N502DA

Part: VALVE — FAILED (FUEL TANK) · airframe 75,534 hrs · 50,900 cycles

FUEL MIGRATION AFTER T/O FROM NBR 3 TANK TO NBR 2 TANK. FOUND NBR 3 DUMP VALVE FAILED OPEN AND NBR 2 FILL VALVE STUCK IN MID POSITION RPLD BOTH VALVES OPS NOW NML

Part: VALVE — STUCK (RT WING) · airframe 75,458 hrs · 50,855 cycles

ATB DUE AFTER T/O HAD LATERAL IMBALANCE. NOTED NR 3 FUEL QTY AT 3500. SHOULD BE 7000. FOUND NR 3 TANK DUMP VALVE FAILED OPEN AND NR 2 VALVE 1/2 OPEN. RPLACED BOTH VALVES PER M/M. LKS CHECKS GOOD. NO FURHTER MIGRATION.

Part: SWITCH — INOPERATIVE (A/C PANEL) · airframe 74,615 hrs · 50,307 cycles

UNABLE TO MAINTAIN CABIN PRESSURE. DESCENDED TO 10,000 FT PRIOR TO REACHING 14,000. CABIN HAD CLIMBED TO 14,000 AND MASKS DROPPED. DIVERTED TO CLE. FOUND LT AC PACK FLOW CONTROL VALVE SWITCH INOP. REPLACED AC CONTROL PANEL AND VALVE.

Part: VALVE — INOPERATIVE (FLOW CONTROL) · airframe 73,767 hrs · 49,738 cycles

CABIN PRESSURE WILL NOT HOLD MANUAL AC W/ OUTFLOW VALVE FULL CLOSED AND CARGO HEAT VALVE CLOSED WOULD NOT CONTROL PRESSURE. REPLACED AVIONICS COOLING AND OUTFLOW VALVE, NO HELP. (S/N 3147) OFF, (S/N 4400) ON, (P/N 254708948). REPLACED BOTH PNEU FLOW CONTROL VALVE ASSYS RAN ENGS PER PFHB A/C PRESSURIZATION SYS CHECK NORMAL PER M/M. NOTE, A/C INSPECTED FOR PRESSURE LEAKAGE AND NO PROBLEMS FOUND A/C RTS.

Part: SWITCH — FAILED (NR 6 LE FLAP) · airframe 73,683 hrs · 49,690 cycles

A/C AIR TURNBACK WITH PR. NR 6 KRUEGER FLAP FAILED TO RETRACT AFTER DEPARTURE. OPERATED FLAPS SEVERAL TIMES, FOUND NR 6 KRUEGER AND ALL FLAPS OPERATE NORMAL. FOUND L/E FLAP INTRANSIT AMBER LIGHT ON FWD PNL AND ON S/O''S PNL ILLUM. REPLACED THE NR 6 KRUEGER FLAP POS SWITCH. OPERATED FLAPS, OPS NORMAL. ALL INDICATIONS NORMAL.

Part: VALVE — STUCK (ACM BAY) · airframe 73,250 hrs · 49,425 cycles

CLIMBING THROUGH FL270 NOTICED CABIN ALTITUDE AT 8000 FT AND CLIMBING. INITIATED LOSS OF PRESSURIZATION PROCEDURES. COULD NOT REGAIN CONTROL OF CABIN. INITIATED EMERGENCY DESCENT. THROUGHOUT PROCEDURES OUTFLOW VALVE INDICATED FULL CLOSED IN ALL POSITIONS (AUTO, STBY, A/C MAN, D/C MAN). EN ROUTE TO CVG AT 10000 FT A PRESSURIZATION SURGE AND CABIN BEGAN DESCENDING AT GREATER THAN 2000 FT/MIN. REPLACED EQUIP COOLING VALVE AND CARGO HEAT VALVE PRESSURIZED A/C CKS OK.

Part: GUSSET — CRACKED (BS 1263)

TORQUE BOX GUSSET CRACKED AT STA 1263 RT BELOW STAIR ACTUATOR PAD. REPLACED PER SRM 53-10-10D FIGURE 803D.

