N847AE

Part: A/C PACK — MALFUNCTIONED (AC BAY) · airframe 27,852 hrs · 24,735 cycles

PACK 2 VLV CLSD MSG ON EICAS. DEFERRED RT PACK IAW MEL 21-29. ACFT OK FOR SERVICE.

Part: INDICATOR — FAILED · airframe 27,769 hrs · 24,659 cycles

ISIS FAILED DURING TAKEOFF ROLL AT 70KTS. ABORTED TAKEOFF. TROUBLE SHOT IAW FIM TASK 34-01-00. RESET IAW AMM 34-01-01. OPERATIONS CHECKED GOOD.

Part: SPRING — DEFECTIVE (BRAKE PEDAL) · airframe 27,640 hrs · 24,541 cycles

CAPTAIN`S RT BRAKE PEDAL IS COMPLETELY LOOSE FELT SOMETHING POP OR BROKEN WHILE APPLYING THE BRAKE. REPLACED CAPTAIN`S RT BRAKE PEDAL SPRING IAW AMM 27-21-01. OPERATIONS GOOD.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 27,555 hrs · 24,473 cycles

AFT EMER FLOOR LIGHT STRIP INOPERATIVE. R & R AFT EMER FLOOR LIGHT STRIP IAW AMM 33-50-12. OPERATIONS CHECKED GOOD.

Part: FCU — FAILED (FUEL SYSTEM) · airframe 27,326 hrs · 24,267 cycles

RETURNED AFTER TAKEOFF DUE TO UNKNOWN FUEL QTY. AT RUNWAY BEFORE TAKEOFF RDU LT TANK IND 4800 & RT TANK IND 4700. EARLY IN CLIMB EICAS MSG FUEL IMBALANCE. LT TANK IND +/- 5300 & RT TANK IND +/- 4500. TRANSFERRED TO EVEN THE INDICATED FUEL. AFTER LANDING =/- 30 MINS RT TANK INDICATOR WAS BOUNCING UP & DOWN BY 200 - 300 LBS DURING SMOOTH LEVEL FLIGHT. R & R THE FUEL CONDITIONING UNIT AMM 28-41-00. PERFORMED OPERATIONS TEST OF THE ELEC FUEL QTY IAW AMM 28-41-00. OPERATIONS CHECKED GOOD.

Part: FLASHLIGHT — INOPERATIVE (AFT) · airframe 27,236 hrs · 24,183 cycles

AFT FLASHLIGHT INOPERATIVE. R & R AFT FLASHLIGHT ASSEMBLY IAW AMM 33-50-16. OPERATIONS CHECKED GOOD IAW AMM 33-51-01.

Part: PROXIMITY SENSOR — FAILED (NLG) · airframe 27,118 hrs · 24,057 cycles

DURING TAKEOFF STEER INOPERATIVE, AFTER PLANE STARTED PULLING TO THE RT. ABORTED TAKEOFF & STEER NORMAL WITH TILLER BACK TO GATE. R & R NLG WOW PROX SWITCH IAW AMM 32-63-02. OPERATIONS CHECKED GOOD. TAXI CHECKED GOOD.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 27,086 hrs · 24,018 cycles

ELECTRICAL SMELL IN COCKPIT AFTER ENCOUNTERING WHAT APPEARED TO BE LIGHTNING STRIKE INFLIGHT. PERFORMED LIGHTNING STRIKE INSPECTION IAW WC 05-200-00, NO DEFECTS NOTED. PERFORMED ETN-EM-72-034 ODOR EVENT TROUBLESHOOTING, NO DEFECTS NOTED.

Part: FLASHLIGHT — DEFECTIVE (CABIN) · airframe 27,072 hrs · 24,006 cycles

FORWARD CABIN FLASHLIGHT WILL NOT STAY IN CRADLE. FLIGHT CREW PLACARDED IAW MEL 25-53. R & R FWD CABIN FLASHLIGHT IAW AMM 33-50-16. OPERATIONS CHECKED GOOD, MEL ITEM RESTORED.

Part: CONTROL UNIT — FAULTY (BRAKE SYSTEM) · airframe 26,942 hrs · 23,853 cycles

DURING FLIGHT 3519 CREW REPORTED CAUTION MSG, BRAKE DEGRADE, ON EICAS WITH FLAPS 22 GEAR DOWN THE ACFT WAS REMOVED FROM SERVICE. R & R BCU IAW AMM 32-41-02 & PERFORMED MAIN BRAKE SYS TEST USING AMM 32-41-00. ALL GOOD NO MSG NOTED. THE ACFT RETURN TO SERVICE.

