N90511

Part: FRAME — DAMAGED (FUSELAGE) · airframe 60,327 hrs · 31,093 cycles

16 EACH IMPROPER FASTENERS INSTALLED IN FRAME STATION 865 BETWEEN LONGERON 9 AND 10 RIGHT (STANDARD FASTENER SHOULD BE 1ST OVER). REMOVED 16 STANDARD LOCK FASTENER, REAMED HOLES AND INSTALLED 1ST OVER LOCK FASTENER PER SRM 51-30-05 AND DRAWING SR09530282 AND EA MD80-53-013448.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 60,327 hrs · 31,093 cycles

OUTER SKIN HOLES AT LONGERON 10 AFT END CLIP AND SKIN HOLES AT FRAME STATION 864 ABOVE LONGERON 10, COUNTERSINKS ARE TOO DEEP (18 HOLES). ACCOMPLISHED BORE/FASTENER REWORK PER EA MD80-53-013440.

Part: FRAME — DAMAGED (FUSELAGE) · airframe 60,327 hrs · 31,093 cycles

AT LONGERON 17 RIGHT AND FRAME 886 LOWER OUTBOARD LOCK FASTENER HAS GAP UNDER HEAD AFTER FASTENER WAS INSTALLED. ACCOMPLISHED FASTENER HOLE REWORK PER SRM 51-30-05 AND EA MD80-53-013438

Part: SKIN — DAMAGED (FUSELAGE) · airframe 60,327 hrs · 31,093 cycles

OUTER SKIN HOLES THROUGH INTERCOSTAL AT LONGERON 10.5 BETWEEN STATIONS 845 TO 864 COUNTERSINKS ARE TOO DEEP (14 HOLES). ACCOMPLISHED REPAIR PER SRM 53-02-00 FIGURE 3 SHEET 1.

Part: FASTENER — IMPROPER PART (FUSELAGE) · airframe 60,327 hrs · 31,093 cycles

REMOVED SPLICE FROM LONGERON 11 RIGHT STATIONS 846 TO 864 DUE TO WRONG FASTENERS. INSTALLED NEW SPLICE DOUBLER WITH CORRECT FASTENERS IAW SRM 53-02-00 AND SRM 51-30-5.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 59,929 hrs · 30,873 cycles

EMERGENCY EQUIPMENT COMPARTMENT INTERCOSTAL AT STATION 180 HAS CRACK INDICATION JUST BELOW FLOOR LINE AND ABOVE AIR CELL COMPUTER. INSTALLED REPAIR DOUBLER PER SRM 53-01-00 FIGURE 2 SHEET 3.

Part: ATTACH BRACKET — CRACKED (RT WING) · airframe 59,929 hrs · 30,873 cycles

RIGHT BUTTE DOOR ATTACH BRACKET BELOW RIGHT INBOARD SPOILER REACTION ARM IS CRACKED. INSTALLED REPAIR DOUBLER AS PER EA MD80-57-011788 AND SRM 57-09-00.

Part: MEMBRANE — DAMAGED (FUSELAGE) · airframe 59,929 hrs · 30,873 cycles

EMERGENCY EQUIPMENT COMPARTMENT CORROSION ON UNDERSIDE OF SUBFLOOR AT STATION 200 APPROXIMATELY 6 TO 8 INCHES INBOARD (MARKED). FABRICATED AND INSTALLED SUBFLOOR DOUBLER FROM STATIONS 160 TO 200 RIGHT AND DOUBLER/OVERLAY FROM STATIONS 160 TO 180 PER AARD 53-20-00-16.

Part: PAN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 59,929 hrs · 30,873 cycles

CORROSION UNDER GALLEY NUMBER 1 DRAIN PAN STATION 155. REMOVED CORROSION AND INSTALLED DOUBLER PER AARD 53-20-00-16.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 59,220 hrs · 30,487 cycles

EMERGENCY LIGHTS ON CONTINUALLY REGARDLESS OF SWITCH POSITION ON THE FIRST HALF OF SEATS 3-15. REPLACED AFT SEAT ROW EMERGENCY BATTERY PACK. OPS CHECKED NORMAL.

Part: COMPRESSOR — STALLED (RT ENGINE) · airframe 58,784 hrs · 30,246 cycles

SAN - CREW REPORTED RIGHT ENGINE COMPRESSOR STALLED TWICE DURING CLIMBOUT. EMERGENCY DECLARED RETURNED SAN LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED RIGHT ENGINE AT SAN ON 02/04/2010. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: DOUBLER — CORRODED (FUSELAGE) · airframe 55,787 hrs · 28,637 cycles

DOUBLER CORRODED AT STATION 1338 BETWEEN LONGERONS 28 RIGHT AND 28 LEFT. INSTALLED A SERVICEABLE DOUBLER.