Part: STRUCTURE — DAMAGED (VENTRAL STAIR WE)

THE AFT AIRSTAIR MOUNTING STRUCTURE WAS DAMAGED WHEN THE AIRCRAFT MOVED BACKWARDS WHILE THE AIRSTAIR WAS DOWN AND OPEN. DAMAGED WERE THE LT AND RT SIDE TORQUE BOX WEBS, THE LT AND RT SIDE BEARING DOUBLERS, THE LT AND RT TAIL SKID CAVITY BRACKETS, THE LT AND RT TAIL SKID CAVITY ANGLES AND THE FUSELAGE SKIN BELOW THE HIGNE POINTS. REPAIRED PER ERA 333311-14, REV C.

Part: SKIN — GOUGED (BS 306)

GOUGE FOUND IN THE FUSELAGE SKIN JUST ABOVE THE THE L1 DOOR LOWER HINGE CUTOUT. REPAIRED PER ERA 333323-14, REV A.

Part: STAIRS — DAMAGED (TAIL)

COMPLY WITH SRM 53-30-3 PERMANENT REPAIR. TIME LTD DBLR AT VENTRAL STAIR CUTOUT. REPAIRED PER ERA 333311-14. REF NR 183 AND NR 741. FABRICATED REPAIR PIECES PER PER ERA 333311-14. OK TO INSTALL. INSTALLED REPAIR PER ERA 333311-14.

Part: SKIN — CRACKED (NR 3 TE MIDFLAP)

DURING SHOP INSPECTION, THE COVE SKIN WAS FOUND CRACKED 32 INCHES FROM I/B END. THE DAMAGE WAS REMOVED AND A DOUBLER INSTALLED PER MM 57-52-0, FIG 809.

Part: SKIN — DENTED (BS 1090)

A DENT IN THE SKIN AT BS 1090 WAS FOUND BETWEEN S29R AND S29L. DAMAGE REMOVAL REQUIRED A SKIN CUTOUT OF APPROX 5 BY 11. REPAIRED PER ERA 333290-14.

Part: DOUBLER — DAMAGED (LE FLAPS)

REMOVED DOUBLER, FABRICATED NEW DOUBLER PER M/M 57-54-00 FIG 809.

Part: FITTING — CORRODED (MLG DOOR HINGE)

NR 4 INB'D FLAP TRACK TYP CORROSION FOUND AT MLG BEAM ATTACH PAD, WEAR AT FWD ATTACH LUGS AND WEAR AT FWD MLG DOOR HINGE FITTING HOLES. MLG BEAM ATTACH PAD MACHINED. FWD ATTACH LUGS OVERSIZED AND BUSHED. FWD MLG DOOR HINGE FITTING HOLES REWORKED PER SB 727-57-0180, REV 1.

Part: SKIN — CRACKED (BS 710-720)

DURING INSPECTIONS PER SI 4-74176-12AD, A CRACK INDICATION WAS FOUND IN THE S4R LAP SPLICE BETWEEN BS 700-720. THE CRACK WAS FOUND IN FASTENER ROW 4 AS ID'D IN FIGURE 6 OF THE SU BJECT SI. REPAIRED PER ERA 333284-14AD.

Part: SKIN — CRACKED (BS 450-460)

DURING INSPECTIONS PER SI 4-74176-12AD, A CRACK INDICATION WAS FOUND IN THE S4R LAP SPLICE BETWEEN BS 440-460. THE CRACK WAS FOUND IN FASTENER ROW 12 AS ID'D IN FIGURE 6 OF THE SUBJECT SI. REPAIRED PER ERA 333280-14AD.

Part: ANGLE — CRACKED (NR 3 TE MIDFLAP)

DURING SHOP INSPECTION, THE AFT LOWER CHORD ANGLE WAS FOUND CRACKED 36 INCHES FROM I/B END. THE DAMAGE WAS REPAIRED PER MM 57-52-0, FIG 802 BY INSTALLING A DOUBLER.

Part: SKIN — CRACKED (NR 3 TE MIDFLAP)

DURING SHOP INSPECTION, THE COVE SKIN WAS FOUND CRACKED 36 INCHES FROM I/B END OF FLAP. THE CRACK WAS REPAIRED BY REMOVING THE DAMAGE AND INSTALLING A DOUBLER PER MM 57-52-0, FIG 809.

