N9302B

Part: WINDOW — CRACKED (COCKPIT) · airframe 67,374 hrs · 33,811 cycles

CREW REPORTED CENTER WINDOW PANE CRACKED DURING CRUISE. FLIGHT RETURNED DFW LANDED WITHOUT INCIDENT. AIRCRAFT REMOVED FROM SERVICE. REPLACED CENTER WINDSHIELD. SYSTEM GROUND CHECK NORMAL OPERATION.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 65,053 hrs · 32,710 cycles

CORROSION AT LOWER AREA FORWARD LAVATORY PAN. REMOVED CORROSION AND INSTALLED INTERNAL DOUBLER IAW EAMD80-53-008917.

Part: DOUBLER — CORRODED (FUSELAGE) · corrosion level 2 · airframe 65,053 hrs · 32,710 cycles

INTERNAL ALUMINUM DOUBLER CORROSION AT AFT LAVATORY PAN. CUT OUT CORROSION AND INSTALLED INTERNAL DOUBLER IAW EA MD80-53-008952.

Part: FRAME — CRACKED (FUSELAGE) · airframe 65,053 hrs · 32,710 cycles

THE 1418 FRAME CRACKED AT LONGERON 2 RIGHT. REPAIRED PER AARD 53-10-00-15.

Part: FRAME — CRACKED (FUSELAGE) · airframe 65,053 hrs · 32,710 cycles

FRAME 1418 CRACKED AT LONGERON 2 LEFT. STOP DRILLED CRACK AND INSTALLED DOUBLER REPAIR PER AARD 53-10-00-15.

Part: SEAL — MISSING (ZONE 500) · airframe 61,586 hrs

AUS INFLIGHT EWR TO DFW - AIRFOIL ANTI ICE SWITCH ON AND UCT PRESSURE AT 30 PSI AND PNEUMATIC X FEED OPEN. THE AIR FOIL ICE PROTECTION PRESSURE ABNORMAL LIGHT REMAINED ON. NO CIRCUIT BREAKERS WERE POPPED. LANDED AUS WITHOUT INCIDENT. FOUND DUCT CONNECTOR MIGRATED ON LEFT WING APPROXIMATELY 12 INCHES INBOARD OF TELESCOPING DUCT. PERI SEAL WAS MISSING. REPLACED SEAL. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ADC — FAILED (NR 1)

TUL INFLIGHT ORD TO SJD - NUMBER ONE AIR DATA COMPUTER FAILED WITH MULTIPLE CAPTAINS INSTRUMENTS INOPERATIVE. LANDED TUL WITHOUT INCIDENT. REPLACED NUMBER 1 AIR DATA COMPUTER. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · 60,893 cycles

SFO EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS WILL NOT TURN OFF. REPLACED BATTERY PACK FOR EMERGENCY LIGHTS AT OVERHEAD FIRST CLASS. SYSTEM GROUND CHECKED NORMAL OPS.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · 60,893 cycles

SFO EMERGENCY LIGHTS AT AFT OVERWING INOPERATIVE. REPLACED BATTERY PACK AT STATION 900 FOR EMERGENCY LIGHT AT AFT OVERWING. SYSTEM GROUND CHECKED NORMAL OPS.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · 60,893 cycles

SFO EMERGENCY LIGHTS AT TAILCONE WILL NOT TURN OFF. REPLACED BATTERY PACK AT AFT LAVATORY FOR EMERGENCY LIGHTS AT TAILCONE. SYSTEM GROUND CHECKED NORMAL OPS.

Part: CONNECTOR — LOOSE (EMERGENCY LIGHT) · 60,684 cycles

SEA EMERGENCY LIGHT AT SEAT 10D INOPERATIVE. SECURED CONNECTOR FOR EMERGENCY LIGHT AT SEAT 10D. SYSTEM GROUND CHECKED NORMAL OPS.

