N828AE

Part: SMOKE DETECTOR — FAILED (LAVATORY) · airframe 28,301 hrs · 25,110 cycles

GATE REPORTED LAVATORY SMOKE DETECTION HORN GOING OFF. R & R LAVATORY SMOKE SENSOR IAW 140 AMM 26-44-01, OPERATIONS CHECKED GOOD.

Part: FLASHLIGHT — DEFECTIVE (COCKPIT) · airframe 28,079 hrs · 24,940 cycles

CAPTAIN`S FLASHLIGHT NOT CHARGING. R & R THE CAPTAIN'S FLASHLIGHT ASSEMBLY IAW EMB 140 AMM 33-50-16, OPERATIONS CHECKED GOOD.

Part: WIRE — BROKEN (EMERGENCY LIGHT) · airframe 27,985 hrs · 24,865 cycles

EMERGENCY LIGHT HAS A BROKEN WIRE. R & R EMERGENCY LIGHT IAW AMM 33-50-12. OPS CHECKED GOOD.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 27,759 hrs · 24,640 cycles

RT OVERWING EMERGENCY LIGHT INOPERATIVE. R & R POWER SUPPLY AND BATTERY PACK IAW WC 33-700-19. OPS CHECKED IAW WC 33-700-17.

Part: CARBON SEAL — LEAKING (LT ENGINE) · airframe 27,497 hrs · 24,394 cycles

HEAVY OIL ODOR THRU ENVIROMENTAL SYS AFTER ADDING THRUST DURING DESCENTS AND CLIMB. FOUND OIL TO BE LEAKING FROM NR 1 ENGINE CARBON SEAL. REMOVED AND REPLACED THE CARBON SEAL IAW MM 72-25-25. OPS CHECKED GOOD. PERFORMED ETN ETN-EM-72-034. NO DETECTABLE ODOR AT THIS TIME. AIRCRAFT RETURNED TO SERVICE.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 27,368 hrs · 24,274 cycles

LEFT OVERWING EMERGENCY LIGHT INOPERATIVE. R & R LAMP IAW AMM 33-50-10, OPS CHECKED GOOD.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 27,368 hrs · 24,274 cycles

RT OVERWING EMERGENCY LIGHT INOPERATIVE. R & R LAMP IAW AMM 33-50-10, OPS CHECKED GOOD.

Part: INVERTER — FAILED (EMERGENCY LIGHTS) · airframe 26,985 hrs · 23,938 cycles

DURING B-INSPECTION, FOUND THE FLOOR PROXIMITY LIGHTS OUT AT ROWS 4-5. ACFT REMOVED FROM SERVICE. R & R THE EMERGENCY LIGHTING DC/AC INVERTER IAW AMM 33-50-01. THE OPS CHECKED GOOD. ACFT RETURNED TO SERVICE.

Part: FLASHLIGHT — BROKEN (CABIN) · airframe 26,769 hrs · 23,764 cycles

DURING B-INSPECTION, FOUND THE FWD CABIN FLASHLIGHT HAS A BROKEN SWITCH. THE ACFT WAS REMOVED FROM SERVICE. R & R THE FORWARD CABIN FLASHLIGHT IAW AMM 33-51-01. THE OPS CHECK WAS GOOD. THE ACFT WAS RETURNED TO SERVICE.

Part: BATTERY — INOPERATIVE (CABIN) · airframe 26,647 hrs · 23,666 cycles

DURING B INSPECTION FOUND THE EMERGENCY LIGHT STRIPS POWERED BY THE NR 3 POWER PACK WAS INOPERABLE. SUSPECT NR 5 INVERTER. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE EMERGENCY LIGHT DC/AC NR 5 INVERTER IAW AMM 33-50-11. PART NUMBER 7824-1. REMOVED AND REPLACED THE NR 3 EMERGENCY POWER SUPPLY AND BATTERY IAW AMM 33-50-04. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BOLT — MISSING (CABIN DOOR) · airframe 26,059 hrs · 23,184 cycles