Part: SKIN — CRACKED (BS 550-560)

DURING INSPECTIONS PER SI 4-74176-12AD, A CRACK INDICATION WAS FOUND IN THE S26R LAP SPLICE BETWEEN BS 540-560. THE CRACK WAS FOUND IN FASTENER ROW 9 AS ID'D IN FIGURE 6 OF THE SUBJECT SI. REPAIRED PER ERA 333288-14AD.

Part: SKIN — CRACKED (BS 1070-1090)

DURING INSPECTIONS PER SI 4-74176-12AD, A CRACK INDICATION WAS FOUND IN THE S4R LAP SPLICE BETWEEN BS 1070-1090. THE CRACK WAS FOUND IN FASTENER ROW 4 AS ID'D IN FIGURE 6 OF THE SUBJECT SI. REPAIRED PER ERA 333282-14AD.

Part: SKIN — CRACKED (BS 610-620)

DURING INSPECTIONS PER SI 4-74176-12AD, A CRACK INDICATION WAS FOUND IN THE S4R LAP SPLICE BETWEEN BS 600-620. THE CRACK WAS FOUND IN FASTENER ROW 10 AS ID'D IN FIGURE 6 OF THE SUBJECT SI. REPAIRED PER ERA 333281-14AD.

Part: SKIN — CRACKED (LT TE FLAP)

T/E WEDGE LWR SKIN CRACKED 36 FROM I/B END. REPAIRED PER M/M 57-52-0 FIG 809.

Part: SPAR — DAMAGED (LT TE FLAP)

LWR AFT SPAR CAP PANEL ATTACH HOLE ELONGATED 55 FROM I/B END. REPAIRED PER M/M 57-52-0 FIG 802 NON SHOP ORDER 791453.

Part: SPAR — CRACKED (LT TE MID FLAP)

NR 2 MID FLAP AFT LWR SPAR CAP, REPAIR CRACKED 36 FROM I /B END. REPAIRED PER M/M 57-52-0 FIG 802.

Part: SPAR — MISDRILLED (NR 2 TE MIDFLAP)

NR 2 MIDFLAP / UPPER SPAR CHORD / WBL 124.2: ALT FASTENER INSTALLATION - AD 94-07-08. DURING ACCOMPLISHMENT OF EO 4-58708-3AD, MTC WAS UNABLE TO INSTALL THE REQUIRED HI-LOK COLLAR DUE TO INTERFERENCE WITH INSIDE SPAR RADIUS. AUTHORIZED INSTALLATION USING MINI-NUT AND RADIUS BLOCK.

Part: RIB — CRACKED (NR 4 LE SLAT)

RIB CRACKED INSIDE NR 4 L/E SLAT INBD SIDE OF ACTUATOR ATTACH POINT. REMOVED DAMAGED AREA FABRICATED DOUBLER AND REPLACEMENT CLIP PER M/M 57-54-00 FIG 809. TREAT AND PAINTED. OK TO INSTALL. REPAIRED CRACKED RIB MM 57-40-00 FIG 809.

Part: STRINGER — CRACKED (VERTICAL STAB)

A 1 INCH CRACK AT BOLT TO EDGE ON STR 8 FIN STA 157.2 RT SIDE. REPAIRED PER M/M 55-30-0 FIG 803.

Part: LIGHT — INOPERATIVE (CABIN)

AFT EMERGENCY EXIT LIGHT INOP. REPLACED LIGHT ASSY AND BATTERIES.

Part: LIGHT — INOPERATIVE (CABIN)

AFT AIRSTAIR EMER LIGHT INOP. REPLACED BATTERY.

Part: BATTERY — DISCHARGED (CABIN)

FOUND L-2 UPPER EMERG LIGHT INOP. REPLACED BATTERY. FOUND L-2 LOWER EMERG LIGHT INOP. REPAIRED GND WIRE.

Part: SKIN — CRACKED (AIRSTAIR CUTOUT)

FOUND DURING F-1 LETTER CHECK, .25 INCH CRACK AT LT CORNER OF AFT AIRSTAIR CUTOUT. REPAIRED PER M/M 53-30-0.