Part: FLASHLIGHT — INOPERATIVE (CABIN) · airframe 26,818 hrs · 23,693 cycles

AFT FLASHLIGHT CABIN INOPERATIVE. DEFERRED AFT FLIGHT ATTENDANT FLASHLIGHT IAW MEL 25-53. M PROCEDURE COMPLIED WITH. FWD FLIGHT ATTENDANT, CAPTAINS & FIRST OFFICER`S FLASHLIGHT OK. MEL 25-53 REQUIRES 3 FLASHLIGHTS FOR DISPATCH, INSTALLED ADDITIONAL SPARE 4TH FLASHLIGHT IAW CREW REQUEST.

Part: SMOKE DETECTOR — MALFUNCTIONED (CARGO BAY) · airframe 26,412 hrs · 23,346 cycles

DECLARED EMERGENCY FOR BAGG SMOKE EICAS MSG & LIGHT IN BAGG EXTN BUTTON. USED BUTTON TO ENGAGE EXTINGUISHERS IN CARGO COMPARTMENT. DEFERRED IAW MEL 26-09 AUTHORIZATION 030398D-C. R & R CARGO SMOKE DETECTORS FWD & AFT IAW 26-15-01. OPERATIONS CHECKED GOOD, MEL RESTORED. R & R SMALL FIRE BOTTLE IAW AMM 26-23-01, OPERATIONS CHECKED GOOD MEL RESTORED.

Part: HOLDER — BROKEN (FLASHLIGHT) · airframe 26,400 hrs · 23,335 cycles

FORWARD FLASHLIGHT HOLDER IN CABIN BROKE. R & R FWD CABIN FLASHLIGHT HOLDER IAW AMM 33-50-16.

Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 26,190 hrs · 23,118 cycles

NOTICED AFTER TAKEOFF CAPTAIN`S WINDSHIELD IS CRACKED AT UPPER LT SIDE BY WINDSHIELD HEAT STRIP BOTTOM. LT SIDE ABOUT 6 INCHES LONG & UPPER SIDE ABOUT 12 INCHES LONG. TRANSFERRED TO NRWC 847-DFW-01408. R & R CAPTAIN`S WINDSHIELD IAW AMM 56-10-01.

Part: FLASHLIGHT — INOPERATIVE (CABIN) · airframe 26,106 hrs · 23,040 cycles

AFT CABIN FLASHLIGHT INOPERATIVE. FLIGHT CREW PLACARDED IAW MEL 25-53 AUTH 010834-C MOC 630997.

Part: LAMP — INOPERATIVE (EMERGENCY LIGHT) · airframe 24,946 hrs · 21,921 cycles

EMERGENCY LIGHT ABOVE SEAT 15A INOPERATIVE. R & R LAMP IAW AMM 33-50-08-000-801-A AND 33-50-08-400-801-A. OPS CHECKED GOOD. NO DEFECTS NOTED.

Part: WIRE HARNESS — FAULTY (CABIN) · airframe 24,709 hrs · 21,722 cycles

THE F/A REPORTED SMOKE AND FUME COMING FROM THE OVERHEAD LIGHT IN THE GALLEY. THE ACFT WAS REMOVED FROM SERVICE. TROUBLESHOT AND FOUND THE OVERHEAD LIGHT SOCKET BURNING. R & R THE GALLEY AREA LIGHT HARNESS ASSY IAW AMM 33-29-03. THE OPS CHECK WAS GOOD AT THIS TIME. THE ACFT WAS RETURNED TO SERVICE.