Part: CUSP WEB — CRACKED (ZONE 100) · airframe 55,787 hrs · 28,637 cycles

RIGHT CUSP CRACKED STATION 802 TO 804. REPLACED SECTION OF CUSP FROM STATION 788 TO 807 PER AARD 53-20-00-16.

Part: FRAME — CRACKED (ZONE 200) · airframe 55,787 hrs · 28,637 cycles

RIGHT OVERWING FRAME AT STATION 864 CRACKED. INSTALLED A SERVICEABLE FRAME PER AARD 51-00-00-012.

Part: FLOORBEAM — CORRODED (ZONE 100) · airframe 55,787 hrs · 28,637 cycles

CORROSION AROUND NUTPLATE CENTER HOLES IN TOP LIP OF FLOORBEAM STATION 1338 AT RIGHT AFT LAVATORY. REPAIRED PER SRM 53-05-00.

Part: DOOR FRAME — CORRODED (ZONE 100) · airframe 55,787 hrs · 28,637 cycles

AFT CARGO DOOR FRAME, CORROSION ON CHORD ANGLE AT FORWARD AND AFT ENDS. INSTALLED REPAIR DOUBLER TO CHORD ANGLE PER SRM 53-10-00-3.

Part: CUSP WEB — CORRODED (ZONE 200) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON LOWER SUFACE OF LEFT CUSP. INSTALLED NEW CUSP SHEET FROM STATION 1250-1309 PER AARD 53-20-00-16.

Part: THRESHOLD — CORRODED (ZONE 100) · airframe 55,787 hrs · 28,637 cycles

FORWARD CARGO DOOR FRAME THRESHOLD PAN CORRODED. INSTALLED THRESHOLD PAN REPAIR PER SRM 53-05-00 FIGURE 44.

Part: FRAME — CRACKED (ZONE 200) · airframe 55,787 hrs · 28,637 cycles

RIGHT OVERWING FRAME AT STATION 886 IS CRACKED. REPLACED FRAME AT STATION 886 PER SB MD80-53A301.

Part: LONGERON — CRACKED (ZONE 200) · airframe 55,787 hrs · 28,637 cycles

LONGERON 4 LEFT CRACKED AT BS 200. INSTALLED SERVICEABLE LONGERON FROM 170 TO 230 PER SRM 53-02-00.

Part: CUSP WEB — CORRODED (ZONE 100) · airframe 55,787 hrs · 28,637 cycles

LEFT CUSP CORRODED STATION 412 TO 495. INSTALLED SERVICEABLE CUSP SHEET PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON RIGHT CUSP STATION 1287. INSTALLED REPAIR PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (ZONE 100) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON LEFT CUSP BS 503. INSTALLED REPAIR PER AARD 53-20-00-16.

Part: ATTACH ANGLE — CRACKED (VERTICAL STAB) · airframe 55,787 hrs · 28,637 cycles

RIGHT ATTACH ANGLE, VERTICAL STABILIZER IS CRACKED. INSTALLED REPAIR ANGLE DOUBLER PER AARD 53-10-00-2, REFERENCE ECO K2221CC.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 55,787 hrs · 28,637 cycles

CUSP MEMBRANE CRACKED AT STATION 218 OUTBOARD OF NUMBER 2 SEAT TRACK. INSTALLED REPAIR PER AARD 53-20-00-16.

Part: CUSP WEB — CORRODED (FUSELAGE) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON CUSP STATION 697 TO 702, LEFT SIDE. INSTALLED REPAIR PER AARD 53-20-00-16.

Part: MOUNT — CORRODED (GIRT BAR) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON AFT SERVICE DOOR, FORWARD GIRT BAR MOUNT. INSTALLED A SERVICEABLE GIRT BAR MOUNT PER SRM 51-01.

Part: MOUNT — CORRODED (NR 2 GALLEY) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON NUMBER 2 GALLEY TIE DOWN MOUNT. INSTALLED A SERVICEABLE GALLEY MOUNT PER SRM 51-01-51-30.

Part: MOUNT — CORRODED (GIRT BAR) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON FORWARD GIRT BAR MOUNT STATION 1145. INSTALLED A SERVICEABLE GIRT BAR MOUNT.