ON FLIGHT 2717 THE CREW REPORTED THEY COULD NOT OPEN THE CABIN DOOR FROM INSIDE THE AIRCRAFT. THE GATE AGENT OPENED FROM OUTSIDE. THE AIRCRAFT WAS REMOVED FROM SERVICE. INSTALLED BOLT AND NUT ON THE INTERNAL ACTUATING HANDLE IAW EMB 145 AMM 52-18-05. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FLASHLIGHT — ODOR (CABIN) · airframe 25,940 hrs · 23,079 cycles

DURING MAINTENANCE INSPECTION FOUND AN UNUSUAL ODOR IN COCKPIT, SUSPECT POSSIBLE SMELL FROM FORWARD FLIGHT ATTENDANT FLASHLIGHT ASSEMBLY. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FORWARD FLIGHT ATTENDANT FLASHLIGHT ASSEMBLY IAW EMB AMM 33-50-16. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONTROL VALVE — FAILED (A/C PACK) · airframe 25,931 hrs · 23,070 cycles

FLIGHT 4190. WHILE ENROUTE, PERFORMED ANTI ICE TEST AND NOTICED AN UNFAMILIAR ODOR AS SOON AS THE TEST WAS COMPLETE. WHEN PACKS WERE BOTH ONLINE, ODOR DISAPPEARED. AIRCRAFT REMOVED FROM SERVICE. PERFORMED OPS CHECK OF ANTI-ICE SYSTEM IAW AMM 30-00-00. NO DEFECTS NOTED NO ODORS NOTED. AIRCRAFT RETURNED TO SERVICE. FCF FAILED. REPLACED NR 1 A/C PACK VALVE IAW NRWC 828-ORD-01203. REPLACED NR 1 AND 2 RECIRCIRCULATION FANS IAW NRWC 828-ORD-01205. REPLACED NR 1 A/C PACK SET DOWN SWITCH AND TEMP SWITCH IAW NRWC 828-ORD-01204. OPS CHECKED GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 25,451 hrs · 22,647 cycles

DURING B INSPECTION FOUND THE LEFT FORWARD EMERGENCY LIGHT ABOVE WING INOPERABLE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE LEFT FORWARD EMERGENCY LIGHT ASSEMBLY PART NUMBER 30-2510-3, IAW EMB 140 AMM 33-50-10 AND THE BATTERY/CHARGER ASSEMBLY. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (CABIN) · airframe 25,014 hrs · 22,315 cycles

DURING B INSPECTION FOUND THE EMREGENCY LIGHTS FLOOR LIGHTING STRIP AT ROWS 7-8 INOPERABLE. THE WIRE WAS BROKEN DURING MAINTENANCE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE EMERGENCY LIGHTING STRIP AT ROWS 7-8 IAW EMB 140 AMM 33-50-08. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNKNOWN — ODOR (CABIN) · airframe 24,716 hrs · 22,076 cycles

THE CREW REPORTED THAT UPON STARTING APU AT GATE AND TURNING ON PACK 2 THERE WAS STONG ODOR OF FUEL IN THE COCKPIT AND BACK TO ABOUT ROW 7. THE AIRCRAFT WAS REMOVED FROM SERVICE. CHECKED APU AND PACKS FOR LEAKS WITH NONE NOTED. FUEL ODOR DISSIPATED OVER TIME. OK FOR CONTINUED SERVICED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CRADLE — DAMAGED (CABIN) · airframe 24,371 hrs · 21,812 cycles

DURING MAINTENANCE INSPECTION FOUND THAT THE AFT CABIN EF-2C RECHARGEABLE FLASHLIGHT CRADLE SHOWS EVIDENCE OF OVERHEATING. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE AFT CABIN EF-2C RECHARGEABLE FLASHLIGHT CRADLE IAW ERJ 140 AMM 33-50-16. THE FLASHLIGHT OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CRADLE — DAMAGED (CABIN) · airframe 24,371 hrs · 21,812 cycles