Part: BEAM — CORRODED (FUSELAGE) · airframe 23,929 hrs · 20,821 cycles

DURING MAINTENANCE INSPECTION FOUND THE CENTER HAT BEAM IN LAVATORY HAS CORROSION AROUND NUT PLATE HOLES AT PREVIOUSLY REPAIRED AREAS. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED CENTER HAT BEAM IAW EO EM-53 MR-2080. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE) · airframe 23,929 hrs · 20,821 cycles

DURING MAINTENANCE INSPECTION FOUND THE RIGHT CABIN FRAME 23 AT STRINGER 15 CRACKED. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED FRAME 23 AT STRINGER 15 RIGHT IAW EMB SRM 53-00-04. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 23,929 hrs · 20,821 cycles

DURING MAINTENANCE INSPECTION FOUND RIGHT FLOORBEAM SUPPORT CRACKED BETWEEN FRAMES 47-48. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED SUPPORT BRACKET IAW SRM 53-23-02. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: GUSSET — UNKNOWN (FUSELAGE) · airframe 24,043 hrs · 20,919 cycles

DURING B INSPECTION FOUND THE FLOOR GUSSET. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE CENTER LAV FLOOR GUSSET IAW EMB SRM 51-40-02. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LIGHT — BROKEN (CABIN) · airframe 24,043 hrs · 20,919 cycles

DURING MAINTENANCE INSPECTION FOUND THE EMERGENCY LIGHT STRIP COVERING FLOORBOARD 241BF BROKEN. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE EMERGENCY LIGHT STRIP COVERING FLOORBOARD 241BF IAW AMM 33-50-12. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: TRANSDUCER — FAULTY (ANTI-ICE SYSTEM) · airframe 23,805 hrs · 20,715 cycles

ON FLIGHT 2897 E2 INLET OPEN INSCRIPTION WAS ON DURING TAXI AND TAKEOFF. AS THEY APPROACHED 10 C THEY SELECTED OVERIDE KNOB TO ALL PER MEL 30-24 ALL ANTI-ICING VALVES INDICATED OPEN. CLIMBING THROUGH MID 20,S THEY GOT AN E-2 ANTIICE FAIL MESSAGE. E2 INLET OPEN HAD GONE OUT. THE CREW DECLARED AN EMERGENCY IN ORDER TO DESCEND AND EXIT ICING CONDITIONS. HAVING DECLARED AN EMERGENCY THEY RETURNED TO DFW AND LANDED AT 42,700LBS. PERFORMED BENCH TEST OF E2 A/I PRESSURE TRANSDUCER IAW KULITE CMM 30-21-06. FOUND TO BE FAULTY. REMOVED AND REPLACED THE TRANSDUCER IAW EMB 140 AMM 30-21-06. OPERATIONAL CHECK GOOD, NO MESSAGES OCCURRED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (CABIN) · airframe 23,640 hrs · 20,580 cycles

DURING MAINTENANCE INSPECTION FOUND THE EMERGENCY FLOOR PROXIMITY LIGHT WIRE BROKEN. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPLACED EMERGENCY FLOOR LIGHT PROXIMITY IAW AMM 33-50-00. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CARBON SEAL — LEAKING (NR 2 ENGINE) · airframe 22,844 hrs · 19,959 cycles

DURING UNSCHEDULED MAINTENANCE, FOUND THE NR 2 ENGINE NR 7 CARBON SEAL LEAKING AND THE ENGINE WAS SMOKING WITH FIRE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE RIGHT ENGINE IAW W/C 71-000-00. THE OPERATIONAL CHECKS AND LEAK CHECKS WERE GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BRACKET — CORRODED (FUSELAGE) · airframe 9,806 hrs · 19,735 cycles

DURING MAINTENANCE INSPECTION FOUND RELAY CLICKING NOISES COMING FROM BEHIND CAPTAIN'S SEAT. NOISE GOES AWAY WHEN GPU DESELECTED. AIRCRAFT REMOVED FROM SERVICE. FOUND FRAME 80 SHUNT BRACKET CORRODED THRU. REPAIRED IAW EO EM-53MR-2000. AIRCRAFT RETURNED TO SERVICE.

Part: FLAP — MALFUNCTIONED (WING) · airframe 21,558 hrs · 18,893 cycles

FOR FLIGHT 3417 CREW RECEIVED FLAP FAIL MESSAGE TRANSFERED TO NRWC 847-DFW-00492. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED RIGHT INBOARD FLAP IAW AMM 27-50-00. OPERATIONAL CHECKS GOOD. THE AIRCRAFT RETURN TO SERVICE.