Part: SEAT TRACK — CORRODED (BS 290) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON NUMBER 4 SEAT TRACK STATION 290. INSTALLED SEAT TRACK PLUG AT STATION 290.

Part: DOUBLER — CORRODED (FUSELAGE) · airframe 55,787 hrs · 28,637 cycles

CORROSION ON DIAMOND DOUBLER (DELTA PLATE) STATION 1338 AT LONGERON 30. REMOVED DIAMOND DOUBLER AND INSTALLED A SERVICEABLE DOUBLER PER SRM 51-01.

Part: FORMER — CRACKED (FUSELAGE) · airframe 55,787 hrs · 28,637 cycles

CRACKED FORMER.

Part: VALVE — INOPERATIVE (AIR CONDITIONING)

DFW INFLIGHT T1119/02FEB RECEIVED PRESSURE FLOW INDICATION FOLLOWED BY REPORT FROM FLIGHT ATTENDANTS OF SMELL AND HAZE IN MAIN CABIN AREA. RETURNED TO DFW AND LANDED WITHOUT INCIDENT. REPLACED LEFT PACK REGULATORY SHUT OFF VALVE AND ACCOMPLISHED PACK BURN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

LGA - EMERGENCY LIGHT IN COCKPIT AND ABOVE L1 AND R1 DOOR INOPERATIVE. REPLACED BATTERY PACK AT B523 FOR EMERGENCY LIGHT IN COCKPIT AND ABOVE L1 AND R1 DOOR. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: COFFEEMAKER — SHORTED (GALLEY)

MIA INFLIGHT FUMES WERE SMELLED IN COCKPIT AND FORWARD GALLEY. LIGHT SMOKE DETECTED IN FORWARD GALLEY. EMERGENCY DECLARED AND LANDED AT MSY. NO PASSENGER OR CREW ILLNESS. FOUND COFFEEMAKER WIRE SHORTED AND BURNED ON WATER SENSOR ON NUMBER 1 COFFEEMAKER. REPLACED NUMBER 1 COFFEEMAKER IN FORWARD GALLEY. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: CONTROLLER — MALFUNCTIONED (CABIN PRESSURE)

DFW - FLT 1035 - EN ROUTE EWR-DFW, CABIN ALTITUDE LIGHT ILLUMINATED AT 35,000 FEET. CABIN PRESSURE WAS CLIMBING. STARTED DESCENT TO LOWER ALTITUDE. TRIED STANDBY. THE MANUAL CONTROL CABIN REACHED 14,000 FEET. MASKS WERE DEPLOYED BY CREW. FINALLY GOT CONTROL OF CABIN WITH MANUAL CONTROLLER. CONTINUED THE FLIGHT WHICH WAS ABOUT 1 HOUR AT 18,000 FEET. IT SEEMED THAT NEITHER OF THE PRIMARY NOR STANDBY AUTO PRESSURIZATION WORKED. BOTH PACKS WORKED. LANDED DFW WITHOUT INCIDENT. REPLACED BOTH NR 1 AND 2 CABIN PRESSURE CONTROLLERS. ACCOMPLISHED ALL REQUIRED LEAK AND OPERATIONS CHECKS. NO FAULTS NOTED. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — LOOSE (TAILCONE)

DFW - DURING OVERNIGHT MAINTENANCE, TAILCONE EMERGENCY EXIT LIGHT INOPERATIVE. TIGHTENED WIRE FOR TAILCONE EMERGENCY EXIT LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: CONTACTOR — DIRTY (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, FIRST CLASS CEILING EMERGENCY EXIT LIGHTS INOPERATIVE. CLEANED FIRST CLASS CEILING EMERGENCY EXIT LIGHTS CONTACTS. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: ACTUATOR — MALFUNCTIONED (OUTFLOW VALVE)

FLT 1487 -ORD-LAX- DURING CRUISE FLIGHT AT 31,000 FT, WARNING LIGHTS ILLUM. ALTITUDE 10,500 FT AND CLIMBING. INITIATED EMERGENCY DESCENT, PACKS SHOWED NORMAL FLOW. NO STANDBY OR LOCKOUT LIGHT ILLUM. ARRESTED AT 11,000 FT AND STAYED BELOW 10,000 FT. LEVELED OFF AT 18,000 FT. AFTER APPROX 5 MIN ENTIRE SEQUENCE REOCCURRED. EMERGENCY DESCENT AT 18,000 FT TO 10,000 FT. STANDBY AND LOCKOUT ILLUM. CABIN ALTITUDE AT 10,000 FT BUT ERRATIC. DUMPED CABIN PRESSURE MANUALLY, LIGHTS EXTINGUISHED. CABIN THEN DESCENDED NORMALLY WITH AIRCRAFT DESCENT. LANDED LAS WITHOUT INCIDENT. INSPECTED TAILCONE AREA NO DAMAGE NOTED REPLACED OUTFLOW VALVE ACTUATOR, PERFORMED BITE TEST ON NR 1 AND 2 CABIN PRESSURE CONTROLLERS. (M)