Part: CONTROL VALVE — DISCONNECTED (RT A/C PACK)

LAX - DURING CLIMB UNABLE TO PRESSURIZE AIRCRAFT. RIGHT PACK ON MEL. LEFT RAM AIR SENSE LINE DISCONNECTED. RECONNECTED LEFT RAM AIR SENSE LINE AND DISCONNECTED RIGHT RAM AIR SENSE LINE. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: ANTI-SKID SYS — UNKNOWN (MLG)

ON TAKEOFF ROLL AT 45 KNOTS WHEEL NOT TURNING LIGHT ILLUMINATED. ABORTED TAKEOFF. LEFT OUTBOARD BRACKET 100 DEGREES HOTTER THAN OTHER THREE. REPLACED LEFT INBOARD AND OUTBOARD ANTI SKID VALVES. REPLACED LEFT OUTBOARD BRAKE ANTI SKID TRANSDUCER. REPLACED ANTI SKID CONTROL BOX. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — LOOSE (EMERGENCY LIGHTS)

LGA - EMERGENCY LIGHTS IN AFT CABIN INOPERATIVE. RESECURED BATTERY PACK FOR EMERGENCY LIGHTS IN AFT CABIN. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

ORD - CABIN AND COCKPIT EMERGENCY LIGHTS INOPERATIVE. RECHARGED BATTERIES AND REPLACED BATTERY PACK AT B5 23. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT)

SFO - FOUR EACH EMERGENCY LIGHTS IN OVERHEAD TAIL CONE AND SLIDE EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK B528 FOR FOUR EACH EMERGENCY LIGHTS IN OVERHEAD TAIL CONE AND SLIDE EMERGENCY LIGHTS. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CABIN)

FORWARD CABIN OVERHEAD EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK FOR FORWARD CABIN OVERHEAD EMERGENCY LIGHT. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (CABIN)

PHX - EMERGENCY LIGHTS IN AFT RIGHT LAVATORY INOPERATIVE. REPLACED BATTERY B527 FOR EMERGENCY LIGHTS AT AFT RIGHT HAND LAVATORY. SYSTEM GROUND CHECKED NORMAL OPERATION.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY SIGN) · airframe 48,076 hrs · 24,515 cycles

THE FWD OVERWING EMERGENCY EXIT SIGNS WERE INOPERATIVE. REPLACED THE BATTERIES IN THE BATTERY PACK. CHECK-C 10-1-02 STL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 47,958 hrs · 24,457 cycles

THE FWD OVERWING EMERGENCY LIGHT WAS INOPERATIVE. REPLACED THE BATTERY PACK. CHECK-C 10-1-02 STL. --CLOSED--

Part: LONGERON — DAMAGED (FUSELAGE) · airframe 43,612 hrs · 21,870 cycles

FOUND LONGERON 19L DAMAGED AT APPROX STA 1202. REPLACED LONGERON 19L AT STA 1202 PER SRM 53-02, FIG 18, AND ARA 17424. CHECK-C 10-16-00 STL.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 43,612 hrs · 21,870 cycles

FOUND THE REPAIR ON THE FUSELAGE, BELOW AND AFT OF THE LEFT SIDE NUMBER 2 CABIN DOOR, HAD RIVET CENTERS NOT PROPERLY PULLED AND RIVETS WERE HIGH, STA 1196 BETWEEN LONGERON 19L AND 20L. REMOVED CLASS III REPAIR AND INSTALLED CLASS I REPAIR PER ARA 17423. CHECK-C 10-16-00 STL.

Part: SEPARATOR — CONTAMINATED (AC BAY) · airframe 42,726 hrs · 21,393 cycles

CABIN ATTENDANTS REPORTED SMOKE IN CABIN ON LANDING. BOTH PACKS AND ENGINE AND AIRFOIL ANTI-ICE ON. PERFORMED PACK BURN OUT, RESET PINS ON LT HOT AIR VALVE, AND REPLACED THE WATER SEPARATORS. CHECK-C 10-16-00 STL.

Part: APU — CONTAMINATED (APU BAY) · airframe 42,462 hrs · 21,253 cycles

DURING SHORT FINAL CREW NOTICED SMELL OF SMOKE. AFTER LANDING SMELL WENT AWAY. AFTER EXTENSIVE CHECKS CAUSE NOT DETERMINED. DID CLEAN SOME OIL FROM APU INLET SO APU OIL MAY HAVE BEEN OVERSERVICED. CHECK-C 10-16-00 STL.

Part: CONNECTOR — LOOSE (ROW 7) · airframe 41,650 hrs · 20,819 cycles

A SECTION OF EMERGENCY ESCAPE PATH LIGHTING WAS ILLUMINATED AT ROW 7 AND AFT. RESEATED POWER FEED CONNECTOR AT THE LIGHT STRIP. CHECK-C 10-6-00 STL.