Part: FLAP — MALFUNCTIONED (RT WING) · airframe 21,554 hrs · 18,889 cycles

DURING TAKEOFF ON FLIGHT 3417 RECEIVED FLAP FAIL CAUTION MESSAGE UPON RETRACTION OF THE FLAPS. CREW PROCEEDED WITH THE FLAP FAIL CHECKLIST AND DETERMINED FLAPS WERE FULLY RETRACTED. CONTACTED ATC AND DECLARED EMERGENCY. TRANSFERRED TO NRWC 847-DFW-00492 THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED RIGHT INBOARD FLAP IAW AMM 27-50-00. OPERATIONAL WAS CHECK GOOD. THE AIRCRAFT RETURNED TO SERVICE.

Part: FLASHLIGHT — INOPERATIVE (COCKPIT) · airframe 21,108 hrs · 18,509 cycles

ON FLIGHT 9306 THE CREW REPORTED THE CAPTAIN'S FLASHLIGHT WILL NOT STAY ON. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FLASHLIGHT REF EMB-140 AMM 33-50-16. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BRACKET — BROKEN (COCKPIT) · airframe 20,888 hrs · 18,433 cycles

ON FLIGHT 4287 THE CREW REPORTED THE PILOT'S EMERGENCY FLASHLIGHT CHARGING BRACKET WAS BROKEN. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE PILOT'S EMERGENCY FLASHLIGHT CHARGING BRACKET IAW EMB CMM 25-60-11. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BRACKET — BROKEN (FLASHLIGHT) · airframe 20,619 hrs · 18,185 cycles

DURING MAINTENANCE INSPECTION FOUND THE FLIGHT ATTENDANTS AFT EMERGENCY FLASHLIGHT BRACKET BROKEN. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE FLIGHT ATTENDANTS AFT EMERGENCY FLASHLIGHT BRACKET IAW EMB-140 AMM 33-50-16. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: LAMP — INOPERATIVE (EXTERIOR) · airframe 20,040 hrs · 17,694 cycles

DURING MAINTENANCE BASE VISIT FOUND THE LEFT AFT EXTERIOR EMERGENCY LIGHT INOPERABLE. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE LEFT AFT EXTERIOR EMERGENCY LIGHT BULB IAW EMB 140 EMB AMM 33-50-10. THE OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SILL — CORRODED (FUSELAGE) · corrosion level 2 · airframe 19,003 hrs · 16,793 cycles

DURING MAINTENANCE BASE VISIT INSPECTION FOUND THE SERVICE DOOR CENTER SILL CORRODED. THE AIRCRAFT WAS REMOVED FROM SERVICE. INSTALLED NEW SERVICE DOOR, CENTER SILL IAW EMBRAER SRM 51-40-02 AND ETA-EM-5300-1706. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FRAME — CRACKED (FUSELAGE) · airframe 19,003 hrs · 16,793 cycles

DURING MAINTENANCE BASE VISIT INSPECTION FOUND FRAME 23 CRACKED BETWEEN STRINGER 15 RIGHT AND 16 RIGHT. THE AIRCRAFT WAS REMOVED FROM SERVICE. REPAIRED FRAME 23 BETWEEN STRINGERS 15 RIGHT AND 16 RIGHT IAW EO EM-63MR-1766. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FITTING — GOUGED (AILERON) · airframe 19,003 hrs · 16,793 cycles

DURING MAINTENANCE BASE VISIT INSPECTION FOUND RIGHT AILERON DAMPNER AND PCA FITTINGS DAMAGED. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED RIGHT AILERON DAMPNER AND PCA FITTINGS IAW EO EM-27MR-112. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ELECTRONIC UNIT — INOPERATIVE (LANDING GEAR) · airframe 18,902 hrs · 16,701 cycles

ON FLIGHT 4456 THE CREW REPORTED THAT UPON APPROACH LANDING GEAR INDICATION WENT FROM UP AND LOCK TO DOWN AND LOCK WITH NOSE IN TRANSIT AND NEVER GOT BUMP IN TRANSIT. TAKEOFF FROM JFK ALSO NEVER GOT IN TRANSIT FROM DOWN TO UP. UPON REACHING BOS THE CREW REQUESTED TOWER & GROUND TO VERIFY AIRCRAFT GEAR DOWN AND LOCKED. OTHER INDICATIONS WERE NORMAL. THE CAPTAIN DECLARED AN EMERGENCY AND LANDED WITHOUT INCIDENT. REMOVED AND REPLACED LANDING GEAR ELECTRONIC UNIT IAW EMB AMM 32-32-01. LANDING GEAR EXTENTION AND RETRACTION OPERATIONAL CHECK WAS GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: PRESSURE SWITCH — INOPERATIVE (RUDDER) · airframe 17,871 hrs · 15,855 cycles

