Narrative:

On pushback the right generator did not come online. Right gen off light illuminated. Ran QRH procedure. Right generator would not come online. Checked MEL. Requirements for fuel; CSD; history; etc combined with the fact that we were 50 ft from the gate and in the way in the alley. Captain selected return to gate to do MEL requirements. Mechanics were in the process of meling the right generator when we noticed that the APU/ground power configuration was wrong. With APU running; blue gen light on; but with bus switched both in off; right bus was powered to APU. Only left bus was powered by ground and with both bus switches in on. Bulb check ok. Mechanics said it was probably a stuck relay. One mechanic said; 'I'm going to get a hammer.' he returned with a large; orange; hand rubber mallet held down by his leg. I watched from the jetbridge as the mechanics removed the electrical panel behind the captain seat and tapped the two electrical relays with the mallet. I could hear the relays switching. They replaced the panel and declared the aircraft ready for departure. As we prepared for pushback the mechanic handed the logbook to the captain; the door was closed and the agent pulled the jetbridge. The captain read the sign off. It stated that the right generator was reset. Since this is no way described the action and did not include any mention of the stuck relay. The mechanic; now back on the jetbridge; said; 'I can't describe what I did. It was illegal and I would be incriminating myself.' the captain asked; 'what would you have to do; to do it legally?' the mechanic replied that he wouldn't have to change the relay. The captain said; 'then why are we not doing that?' the mechanic replied that the aircraft would go out of service. The captain verified that the correct action for a stuck relay was to change it. The mechanic confirmed this. The captain then said that there didn't seem to be any other course of action. The captain asked me to check the dispatch on a 'plan B' for the flight. Dispatch said there were no other aircraft available and that maintenance needed to 'get on with it;' and fix the aircraft. I asked for an estimated time to change the relay and dispatch said to asked station maintenance. I called station maintenance and they said that they had a flight to handle and other things and that it would; 'take a long; long time' to fix the aircraft. I asked how long and he repeated 'a long; long time.' wanting some type of estimate I said 'we are just coming off a layover and are probably good for ten hours plus the time enroute; can it be fixed in ten hours? The mechanic said 'I don't know; maybe.' I asked if he had the part and he said; 'I don't know; we might?' I am writing this report four hours later and maintenance has not yet been out to the aircraft.

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Original NASA ASRS Text

Title: A MD80's right generator relay stuck so that the APU powered the right bus with ground power selected. A Mechanic used a rubber mallet to reset the relay but would not enter the method of reset into the maintenance logbook. The flight crew refused the aircraft.

Narrative: On pushback the right generator did not come online. R GEN OFF light illuminated. Ran QRH procedure. Right generator would not come online. Checked MEL. Requirements for fuel; CSD; history; etc combined with the fact that we were 50 FT from the gate and in the way in the alley. Captain selected return to gate to do MEL requirements. Mechanics were in the process of MELing the right generator when we noticed that the APU/Ground power configuration was wrong. With APU running; Blue Gen light ON; but with bus switched both in OFF; right bus was powered to APU. Only left bus was powered by GND and with both bus switches in ON. Bulb check OK. Mechanics said it was probably a stuck relay. One Mechanic said; 'I'm going to get a hammer.' He returned with a large; orange; hand rubber mallet held down by his leg. I watched from the jetbridge as the mechanics removed the electrical panel behind the Captain seat and tapped the two electrical relays with the mallet. I could hear the relays switching. They replaced the panel and declared the aircraft ready for departure. As we prepared for pushback the Mechanic handed the logbook to the Captain; the door was closed and the agent pulled the jetbridge. The Captain read the sign off. It stated that the right generator was RESET. Since this is no way described the action and did not include any mention of the stuck relay. The Mechanic; now back on the jetbridge; said; 'I can't describe what I did. It was illegal and I would be incriminating myself.' The Captain asked; 'What would you have to do; to do it legally?' The Mechanic replied that he wouldn't have to change the relay. The Captain said; 'Then why are we not doing that?' The Mechanic replied that the aircraft would go out of service. The Captain verified that the correct action for a stuck relay was to change it. The Mechanic confirmed this. The Captain then said that there didn't seem to be any other course of action. The Captain asked me to check the dispatch on a 'plan B' for the flight. Dispatch said there were no other aircraft available and that Maintenance needed to 'get on with it;' and fix the aircraft. I asked for an estimated time to change the relay and Dispatch said to asked Station Maintenance. I called Station Maintenance and they said that they had a flight to handle and other things and that it would; 'take a long; long time' to fix the aircraft. I asked how long and he repeated 'a long; long time.' Wanting some type of estimate I said 'We are just coming off a layover and are probably good for ten hours plus the time enroute; can it be fixed in ten hours? The Mechanic said 'I don't know; maybe.' I asked if he had the part and he said; 'I don't know; we might?' I am writing this report four hours later and Maintenance has not yet been out to the aircraft.

Data retrieved from NASA's ASRS site as of April 2012 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.