DURING MAINTENANCE INSPECTION FOUND THAT THE FORWARD CABIN EF-2C RECHARGEABLE FLASHLIGHT CRADLE SHOWS EVIDENCE OF OVERHEATING. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FORWARD CABIN EF-2C RECHARGEABLE FLASHLIGHT CRADLE IAW ERJ 140 AMM 33-50-16. THE FLASHLIGHT OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: MECHANISM — UNSECURE (PAX DOOR) · airframe 24,291 hrs · 21,745 cycles

ON FLIGHT 2897 THE CREW REPORTED THE MAIN ENTRY DOOR WILL NOT OPEN FROM INSIDE OF AIRCRAFT. THE AIRCRAFT WAS REMOVED FROM SERVICE. RE-SECURED DOOR MECHANSIM PER STANDARD PRACTICIES. THE OPERATIONAL CHECK OF MAIN PASSENGER DOOR OPEN AND CLOSED CHECKED OK PER AMM PART 1 52-18-00. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE) · airframe 23,904 hrs · 21,462 cycles

DURING MAINTENANCE INSPECTION FOUND FRAME 23 CRACKED BELOW STRINGER 15R. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED FRAME 23 IAW AEA EO EM-53MR-1808. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (CABIN) · airframe 23,907 hrs · 21,465 cycles

DURING MAINTENANCE INSPECTION FOUND THE EMERGENCY LIGHT STRIP WIRE BROKEN AT SIDE FLOOR PANEL 261BF. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED EMERGENCY LIGHT STRIP WIRE (AIRCRAFT SIDE) AT FLOOR PANEL 261BF IAW EMB 140 WM 20-21-00. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CHARGER — INOPERATIVE (CABIN) · airframe 23,786 hrs · 21,376 cycles

DURING MAINTENANCE INSPECTION FOUND THE NR 4 BATTERY CHARGER ASSEMBLY DUE A CHANGE, DUE TO FAULTY LEFT OVERWING EXTERIOR EMERGENCY LIGHT. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE NR 4 BATTERY CHARGER ASSY IAW EMB 140 AMM 33-50-04. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LENS — CRACKED (CABIN) · airframe 23,786 hrs · 21,376 cycles

DURING PS-2 INSPECTION FOUND THE LEFT AFT EMERGENCY LIGHT LENS CRACKED. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE EMERGENCY LIGHT ASSEMBLY IAW 33-28-03. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: HOLDER — BROKEN (COCKPIT) · airframe 23,737 hrs · 21,336 cycles

DURING MAINTENANCE INSPECTION FOUND THE FIRST OFFICER’S EMERGENCY FLASHLIGHT HOLDER BROKEN. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FLASHLIGHT ASSEMBLY IAW AMM33-50-16. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CRADLE — CRACKED (COCKPIT) · airframe 23,507 hrs · 21,158 cycles

DURING B-INSPECTION, FOUND THE LOWER ARM OF EMERGENCY FLASHLIGHT HOLDER BEHIND CAPTAIN'S SEAT IS CRACKED. AIRCRAFT REMOVED FROM SERVICE. REMOVED AND REPLACED BRACKET FOR FLASHLIGHT IAW AMM 33-50-16. OPS CHECKED GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: STRUT — FAILED (RT MLG) · airframe 22,378 hrs · 20,162 cycles

ON FLIGHT 3240 THE CREW REPORTED THE RIGHT MAIN GEAR STRUT FAILED. THE CREW DECLARED AN EMERGENCY INBOUND TO DFW. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE RIGHT MAIN LANDING GEAR STRUT IAW EMB 140 AMM 32-10-02. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: COUPLING — DEFECTIVE (AC BAY) · airframe 19,284 hrs · 17,431 cycles