ON FLIGHT 2726 DURING THE CLIMB THE CREW REPORTED, RECEIVED A RUDDER SYSTEM 1-2 INOPERABLE MESSAGE. THE CREW RAN THE AIRCRAFT OPERATIONS MANUAL PROCEDURES AND COULD NOT CLEAR. THE CAPTAIN DECLARED AN EMERGENCY AND RETURNED TO DFW. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE SYSTEM 1 & 2 PRESSURE SWITCHES IAW EMB-140 AMM 27-23-04. PERFORMED ADJUSTMENTS AND TEST OF THE RUDDER-ELECTRICAL SYSTEM IAW EMB-140 AMM 27-30-00-700-804-ASTEMJ (2). THE OPERATIONAL CHECK WAS GOOD. NO DEFECT NOTED AT THIS TIME. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNKNOWN — ODOR (CABIN & COCKPIT) · airframe 17,673 hrs · 15,721 cycles

FOR FLIGHT 2737 WHILE AT THE GATE THE CREW REPORTED A HOT ELECTRICAL ODOR IN THE COCKPIT AND CABIN AND A SLIGHT SMOKE HAZE WAS OBSERVED IN THE COCKPIT WHILE THE AUXILIARY POWER UNIT WAS RUNNING. THE AIRCRAFT WAS REMOVED FROM SERVICE. PERFORMED ETN EM 72-034 R4 ENGINE ODOR EVENT TROUBLESHOOTING SUPPLEMENT. NO ELECTRICAL ODOR OR ANY OTHER ODOR WITH VISIBLE SMOKE WAS DETECTED AT THIS TIME. NO PARTS REMOVED OR REPLACED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CARBON SEAL — MALFUNCTIONED (NR 2 ENGINE) · airframe 17,584 hrs · 15,648 cycles

ON FLIGHT 9804 AFTER TAKEOFF THE CREW REPORTED, SMOKE AND OIL ODOR IN COCKPIT. THEREAFTER THE SMOKE WARNING ILLUMINATED. THE CAPTAIN DECLARED AN EMERGENCY AND RETURNED TO DFW. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS REMOVED FROM SERVICE. REMOVED AND REPLACED THE NR 2 ENGINE IAW MTX W/C 71-000-00. THE AIRCRAFT PASSED THE FUNCTIONAL CHECK FLIGHT. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNKNOWN — SMOKE (CABIN) · airframe 17,584 hrs · 15,647 cycles

ON FLIGHT 3297 AFTER TAKEOFF CLIMBING THROUGH 500 FEET THE FLIGHT ATTENDANT REPORTED SMOKE IN THE MID CABIN AREA. SEVERAL SECONDS LATER THE LAVATORY SMOKE WARNING CAME ON. THE CREW ELECTED TO RETURN TO DFW FOR AN IMMEDIATE LANDING. THE LANDING WAS NOT OVERWEIGHT. AFTER PARKING, IT WAS REPORTED THAT A HAZE WAS LEFT IN THE CABIN. THE AIRCRAFT WAS REMOVED FROM SERVICE. A SLIGHT ODOR WAS DETECTED ON PACK 2 ON ENGINE AT IDLE IN FULL HOT AND PACK 2 ON FULL HOT AT IDLE, WORK PERFORMED IAW ETN EM72-034R4. PERFORMED BOROSCOPE OF NR 2 ENGINE INLET FOR EVIDENCE OF OIL LEAKAGE, NO LEAKAGE FOUND IAW RRMM FIM 72-00-00-810-814 AND ETN 72-026. NO PARTS REMOVED OR REPLACED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNKNOWN — SMOKE (CABIN) · airframe 17,494 hrs · 15,569 cycles

