOR) · airframe 53,935 hrs · 61,178 cycles

FLT 952, HNL-ITO -ON TAKEOFF, THE AFT CARGO LIGHT CAME ON. RETURNED TO HNL, NO EMERGENCY. MAINTENANCE FOUND A STRAP LODGED BETWEEN THE DOOR AND SWITCH. REPOSITIONED THE STRAP, VERIFIED DOORS OPS CHECK OK. NO PRESSURE PROBLEMS NOTED. AIRCRAFT RETURNED TO SERVICE.

Part: INDICATOR — FAILED (TE FLAP) · airframe 53,474 hrs · 60,175 cycles

CARGO FLIGHT 940 HNL-KOA, ON DESCENT TO KOA, THE CREW WAS ONLY ABLE TO EXTEND THE FLAPS TO 8 UNITS. THE CREW DECLARED AN EMERGENCY AND RETURNED TO HNL WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE FLAP POSITION INDICATOR AND OPERATIONALLY CHECKED THE FLAPS EXTENSION AND RETRACTION PER AMM 27-58-41. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: INDICATOR — FAILED (NR 1) · airframe 53,373 hrs · 59,933 cycles

FLIGHT 269 HNL-LIH - AT TAKEOFF, THE CREW NOTED THE NR 1 EGT READ LOW AT APPROXIMATELY 250 DEGREES AND ELECTED TO ABORT THE TAKEOFF AT 90 KTS AIRSPEED. THE AIRCRAFT WAS TAXIED BACK TO THE GATE WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE NR 1 ENGINE EGT INDICATOR AND COMPLETED A HIGH POWER ENGINE RUN WITH ALL CHECKS SATISFACTORY. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: HOSE — FAILED (HYD SYS) · airframe 53,333 hrs · 59,836 cycles

NON-ETOPS FLIGHT 215 HNL-LIH, DURING CRUISE FLIGHT, THE CREW NOTED THE HYDRAULIC QUANTITY GAUGE DROPPED TO ZERO. CREW COMPLETED THE HYDRAULIC SYSTEM A FAILURE CHECKLIST AND DECLARED AN EMERGENCY. THE CREW RETURNED TO HNL WITHOUT FURTHER INCIDENT. MAINTENANCE TOWED THE AIRCRAFT FROM RUNWAY 8L AFTER ARRIVAL. THE A SYSTEM LT REAR SPAR HYDRAULIC HOSE ASSEMBLY WAS REPLACED. ALL OPERATIONAL AND LEAK CHECKS SATISFACTORY PER AMM 29-11-0 PG 201. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: DADC — FAILED (NR 2) · airframe 52,702 hrs · 58,386 cycles

NON-ETOPS CARGO FLIGHT 946 HNL-KOA - DURING CLIMB, THE CREW NOTED WARNING FLAGS IN THE FIRST OFFICER’S AIRSPEED INDICATOR, ALTIMETER AND VERTICAL SPEED INDICATOR. THE CREW RETURNED TO HNL WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE DIGITAL AIR DATA COMPUTER PER AMM 34-12-11 WITH ALL CHECKS SATISFACTORY. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — CRACKED (BS 306 S18R) · airframe 52,655 hrs · 58,262 cycles

WHILE ACCOMPLISHING VISUAL INSPECTION DURING SERVICE CHECK, A CRACK WAS DISCOVERED AT BS 306 AT STR 18. MAINTENANCE ALONG WITH ENGINEERING IS RESEARCHING THE REPAIR. ECO 3673 REPAIRED CRACKED. 8100-9 WAS RECEIVED FROM BOEING. AIRCRAFT WAS RETURNED TO SERVICE.

Part: ACCESSORY UNIT — FAILED (LE FLAP/SLATS) · airframe 52,440 hrs · 57,804 cycles

NON-ETOPS FLIGHT 226 HNL-OGG - WHEN THE CREW APPLIED TAKEOFF POWER, THE CONFIGURATION WARNING HORN SOUNDED. CREW ABORTED TAKE OFF AT 60 KNOTS INDICATED AIRSPEED. CREW RETURNED TO GATE WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE FLAP SLAT LEADING EDGE POSITION INDICATOR ACCESSORY UNIT. CONFIGURATION WARNING SYSTEM OPERATIONAL CHECK OK PER AMM 31-26-0. AIRCRAFT WAS RETURNED TO SERVICE.