ON FLIGHT 4359 DURING THE CLIMBOUT PASSING THROUGH 7,000 FEET THE CREW RECEIVED A PACK 1/2 VALVE FAIL MESSAGE FOLLOWED BY A STRONG ELECTRICAL BURNING ODOR. THE CREW ALSO REPORTED HEARING A LOUD NOISE IN THE CABIN. THE ODOR SEEMED TO DISSIPATED WHEN THE PACKS WERE DESELECTED. AN EMERGENCY WAS NOT DECLARED BUT TRUCKS DID ROLL AS A PRECAUTION. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS REMOVED FROM SERVICE. RE-SECURED CONNECTION AS REQUIRED. RAN PACK NR 2 ON AUXILIARY POWER UNIT, AND NO LEAKS WERE NOTED. REMOVED AND REPLACED COUPLING BETWEEN THE HEAT EXCHANGER AND AIR CYCLE MACHINE AS REQUIRED. GROUND RAN ENGINES AT TAKEOFF POWER AND TESTED COOLING PACKS. NO DEFECTS NOTED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 19,109 hrs · 17,278 cycles

DURING MAINTENANCE BASE INSPECTION FOUND TOOL MARKS ON INBOARD WEB OF FRAME 61 BETWEEN STRINGERS 16R AND 17R. THE AIRCRAFT WAS REMOVED FROM SERVICE. COMPLIED WITH REPAIR TO THE FRAME 61 IAW EO EM-53MR-1556. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FITTING — GOUGED (AILERON) · airframe 19,109 hrs · 17,278 cycles

DURING MAINTENANCE BASE INSPECTION FOUND THE RIGHT AILERON PCA FITTING LUGS ON AILERON TO BE GOUGED. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED FITTING IAW EO EM-27MR-112. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ATTACH FITTING — WORN (AILERON) · airframe 19,109 hrs · 17,278 cycles

DURING MAINTENANCE BASE INSPECTION FOUND LEFT AILERON PCA OUTBOARD ATTACH FITTING ON AILERON HAT BUSHING MIGRATING. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED FITTING IAW EO EM-27MR-112. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FITTING — GOUGED (FUSELAGE) · airframe 19,109 hrs · 17,278 cycles

DURING MAINTENANCE BASE INSPECTION FOUND FRAME 68 SHEAR CLIP GOUGED JUST ABOVE CARGO DOOR SILL. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED GOUGED AREA IAW EO EM-53MR-1129. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SILL — CORRODED (FUSELAGE) · airframe 19,109 hrs · 17,278 cycles

SUPPLEMENTAL INFORMATION: CARGO DOOR SILL HAS NUMEROUS AREAS OF CORROSION. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED CARGO DOOR SILL IAW EMBRAER STRUCTURAL REPAIR MANUAL 51-40-02. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — CRACKED (FUSELAGE) · airframe 19,109 hrs · 17,278 cycles

DURING MAINTENANCE BASE VISIT FOUND THE FUSELAGE SKIN HAS SMALL CRACKS AT FRAME 75 APPROXIMATELY 2 INCHES RIGHT OF VERTICAL STABILIZER. THE CRACK LENGTH ARE: 3 EACH .25 INCH AND 1 .375 INCH. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED SKIN BY CUTTING OUT DAMAGED AREA AND INSTALLING A DOUBLER IAW ETA EM-5300-1235. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SKIN — CRACKED (FUSELAGE) · airframe 19,109 hrs · 17,278 cycles

DURING MAINTENANCE BASE VISIT FOUND THE FUSELAGE SKIN HAS SMALL CRACK AT FRAME 75 APPROXIMATELY 2 INCHES LEFT OF VERTICAL STAB. THE CRACK LENGTH IS .25 INCH. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED SKIN BY CUTTING OUT DAMAGED AREA AND INSTALLING A DOUBLER IAW ETA EM-5300-1235. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SILL — CORRODED (FUSELAGE) · airframe 19,109 hrs · 17,278 cycles

DURING MAINTENANCE BASE VISIT FOUND THE CARGO DOOR SILL HAS NUMEROUS AREAS OF CORROSION. THE AIRCRAFT WAS REMOVED FROM SERVICE. THE CORRECTIVE ACTION INFORMATION IS PENDING.