ON FLIGHT 3011 DURING LIFT OFF THE CREW REPORTED A LAVATORY SMOKE MESSAGE ON EICAS. PULLED CIRCUIT BREAKER E11, AND THE FLIGHT ATTENDANT PERFORMED SMOKE DETECTOR TEST AND OPERATIONAL TESTS WERE NORMAL. THE FLIGHT ATTENDANT REPORTEDLY DID OBSERVE SMOKE. THE AIRCRAFT LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS REMOVED FROM SERVICE. RESET CIRCUIT BREAKER E11, FLUSHED LAVATORY MOTOR REPEATEDLY, NO DEFECTS NOTED. VISUALLY INSPECTED THE LAVATORY FLORESCENT LIGHTS FOR SIGNS OF OVERHEATING, NO DEFECTS NOTED. RAN AUXILIARY POWER UNIT BLEED ON PACKS, NO ODOR OR SIGNS OF SMOKE. CHECKED ELECTRICAL HYDRAULIC PUMPS OPERATION, NO DEFECTS NOTED. PERFORMED OPERATIONAL CHECK OF LAVATORY SMOKE DETECTION SYSTEM, NO DEFECTS NOTED AT THIS TIME, THE OPERATIONAL CHECK WAS GOOD. NO PARTS REMOVED OR REPLACED. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 16,617 hrs · 14,257 cycles

ON FLIGHT 3614 AFTER TAKEOFF THE CREW REPORTED A SMOKE SMELL. NO VISUAL INDICATIONS WERE REPORTED. THE AIRCRAFT RETURNED AND LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS REMOVED FROM SERVICE. PERFORMED ETN EM 72-034-R4 TWO TIMES ON THE GROUND. COULD NOT DUPLICATE. OPERATION CHECK GOOD AT THIS TIME ON THE GROUND. NO PARTS REMOVED OR REPLACED. PERFORMED FUNCTIONAL CHECK FLIGHT AND FOUND IT TO BE SATISFACTORY THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: ENGINE — ODOR (NR 1) · airframe 10,156 hrs · 8,629 cycles

CREW NOTICED ODOR AND SMOKE IN COCKPIT ON TAKEOFF ROLL. REMOVED AND REPLACED NUMBER ONE ENGINE IAW AMERICAN EAGLE WORK CARD 72-00-00. LEAK AND OPERATIONAL CHECK GOOD, RETURNED AIRCRAFT TO SERVICE.

Part: SILL — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,685 hrs · 8,229 cycles

FOUND BAGGAGE DOOR LOWER SILL FOUND CORRODED. REMOVED AND REPLACED SILL IAW EMB SRM 51-40-02, 51-40-06 AND 51-20-03.

Part: SILL — CORRODED (ZONE 100) · corrosion level 2 · airframe 9,685 hrs · 8,229 cycles

SERVICE DOOR CENTER SILL FOUND CORRODED. BLENDED DAMAGED AREA AND FILLED WITH EA934NA RESIN. FABRICATED AND INSTALLED A DOUBLER IAW EMB SRM 53-21-02. RETURNED AIRCRAFT TO SERVICE.

Part: WIRE — DAMAGED (UNKNOWN) · airframe 9,277 hrs · 7,983 cycles

LOUD THUMPING NOISE UNDER FLIGHT DECK FLOOR. REPAIRED DAMAGED WIRE W102-1232-24 IAW EMB WRM. PERFORMED RETRACTION CHECK WITH NO DEFECTS, RETURNED AIRCRAFT TO SERVICE.

Part: UNKNOWN — UNKNOWN

ORD - FLT 3900 - DURING CLIMB-OUT A SHARP THUMP WAS FELT IN THE FORWARD PORTION OF AIRCRAFT AND SOUNDED LIKE SOMETHING HAD CONTACTED THE AIRCRAFT. ALTITUDE WAS 23,000 FEET AND AIRSPEED 250-260 KNOTS, SOUND AND THUMP WAS FELT AND/OR HEARD AT LEAST TO ROW 6 IN CABIN. EVENT OCCURRED REPETITIVELY, BUT AT NO DISCERNABLE INTERVAL. A BRIEF YAW AND CONCURRENT DROP IN SYSTEM 1 HYDRAULIC PRESSURE WAS NOTED WITH EACH THUMP EVENT, SEEMED LESS FREQUENT AT LOWER AIRSPEED, BUT UNAFFECTED BY AUTO PILOT AND YAW DAMPNER DISENGAGEMENT, LOWER ALTITUDES, OR AIRCRAFT CONFIGURATION.