Part: BATTERY — DISCHARGED (ROWS 15 - 22) · airframe 41,651 hrs · 20,820 cycles

THE EGRESS LIGHTS WERE ILLUMINATED AT ROWS 15 TO 22. FOUND BATTERY CONNECTORS LOOSE AT THE BATTERY PACK. SECURED CONTACTS AND REPLACED THE BATTERIES. CHECK-C 10-6-00 STL.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 41,653 hrs · 20,821 cycles

THE EGRESS LIGHTS AT ROW 15 TO 22 ILLUMINATED INTERMITTENTLY DURING FLIGHT. CHANGED THE BATTERY PACK B5-9002. CHECK-C 10-6-00 STL.

Part: OUTFLOW VALVE — STUCK (FUSELAGE) · airframe 40,799 hrs · 20,342 cycles

CREW REPORTED RAPID DECOMPRESSION AT ALTITUDE PRECEEDED BY A LOW AIRFLOW INDICATION. PASSENGER O2 MASKS DEPLOYED AUTOMATICALLY EXCEPT FOR ROW 7 RT. AN UNSCHEDULED LANDING WAS MADE AT DEN. MAINTENANCE FERRIED AIRCRAFT TO MCI FOR CORRECTION. FOUND INSULATION HOLDING THE FORWARD CABIN PRESSURE RELIEF VALVE OPEN. REPLACED THE FORWARD, PN 103636-1, AND AFT PRESSURE RELIEF VALVES. THE PSU AT ROW 7 DEF WAS REPLACED FOR THE DEPLOYMENT MALFUNCTION, PN 5951092-537. SHOP TEST INDICATES THE PSU ELECTRICAL WIRING LEADING TO THE DOOR LATCH APPARENTLY HAS AN OPEN. CHECK-C 10-18-99 MCI. ---CLOSED---

Part: VALVE — MALFUNCTIONED (FUEL SYSTEM) · airframe 40,743 hrs · 20,317 cycles

IN FLIGHT RIGHT MAIN FUEL BEGAN TO DECREASE. MADE UNSCHEDULED LANDING AT ATL. FOUND RT MAIN REFUEL/DEFUEL VALVE PARTIALLY OPEN. CLOSED VALVE. CHECK-C 10-18-99 MCI.

Part: SPLICE — CRACKED (LT MLG DOOR)

DURING CHECK C, LT MLG DOOR HAD A CRACK IN DOUBLER AT AFT EDGE OF DOOR ABOUT 2 AND ONE HALF INCHES LONG. REMOVED AND REPLACED DOUBLER PER MSA 692, SPM 6-70-01 AND SRM 51-01 PAGE 1. CHECK C 9/8/99 MCI.

Part: SKIN — CORRODED (BS 350)

DURING CHECK-C MAINT FOUND FUSELAGE SKIN BULGED AT STA 350 BETWEEN LONGERON 22L AND 23L. ACCOMP HFEC PER NDT MANUAL PART 6, 51-00-03, AND NO CRACK FOUND. REPAIRED PER SRM 53-04, PAGE 35, FIG 12B.

Part: SKIN — DENTED (BS 316)

DURING CHECK-C MAINT FOUND A 4 IN LONG BY 2 IN WIDE BY 0.180 DEEP DENT IN THE FUSELAGE SKIN AT STA 316, LONGERON 22L. REPAIRED PER SRM 53-04, PAGE 35.

Part: SKIN — CORRODED (BS 389)

DURING CHECK-C MAINT FOUND THE FUSELAGE SKIN HAD A BULGE AT STA 389, LONGERON 30 TO 28R. ACCOMP NDT PER 51-00-03, PART 6, AND NO CRACKS FOUND. REPAIRED PER SRM 53-04, PAGE 35.

Part: FLOOR — CORRODED (BS 503)

DURING CHECK-C MAINT, FOUND CORROSION ON FLOOR WEB AT STA 503, LONGERON 18R. REPLACED WEB PER SRM 53-01, FIG 2, FROM STA 503 TO 551.

Part: FLOOR — CORRODED (BS 522&541)

DURING CHECK-C MAINT, FOUND CORROSION ON FLOOR WEB AT STA 522 AND 541, LONGERON 18R. REPLACED WEB PER SRM 53-01, FIG 2, FROM STA 503 TO 551.

Part: SEAT TRACK — CORRODED (BS 200)

DURING CHECK-C MAINT, FOUND CORROSION ON CHAIR TRACK AT STA 200, RBL 22. REPLACED SECTION OF TRACK PER SRM 53-05, FIG 4F.