Part: WARNING SYSTEM — MALFUNCTIONED (SPOILER) · airframe 17,394 hrs · 15,762 cycles

ON FLIGHT 4601 - CREW RECEIVED AN EICAS MESSAGE INDICATING A SPOILER FAIL MESSAGE THAT CYCLED BETWEEN OPEN AND CLOSED. CREW DECLARED AN EMERGENCY AND LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. MAINTENANCE PERFORMED OPERATIONAL CHECK OF THE SPOILER SYSTEM IAW EMB AMM 27-63-01. OPERATIONAL CHECK GOOD, UNABLE TO DUPLICATE PROBLEM, NO FAULTS FOUND. AIRCRAFT RETURNED TO SERVICE.

Part: SILL — CORRODED (SERVICE DOORWAY) · corrosion level 2 · airframe 14,389 hrs · 13,223 cycles

DURING A MBV INSPECTION, THE SERVICE DOOR CENTER SILL WAS FOUND CORRODED. REMOVED DAMAGED SILL. CLEANED AND ALODINED NEW SLLL AND INSTALLED IAW EMB 145 SRM (SRM EMB-14511142 REV 39) CHAPTER 51-40-02. AIRCRAFT RETURNED TO SERVICE.

Part: DOWNLOCK SWITCH — DEFECTIVE (LT MLG) · airframe 13,170 hrs · 12,356 cycles

CREW REPORTED THAT THE LANDING GEAR WOULD NOT RETRACT. ALSO HAD A LANDING GEAR AIR/GND FAIL ON EICAS. CAPT DIVERTED TO LGA. AIRCRAFT LANDED SAFELY WITH NO OTHER PROBLEMS. FOUND MAIN LEFT DOWNLOCK PROXIMITY SWITCH DEFECTIVE. REMOVED AND REPLACED LEFT MAIN PROX SWITCH IAW EMB140 AMM 32-61-02. ALSO, PERFORMED MULTIPLE GEAR SWINGS IAW EMB 140 AMM 32-30-00. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN)

CREW NOTED WHEN ACTIVATING EMERGENCY LIGHTS FOR TEST, LIGHTS WOULD ILLUMINATE THEN FADE OUT FAST. CA REPLACED ALL 4 EMERGENCY LIGHT BATTERIES. OPERATONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (K)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DURING CPCP INSPECTION, MAINTENANCE FOUND CORROSION ON LEFT OMEGA BEAM. REPAIRED LEFT OMEGA BEAM IAW EMB 140 SRM 53-21-10 FIG 201. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: CHANNEL — CORRODED (FUSELAGE)

SAW - DURING CPCP INSPECTION, MAINTENANCE FOUND CORROSION ON SERVICE DOOR SILL PLATE. REMOVED AND REPLACED THE SERVICE DOOR SILL PLATE CHANNEL IAW EMB 140 SRM 51-40-02. AIRCRAFT AS RETURNED TO SERVICE. (M)

Part: CHANNEL — CORRODED (FUSELAGE)

SAW - DURNG CPCP INSPECTION, MAINTENANCE FOUND HAT BEAM CORRODED BETWEEN FRAMES 19 AND 20. HAT BEAM REPLACED IAW SRM 51-40-02. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

DURING TAXI IN CRWE NOTED FORWARD PORTION OF CABIN EMERGENCY LIGHTS INOPERATIVE. RAI NR 1 EMERGENCY BATTERY PACK P/N 20131A, S/N 67884, NR 2 BATTERY PACK P/N 20131A S/N 69700, AND NR 3 EMERGENCY BATTERY PACK P/N 20131A AND S/N 71003, OPS CHECK GOOD. (M)

Part: ENGINE — BIRD INGESTION

AFTER TAKE OFF FROM SJC THE AIRCRAFT ENCOUNTERED ABOUT A DOZEN BIRDS WHICH WERE INGESTED INTO BOTH ENGINES. AN EMERGENCY WAS DECLARED AND AIRCRAFT RETURNED TO SJC WITH NO FURTHER INCIDENTS REPORTED. C/A: MAINTENANCE PERFORMED A BIRDSTRIKE INSPECTION IAW AE MCM. NO DAMAGE WAS FOUND FROM THE BIRDS. THE INSPECTION WAS COMPLETED AND AIRCRAFT WAS RETURNED TO SERVICE. (PTRS SW2002B5973)