2025-06 · NASA ASRS report 2256992
B747-400 First Officer reported during climb they got a pack 1 EICAS message and the flight crew decided to return to the airport.
Climbing through 1000 ft on departure we had a Pack 1 EICAS message. We continued on our route and cleaned up. The Captain; who was PM; ran the Pack 1 non normal checklist. Pack 1 had to be turned off with the checklist complete. We then decided to hold at position ZZZZZ so that we could call Dispatch and set up for a return to ZZZ. Since pack 1 had to be shut down and pack 2 was already INOP due to MEL. We knew we would not continue to ZZZ1 with just 1 pack and not enough gas to fly to ZZZ1 at 10;000ft. After confirming with Dispatch that ZZZ was the best option; we diverted to ZZZ. Cause: I believe this air return was avoidable and caused directly by maintenance. The airplane landed in ZZZ with a broken pack 1. Maintenance did ground tests and said everything passed. They then took the actuator out of pack 1 and swapped it with pack 2. Ran the ground tests again and everything passed for both packs. After those tests passed; maintenance put pack 2 on MEL and deactivated it. The plane was then signed off even though nothing was fixed on pack 1 and pack 2 was deactivated for seemingly no reason.Suggestions: We could have removed the cargo from the forward lower lobe and just deactivated Pack 1. That way we could have made it to ZZZ1 with both pack 2 and 3 working normally. Or the flight could have delayed until the reason for pack 1 faulting in flight was found and then fixed.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.
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