Part: SKIN — VIBRATES (FUSELAGE)

DURING CLIMB HEARD A LOUD POPPING SOUND AT 16,100 AND 30,500. ON DESCENT INTO CVG, SOUND AGAIN AT ALTITUDES 26,000, 18,000, 13,400, 10900, 6,700, 4,400, AND 3,200. INSPECTED AND FERRIED AIRCRAFT TO SAW FOR REPAIR. REPAIRED OIL CANNING OF SKIN BETWEEN FRAMES 8 AND 9 AND BETWEEN STRINGER 15L AND 17L BY BONDING IN AN INTERNAL DOUBLER IAW EO EM-53-643. RELEASED AIRCRAFT FOR FUNCTIONAL CHECK FLIGHT AND FOUND SATISFACTORY. AIRCRAFT WAS RETURNED TO SERVICE. (M)

Part: CONTACTOR — BROKEN (BATTERY)

DFW - FLT 3831 - RETURN TO FIELD WITH EICAS MESSAGE `ELECTRICAL EMERGENCY ABNORMAL.` AIRCRAFT STAYED ALOFT TO BURN FUEL. LANDED WITHOUT INCIDENT AND UNDER WEIGHT. REPLACED BATTERY CONTACTOR K0015. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BRAKE ASSY — FAILED (LOWER FUSELAGE)

DURING LANDING, ANTI SKID CYCLED ABNORMALLY. AIRCRAFT WOULD NOT STOP IN NORMAL DISTANCES. REPLACED BRAKE CONTROL UNIT. OPERATIONAL CHECK GOOD. AC RETURNED TO SERVICE. (K)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DURING CPCP INSPECTION FOUND; LT OMEGA BEAM IS CORRODED AT FRAME 20. MAINTENANCE REPAIRED LT OMEGA BEAM AT FRAME 20 IAW SRM BY INSTALLING REPAIR DOUBLER. AIRCRAFT RETURNED TO SERVICE. (SW21200505715) (K)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DURING CPCP INSPECTION; FOUND ANGLE SUPPORT AT RT FUSELAGE FLOORBOARD SUPPORT AT FRAME 23 IS CORRODED. REPLACED ANGLE IAW SRM. AIRCRAFT RETURNED TO SERVICE. (SW21200505715) (K)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DURING CPCP INSPECTION FOUND; CENTER OMEGA BEAM CORRODED AT FRAME 25. MAINTENANCE INSTALLED REPAIR DOUBLER AT FRAME 25 IAW SRM. AIRCRAFT RETURNED TO SERVICE. (SW21200505715) (K)

Part: FLOOR SUPPORT — CORRODED (FUSELAGE)

DURING CPCP INSPECTION; FOUND LT OMEGA BEAM CORRODED AT FRAME 25 CROSSBEAM. INSTALLED REPAIR DOUBLER AT FRAME 25 IAW SRM. AIRCRAFT RETURNED TO SERVICE. (SW21200505715) (K)

Part: ODOR — DETECTED (NR 1 A/C PACK)

CREW REPORTED A PACK 1 OVERLOAD MESSAGE INFLIGHT WITH A STRONG ODOR THROUGH REMAINDER OF FLT. PERFORMED GROUND RUNS AND OPERATIONAL CHECK OF THE AIR CONDITIONING SYSTEMS WITH NO DISCREPANCIES NOTED. AIRCRAFT RETURNED TO SERVICE. (M)

Part: BATTERY — DISCHARGED (EMERGENCY LIGHT)

CREW REPORTED THE LAST THREE FLOOR PROXIMITY EMERGENCY LIGHTS TO BE INOPERATIVE. MAINTENANCE CHARGED THE BATTERY AND AN OPERATIONAL CHECK WAS COMPLIED WITH. AICRAFT WAS RETURNED TO SERVICE. (M)

Part: CONTROL UNIT — INOPERATIVE (TE FLAPS)

AMA - FLT 3733 - DURING DESCENT, CREW REPORTED A FLAP FAIL MESSAGE ON EICAS WHEN FLAPS WERE SELECTED TO NINE DEGREES. FLAP INDICATOR SHOWED A YELLOW DASH AND ZERO FLAP MOVEMENT WAS CONFIRMED. AN EMERGENCY WAS DECLARED AND AIRCRAFT WAS LANDED WITH NO FURTHER INCIDENTS. MAINTENANCE REMOVED AND REPLACED THE FLAP ELECTRONIC CONTROL UNIT AND THE FLAP DRIVE MOTOR (P/N 3632501003 S/N 01867) IAW EMB MM. OPERATIONAL CHECKS WERE GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)