Part: FLOOR — CORRODED (BS 1094)

DURING CHECK-C MAINT, FOUND CORROSION ON FLOOR WEB AT STA 1094, LONGERON 18R. REPAIRED PER SRM 53-01, FIG 2.

Part: FLOOR — CORRODED (BS 1079)

DURING CHECK-C MAINT, FOUND CORROSION ON FLOOR WEB AT STA 1079, APPROXIMATELY LONGERON 18R. REPAIRED PER SRM 53-01, FIG 2.

Part: FLOOR — CORRODED (BS 1199)

DURING CHECK-C MAINT, FOUND CORROSION ON FLOOR WEB BETWEEN STA 1199 AND 1209. INSTALLED DOUBLER PER SRM 53-01, FIGURE 2.

Part: SEAT TRACK — CORRODED (BS 205)

DURING CHECK-C MAINT, FOUND FLOOR TRACK CORROSION OUT OF LIMITS AT STA 205, RBL 22. REPLACED SECTION OF TRACK PER SRM 53-05, FIG 4F, AT STA 200 TO 266.

Part: SKIN — DENTED (BS 1303)

DURING CHECK-C MAINT, FOUND A 16 INCH BY 7 INCH BY O.156 INCH DEEP DENT IN A PREVIOUS REPAIR AT STA 1303 TO 1310, BETWEEN LONGERON 25R AND 23R. FOUND NO CRACKS PER PART 6, 51-00-03. REPAIRED PER SRM 53-04 SHEET 5 FIG 12B.

Part: SKIN — DENTED (BS 197)

DURING CHECK-C MAINT, FOUND A SKIN DENT .095 INCHES DEEP AND 1.75 INCHES BY 5 INCHES LONG, AT STA 197 BETWEEN LONGERON 30 AND 29R. ACCOMP NDT AND FOUND NO CRACKS. REPAIRED PER SRM 53-04, FIG 12B.

Part: SKIN — DENTED (BS 194)

DURING CHECK-C MAINT, FOUND A SKIN DENT 1.5 INCHES LONG BY 1.75 INCH WIDE BY 0.095 INCH DEEP AT STA 194 BETWEEN LONGERON 30 AND 29R. ACCOMPLISHED NDT AND FOUND NO CRACK. REPAIRED PER SRM 53-04 FIG 12B.

Part: BULKHEAD — DAMAGED (AFT PRESS BLKHD)

FOUND A 7 INCH SLICE AFT OF PRESSURE BULKHEAD IN FUSELAGE SKIN AT LONGERON 9R. SECTION OF LONGERON SPLICED AND DOUBLER INSTALLED PER ARA 16004, AND SRM 63-03, FIG 6, AND SRM 53-01, FIG 4. CHECK-C 10-3-98 MCI.

Part: APU — OIL LEAK (APU COMPT)

STL - FLT 345 - AFTER PARKING IN GATE, AIRCRAFT STARTED FILLING WITH SMOKE. REPLACED APU MFG P/N 381276-1 DUE TO OIL COMING FROM INLET. (M)

Part: GASKET — FAILED (TAIL COMPT)

STL - DURING CLIMB-OUT, TAIL COMPARTMENT OVERHEAT LIGHT ILLUMINATED. REMOVED AND REPLACED THERMOSTAT GASKET, MFG P/N 856411-1. OPERATIONAL CHECK NORMAL.

Part: OIL LINE — FRACTURED (NR 1 ENG)

MCI - DURING CRUISE, SHUT DOWN NR 1 ENGINE DUE TO LOSS OF OIL QUANTITY. FOUND OIL LINE, MFG PN A02923-1, FROM SNUBBER 'T' TO OIL PRESSURE TRANSMITTER, FRACTURED. REPLACED OIL LINE AND SERVICED OIL. ENGINE OPERATION AND LEAK CHECKS NORMAL. (M)

Part: FIRE LOOP B — CHAFED WIRE (RT ENGINE)

MCI - FLT 1159 - DURING CLIMB, RT ENGINE 'B' FIREWARNING LOOP FLICKERED ON, SWITCHED TO 'A' LOOP. AFTER LEVEL-OFF AT CRUISE, 'A' LOOP WARNING CAME ON AND WENT OFF. FOUND LOWER APRON 'A' AND 'B' LOOPS CHAFED. REPLACED 'A' AND 'B' APRON LOOPS, MFG PN 5938323-505 AND PN 5938323-506, AND FIREWARNING SYSTEM OPERATION CHECKED NORMAL. CHECK C-2D - 11-15-95 - MCI. REFERENCE: OPERATOR CONTROL NR 96ZZZX1193.