Part: ADC — FAILED (COCKPIT) · airframe 52,409 hrs · 57,729 cycles

NON-ETOPS FLIGHT 946 HNL- KOA - DURING CLIMB, THE CREW NOTED LOSS OF INDICATION ON THE AIRSPEED INDICATOR, ALTIMETER AND VERTICAL SPEED INDICATOR. CREW RETURNED TO HNL WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE DIGITAL AIR DATA COMPUTER AND FOUND ALL OPERATIONAL CHECKS OKAY. AIRCRAFT WAS RETURNED TO SERVICE.

Part: COMPRESSOR WHEEL — FAILED (NR 1 ENGINE) · airframe 52,283 hrs · 57,425 cycles

NON-ETOPS CARGO FLIGHT 956 HNL-ITO - DURING CLIMB AT 24500 FEET, CREW HEARD WHAT SOUNDED LIKE A COMPRESSOR STALL FROM THE NR 1 ENGINE. CREW REDUCED POWER SETTINGS AND ALL ENGINE PARAMETERS WERE NORMAL. CREW LANDED IN ITO WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND DAMAGE TO THE C2 DISK AND NUMEROUS STATOR VANES. MAINTENANCE REMOVED AND REPLACED THE NR 1 ENGINE PER ALOHA MAINTENANCE FORMS M-211, M-212, M-213 AND M-215. AIRCRAFT WAS RETURNED TO SERVICE.

Part: GENERATOR — FAILED (NR 2 ENGINE) · airframe 51,566 hrs · 55,795 cycles

FLT 950 HNL-ITO: DURING FLIGHT, CREW ENCOUNTERED RADIO PROBLEMS AND FOUND NR 2 AND NR 3 TRANSFORMER RECTIFIER CIRCUIT BREAKERS POPPED. THE CREW ALSO NOTED THE BOOST PUMP TANK 2 FWD CIRCUIT BREAKER OPEN. THE CREW RESET THE CIRCUIT BREAKERS BUT CIRCUIT BREAKERS POPPED AGAIN. AIRCRAFT RETURNED TO HNL AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE TROUBLESHOT THE PROBLEM TO THE NR 2 ENGINE GENERATOR AND REPLACED IAW AMM 24-21-11. MAINTENANCE PERFORMED AN OPERATIONAL CHECK OF THE NR 2 ENGINE GENERATOR. AIRCRAFT WAS RETURNED TO SERVICE.

Part: INDICATOR — INOPERATIVE (AIRSPEED) · airframe 51,439 hrs · 55,504 cycles

DURING TAKEOFF, THE CREW NOTED THERE WAS NO FIRST OFFICER AIRSPEED INDICATION. THE CREW ABORTED TAKEOFF AT 100 KNOTS. AIRCRAFT RETURNED TO FREIGHT RAMP WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND AND CLEARED OUT BLOCKAGE FROM THE FIRST OFFICER’S PITOT LINE. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SWITCH — FAILED (NR 1 ENGINE)

CREW SHUTDOWN NR 1 ENGINE AFTER OIL FILTER BYPASS LIGHT ILLUMINATED. CREW THEN LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REMOVED AND REPLACED THE OIL BYPASS SWITCH IAW MM 79-35-11. ALSO REMOVED AND REPLACED MAIN OIL STRAINER IAW MM 72-61-53 AS A PRECAUTION. NO DEFECTS NOTED. OPS AND LEAK CHECKS OK IAW MM 79-35-0 AND MM 72-61-53. AIRCRAFT RETURNED TO SERVICE.

Part: WARNING SYSTEM — MALFUNCTIONED (COCKPIT)

FLT 66, LIH-HNL - CONFIGURATION WARNING AT 40 KTS. PUSHED SPEEDBRAKE DOWN AND HORN STILL SOUNDING. ABORTED TAKEOFF AND RETURNED TO GATE. MAINTENANCE COMPLIED WITH THE CONFIGURATION WARNING PARTIAL TEST PER AMM 31-26-0, PAGE 522. ALL TESTS GOOD AND AIRCRAFT APPROVED FOR RETURN TO SERVICE.