Part: CAP — LOOSE (NR 1 ENGINE)

LAX - FLT 1816 - EN ROUTE LGB-LAX - SHORTLY AFTER TAKEOFF, LEFT ENGINE OIL BEGAN TO DECREASE. RAN OIL QUANTITY DECREASING CHECK LIST. LANDED LAX WITHOUT FURTHER INCIDENT. RE-SECURED LEFT SIDE ENGINE OIL TANK CAP. SERVICED LEFT SIDE ENGINE OIL TANK. REPLACED MAIN OIL FILTER. LEAK CHECKED OK. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: LIGHT — INOPERATIVE (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT ESCAPE FLOOR PATH LIGHTS IN FORWARD SECTION INOPERATIVE. REPLACED EMERGENCY EXIT ESCAPE FLOOR PATH LIGHT STRIP IN FORWARD SECTION. SYSTEM GROUND CHECK NORMAL OPERATION. (M)

Part: WIRE — BROKEN (ROWS 10 AND 19)

DFW - DURING OVERNIGHT MAINTENANCE EMERGENCY, EXIT FLOOR PATH LIGHTS BETWEEN ROW 10 AND ROW 19 INOPERATIVE. REPAIRED WIRE FOR EMERGENCY EXIT FLOOR PATH LIGHTS BETWEEN ROW 10 AND ROW 19. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: WIRE — BROKEN (CABIN)

DFW - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT FLOOR PATH LIGHTS AT SEAT 15D INOPERATIVE. REPAIRED EMERGENCY EXIT FLOOR PATH LIGHT WIRING AT SEAT 15D. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: CONNECTOR — LOOSE (ROW 20)

YYC - DURING OVERNIGHT MAINTENANCE, EMERGENCY EXIT FLOOR PATH LIGHTS AT ROW 20 INOPERATIVE. RE-CONNECTED EMERGENCY EXIT FLOOR PATH LIGHTS AT ROW 20. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: HYD SYSTEM — MALFUNCTIONED (RIGHT)

LAX - FLT 613 - EN ROUTE BUR FROM DFW, RIGHT THRUST REVERSER ACCUMULATOR LIGHTS ILLUMINATED WITH LOSS OF RIGHT HYDRAULIC SYSTEM. AIRCRAFT DIVERTED TO LAX AND ALTERNATE GEAR EXTENSION ACCOMPLISHED. LANDING ACCOMPLISHED WITH GEAR DOORS IN OPEN POSITION. HYDRAULIC SYSTEM CHECKED WITH NO FAULTS NOTED. FUNCTIONAL CHECK FLIGHT ACCOMPLISHED. COULD NOT DUPLICATE PROBLEM. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: WIRE — BROKEN (AFT STAIRWAY)

LGA - DURING OVERNIGHT MAINTENANCE, AFT STAIRWAY EMERGENCY EXIT LIGHTS INOPERATIVE. REPAIRED WIRE BEHIND RELEASE HANDLE FOR AFT STAIRWAY/TAIL CONE. SYSTEM GROUND CHECKED, NORMAL OPERATION. (X)

Part: WIRE — BROKEN (CABIN)

DFW - DURING OVERNIGHT CHECK EMERGENCY EXIT FLOOR PATH LIGHT AT WINDOW ESCAPE AREA INOPERATIVE. SPLICED WIRE AT WINDOW ESCAPE AREA ON EMERGENCY EXIT FLOOR PATH LIGHT STRIP. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: BULB — LOOSE (CABIN)

DFW - DURING OVERNIGHT CHECK, EMERGENCY EXIT FLOOR PATH LIGHT BULB INOPERATIVE. RESEATED EMERGENCY EXIT FLOOR LIGHT BULB. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)

Part: LIGHT — DEFECTIVE (CABIN)

DFW - DURING OVERNIGHT CHECK, FORWARD EMERGENCY EXIT FLOOR PATH LIGHTS INOPERATIVE. REPAIRED FORWARD EMERGENCY EXIT FLOOR PATH LIGHT STRIP. SYSTEM GROUND CHECKED NORMAL OPERATION. (M)