Part: FIRE LOOP A — CHAFED WIRE (RT ENGINE)

MCI - FLT 1159 - DURING CLIMB, RT ENGINE 'B' FIREWARNING LOOP FLICKERED ON, SWITCHED TO 'A' LOOP. AFTER LEVEL-OFF AT CRUISE, 'A' LOOP WARNING CAME ON AND WENT OFF. FOUND LOWER APRON 'A' AND 'B' LOOPS CHAFED. REPLACED 'A' AND 'B' APRON LOOPS, MFG PN 5938323-505 AND PN 5938323-506, AND FIREWARNING SYSTEM OPERATION CHECKED NORMAL. CHECK C-2D - 11-15-95 - MCI. REFERENCE: OPERATOR CONTROL NR 96ZZZX1194.

Part: FIRE LOOP — CHAFED (RT ENGINE)

MCI - DURING CLIMB RIGHT ENGINE 'B' FIRE WARNING LOOP FLICKERED ON, SWITCHED TO 'A' LOOP. AFTER LEVEL OFF AT CRUISE. 'A' LOOP WARNING CAME ON AND WENT OFF. FOUND LOWER APRON 'A' AND 'B' LOOPS CHAFED. REPLACED 'A' AND 'B' APRON LOOPS, MFG P/N 5938323-505 AND 5938323-506, AND FIRE WARNING SYSTEM OPERATION CHECKED NORMAL.

Part: FIRE LOOP — CHAFED (RT ENGINE)

MCI - DURING CLIMB RIGHT ENGINE 'B' FIRE WARNING LOOP FLICKERED ON, SWITCHED TO 'A' LOOP. AFTER LEVEL OFF AT CRUISE. 'A' LOOP WARNING CAME ON AND WENT OFF. FOUND LOWER APRON 'A' AND 'B' LOOPS CHAFED. REPLACED 'A' AND 'B' APRON LOOPS, MFG P/N 5938323-505 AND 5938323-506, AND FIRE WARNING SYSTEM OPERATION CHECKED NORMAL.

Part: FIRE CNTRL UNIT — MALFUNCTIONED (NR 2 ENGINE)

STL - DURING DESCENT, NR 2 ENGINE, S/N 3231, WAS SHUT DOWN DUE TO FIRE INDICATION LIGHT ILLUMINATION AND FIRE BELL SOUNDED. BOTH FIRE EXTINGUISHER BOTTLES WERE DISCHARGED. REMOVED AND REPLACED NR 2 ENGINE FIRE DETECTION CONTROL UNIT, MFG P/N 892809-0400-02. OPERATIONAL CHECK NORMAL.

Part: TIRE — FAILED (NLG)

PHX - FLT 730 - ON TAKEOFF FOLLOWING A SHARP IMPACT ON FUSELAGE FROM RIGHT NOSE TIRE TREAD FAILURE, BOTH COMPASSES, FLIGHT DIRECTORS, AND ATTITUDE DIRECTOR INDICATORS FAILED. AFTER LANDING, REMOVED AND RE-ESTABLISHED POWER TO ATTITUDE AND HEADING REFERENCE SYSTEMS. ALIGNMENT OF BOTH SYSTEMS WAS NORMAL AND SYSTEMS OPERATIONAL CHECK WAS NORMAL. CHECK C-1D - 4-6-95 - MCI.

Part: BEARING — FAILED (LT ENGINE)

MCI - MADE UNSCHEDULED LANDING ON ACCOUNT THAT THE LEFT ENGINE SHUT DOWN DUE TO POWER LOSS. FOUND METAL IN TAIL PIPE. REPLACED ENGINE S/N 3214. INVESTIGATION INTO LEFT ENGINE SHUT DOWN DUE TO LOSS OF POWER REVEALED NR 3 BEARING MFG P/N 739483 FAILED, DISENGAGING ACCESSORY GEARBOX DRIVE. ENGINE S/N 3214 WAS REPAIRED AND RETURNED TO SERVICE. ENGINE TOTAL TIME 32,672. ENGINE TOTAL TIME 17,193. (W)