Part: TRANSMITTER — FAILED (NR 1 ENG EPR) · airframe 48,501 hrs · 48,674 cycles

ABORTED TAKE-OFF DUE TO LOW POWER INDICATION ON NR 1 ENGINE EPR. (NR 1 EPR=1.78, NR 2 EPR=2.01) RETURNED TO FREIGHT RAMP. LEAK CHECK NR 1 ENGINE PT7 SYSTEM, SYSTEM CHECKS GOOD. REPLACED NR 1 EPR. PERFORM POWER ASSURANCE CHECK IAW FORM M-215, OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: BYPASS SWITCH — FAILED (NR 2 ENGINE)

ON DESCENT, OIL FILTER BYPASS LIGHT ILLUMINATED AND STAYED ON. SHUT DOWN ENGINE. REPLACED NR 2 FILTER BYPASS SWITCH FOR ILLUMINATION DUE TO FILTER CONTAMINATION. IDLE CHECK OK. REPLACED NR 2 ENGINE OIL FILTER FOR CONTAMINATION IAW 79-61-00. IDLE CHECK OK. DRAINED AND SERVICED NR 2 ENGINE OIL IAW 79-11-01. IDLE CHECK OK.

Part: PITOT LINE — OBSTRUCTED (AIRSPEED)

FLT 220 - HNL-OGG - F/O AIRSPEED AT 70 KTS, CAPTAINS AIRSPEED AT 100KTS. ABORTED T/O AND RETURNED TO GATE. INSPECTED F/O PITOT SYSTEM. FLUSHED OUT DEBRIS FROM SYSTEM. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

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

Part: FRAME — CORRODED (FUSLEAGE)

TRIMMED OUT BODY FRAME AND REMOVED DAMAGED PART OF FRAME. FABRICATED REPAIR CHANNELS AND FILLER PER TABLE 1 FROM .063 INCH THICK 7075-T6 CLAD. ALODINED AND PRIMED REPAIR PART. INSTALLED THE REPAIR PARTS MAKING A FRAYING SEAL WITH BMS 5-95 SEALANT IAW SRM 53-10-4, FIGURE 6. (M)

Part: STRINGER — CORRODED (FUSELAGE)

REMOVED DAMAGED PART OF STRINGER. FABRICATED REPAIR PARTS PER TABLE 1 FROM 2024-T4 AND 7075-T6 CLAD. ALODINED AND PRIMED REPAIR PARTS. INSTALLED REPAIR PARTS IAW SRM 53-10-3, FIGURE 1. (M)

Part: STRINGER — CORRODED (FUSELAGE)

CUTOUT AND REMOVED DAMAGED PART OF STRINGER. FABRICATED REPAIR PARTS PER TABLE 1 FROM 2024-T4 AND 7075-T6 CLAD. ALODINED AND PRIMED REPAIR PART. INSTALLED THE REPAIR PART IAW SRM 53-10-3, FIGURE 1. (M)

Part: ENGINE — MALFUNCTIONED (NR 2)

DURING THE CLIMB, THERE WAS A DROP IN OIL PRESSURE ON THE NR 2 ENGINE. THE CREW RETURNED TO ITO AND MADE AN UNEVENTFUL LANDING WITH NO FURTHER INCIDENT. MAINTENANCE PERSONNEL SERVICED THE NR 2 ENGINE AND CONDUCTED AN ENGINE RUN. THE NR 2 ENGINE HAD CONSUMED 14 QUARTS OF OIL IN 20 MINUTES. THE NR 2 ENGINE WAS REMOVED AND REPLACED. GROUND OPERATIONAL CHECKS WERE GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE. OIL LEAKAGE WAS EVIDENT AROUND THE NR 4.5 BEARING CARBON SEALS AND THE NR 5 BEARING SEAL SUPPORT AREAS. ALL NR 4.5 BEARING CARBON SEALS WERE REPLACED. THE NR 5 BEARING SEAL SUPPORT SPRING AND SEAL RINGS WERE REPLACED. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 3 AND 5 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OP CHECKS OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: SHEAR TIE — CRACKED (FUSELAGE)

FUSELAGE SHEAR TIE CRACK AT BS 460, S-17L. PERFORMED TRIMOUT TO DAMAGED AREA. HFEC INSPECTION COMPLETED NO DEFECTS NOTED, FABRICATED AND INSTALLED NEW T-CHORD IAW ECO. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED OVERWING EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (TSAA 8000.3325 DH)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR1 AND NR2 EMERGENCY FLOOR LIGHT BATTERIES DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED LEFT OVERWING EMERGENCY EXIT IDENTIFIER LIGHT BATTERY DUE TO INOPERATIVE. OPS CHECK, OK. AIRCRAFT RETURNED TO SERVICE.

Part: HYDRAULIC LINE — RUPTURED (HYD SYSTEM)

FLT 833 - OGG-HNL - EN ROUTE TO HNL, THE HYDRAULIC 'A' SYSTEM FAILED LOSING ALL HYDRAULIC FLUID. THE AIRCRAFT LANDED IN HNL WITH NO FURTHER INCIDENT. MAINTENANCE REPLACED A RUPTURED NR 2 ENGINE HYDRAULIC PRESSURE FLEX-LINE. THE NR 2 ENGINE DRIVEN HYDRAULIC PUMP WAS ALSO REPLACED AS A PRECAUTIONARY DUE TO PUMP CAVITATION. LEAK AND OPERATIONAL CHECKS WERE GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

REPLACED RIGHT OVERWING EMERGENCY LIGHT ASSEMBLY DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BUSHING — ELONGATED (T/E FLAP)

DISCOVERED NR 2 ENGINE AND NR 3 FLAP TRACK ASSY MOVING LATERALLY DURING SERVICE CHECK. FURTHER INVESTIGATION REVEALED CORRODED MOUNT BOLT WASHER ASSY AND ELONGATED BUSHING. FABRICATED BUSHINGS PER BOEING DRAWING 65-46429-19. INSTALLED BUSHINGS , CLEANED AND TREATED ALL EXPOSED AREAS. REINSTALLED NR 3 FLAP TRACK ASSEMBLY AND NR 2 ENGINE. RECEIVED 8110-3 APPROVAL IAW ECO 3225. A/C RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: SKIN — CORRODED (FUSELAGE)

FOUND BS 500B, CORROSION FOUND AT STATION 500B STRINGER 28R KEEL BEAM. REMOVED CORROSION AND CUT OUT A 5 INCH HOLE. FABRICATED FILLER AND SKIN PATCH. INSTALLED FILLER, PATCH PER SRM 51-10-6 PAGE 4, REPAIR COMPLETED. AIRCRAFT RETURNED TO SERVICE. (M)

Part: INTERCOSTAL — CRACKED (FUSELAGE)

REMOVED AND REPLACED BS 178, WL 195, LBL 24 AND RBL 24 DUE TO CRACKED INTERCOSTALS CONFIRMED BY HFEC METHOD IAW ECO 3138. AIRCRAFT RETURNED TO SERVICE. REF: OPER CNTRL NR 20001122SH006. (X)

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 41,562 hrs · 32,778 cycles

REMOVED AND REPLACED BS 178, WL 195, LBL 24 AND RBL 24 DUE TO CRACKED INTERCOSTALS CONFIRMED BY HFEC METHOD IAW ECO 3138. AIRCRAFT RETURNED TO SERVICE. REF: OPER CNTRL NR TSAA0053213. (X)

Part: LIGHT — INOPERATIVE (CABIN)

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

Part: BATTERY PACK — INOPERATIVE (CABIN)

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

Part: BATTERY PACK — INOPERATIVE (CABIN)

REPLACED LEFT OVERWING EXIT EMERGENCY LIGHT ASSY BATTERY PACK DUE TO INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: COVER — CRACKED (CABIN)

REPLACED RIGHT WING EXIT IDENTIFIER LIGHT ASSY DUE TO CRACKED COVER. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED FORWARD SERVICE EXIT IDENTIFIER BATTERY PACK DUE TO LOW VOLTAGE. OPS CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 EMERGENCY FLOOR BATTERY PACK DUE TO INOPERABLE. OPS CHECKED OK, AIRCRAFT RETURNED TO SERVICE. (X)

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: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: SKIN — TORN (FUSELAGE)

TEAR IN AFT FUSELAGE SKIN FORWARD OF APU DOOR ON LEFT SIDE IN NON-PRESSURIZED AREA. REPAIRED IAW ECO 3029. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED AFT EMERGENCY CONTROL MODULE (INTERVALVE) BATTERY DUE TO INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TOR SERVICE. (X)

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: PRESSURE SWITCH — DEFECTIVE (NR 1 ENGINE)

FLT 943 - KOA-HNL - DURING CRUISE, NR 1 OIL FILTER BYPASS LIGHT ILLUMINATED. PER SOP, SHUT DOWN NR 1 ENGINE IN FLIGHT. DECLARED EMERGENCY. NORMAL LANDING AT HNL. INSPECTED NR 1 ENGINE FILTER. NO DEFECTS NOTED. REMOVED AND REPLACED OIL FILTER BYPASS SWITCH. GROUND RUNUP CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 6 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 INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (LT EMER EXIT)

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

Part: BATTERY PACK — DISCHARGED (LT EMER EXIT)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACKS — DISCHARGED (CABIN)

REPLACED NR 4, 5, 6 EMERGENCY FLOOR LIGHT BATTERY PACKS 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 LOW VOLTAGE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (M)

Part: LIGHT — INOPERATIVE (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 1 FLOOR PROXIMITY AISLE LIGHT BATTERY PACK DUE LED INOPERATIVE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED POSTION 2 AND 5 BATTERY PACK FOR SEAT EMERGENCY LIGHT ASSY DUE TO NO 'ALL WELL' LIGHT. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 4 BATTERY PACK DUE LIGHT DID NOT TEST. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 2 AND NR 5 SEAT EMERGENCY LIGHT ASSY BATTERY PACKS DUE TO NO 'ALL'S WELL LIGHT'. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

RIGHT OVERWING EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK FOR RIGHT OVERWING EMERGENCY LIGHT ASSY. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

RIGHT OVERWING EMERGENCY LIGHT INOPERABLE. REPLACED BATTERY PACK FOR RIGHT OVERWING EMERGENCY LIGHT ASSY. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED RIGHT WING EMERGENCY EXIT LIGHT BATTERY PACK DUE TO INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 4 AND NR 5 FLOOR EMERGENCY LIGHT BATTERY PACK DUE TO INOPERABLE. OPS CHECK OK. ARICRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 3 EMERGENCY FLOOR LIGHT BATTERY PACK DUE TO INOPERABLE. OSP CHECK OK. AIRCRAFT REUTRNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED NR 6 EMERGENCY FLOOR PROXIMITY LIGHT BATTERY PACK ON AFT OVERHEAD ISLE EMERGENCY DUE TO LOW VOLTAGE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: LIGHT — INOPERATIVE (CABIN)

REPLACED NR 5 FLOOR LIGHT ASSY DUE TO BEING INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED BATTERY PACK ON AFT OVERHEAD ISLE EMERGENCY EXIT SIGN DUE TO INTERMITTENT. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY PACK — DISCHARGED (CABIN)

REPLACED BATTERY PACK POSITIONS NR 2 AND NR 5 FLOOR PROXIMITY LIGHT ASSEMBLY DUE TO BEING INOPERABLE. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: BATTERY — DISCHARGED (CABIN)

FORWARD RIGHT SIDE EMERGENCY FLASH LIGHT INOPERABLE. REPLACED BATTERY. OPS CHECK OK. AIRCRAFT RETURNED TO SERVICE. (X)

Part: LIGHT — INOPERATIVE (CABIN)

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

Part: BATTERY PACK — DISCHARGED (CABIN)

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