Part: STIFFENER — CRACKED (LT FRONT SPAR)

A .75 INCH CRACK NR 3 SLAT O/B TRACK VERTICAL STIFFENER ON WING FRONT SPAR. REPLACED ANGLE PER M/M 57-20-21 NR 14.

Part: SKIN — DAMAGED (RT ELEVATOR)

FOUND DURING F-1 LETTER CHECK, RIGHT ELEVATOR LWR SKIN DAMAGED O/B OF TAB CUTOUT. ALSO, RIGHT ELEVATOR REAR SPAR LWR LEG DAMAGED O/B OF TAB CUTOUT. SKIN REPAIRED PER 55-20-3 FIG 4. SPAR REPAIRED PER SRM 51-40-3 FIG 1.

Part: HOSE — RUPTURED (LT MLG DOOR ACT)

A-SYS HYD LOST QTY AND PRESS AFTER GEAR AND FLAP EXTENSION B-SYS OK. FOUND PRESS HOSE AT LT GEAR DOOR ACT LEAKING. REPLACED HOSE, REPLACED ENG 1 AND 2 CASE DRAIN FILTERS. RAN ENGINES, PUMPS CK NORMAL.

Part: SKIN — CORROSION (BS 950)

CORROSION WAS FOUND ON THE SKIN AND STRINGER BELOW THE C2 DOOR BETWEEN STA 950-F-970 AT STR 28R. THE CORROSION IN THE SKIN WAS TRIMMED OUT LEAVING A CUTOUT MEASURING 12.75 BY .75 STRINGER 28R WAS CUT AT STA 950F PLUS 10 AND STA 980 TO ORDER TO REMOVE CORROSION. THE REPAIR SPLICED IN A NEW STRINGER SECTION.

Part: LIGHT — INOPERATIVE (CABIN)

LT AFT EMER LT INOP. REPLACED LT ASSY, CKS OK.

Part: LIGHT — INOPERATIVE (CABIN)

MID CABIN OVERHEAD EMERGENCY EXIT LIGHT INOP. REPLACED LIGHT ASSY. LIGHT FUNCTIONS NORMAL. TRANS BATTERY INSPECTION STICKER TO NEW LIGHT ASSY.

Part: LENS — MISSING (CABIN)

ONE EMERGENCY EXIT RED TRACK LIGHT INOP. LENS MISSING NEAR AFT GALLEY. INSTALLED NEW LENS, OPN CKS NORMAL.

Part: BALLAST — SHORTED (CABIN)

SMOKE AND FUMES COMING FROM FWD LAV. SECURED WATER HEATER AND FLUSH MOTOR, SMOKE AND FUMES IMMEDIATELY DISSIPATED. AIRCRAFT WAS ON APPROACH INTO PHX. MAINTENANCE ACTION TROUBLESHOOTING FOUND FWD ENTRY LIGHT BRIGHT C/B POPPED AND WOULD NOT RESET. FOUND BAD ENTRY LIGHT BALLAST. REPLACED BALLAST, OPERATIONAL CHECKS OK.

Part: CONNECTORS — DIRTY (L1 DOR)

ON LAYOVER, FOUND L-1 DOOR OVERHEAD EMERGENCY EXIT SIGN INOP. CLEANED BATTERY CONNECTORS AND LIGHT ASSY CONTACTS, ALL OPS NORMAL.

Part: LIGHT — INOPERATIVE (CABIN)

AFT AIRSTAIR EMERGENCY EXIT LIGHT INOP. FWD TO MCO AND PLAC PER MEL 33-00-16, AFTER CHANGING BATTERY AND LIGHT BULBS.

Part: PRESS BLKHD — CRACKED (BS 289)

ADDITIONAL CRACKING OF .75 WAS FOUND ON PRESSURED DECK AT FS 289 RBL4.5. REPAIRS ACCOMPLISHED PER DL ERA 258994-14 REV A.

Part: VERTICAL WEB — CRACKED (BS 1214)

FOUND DURING D-2 LETTER CHECK, TWO .5 INCH CRACKS IN LT LOWER TORQUE BOX VERTICAL WEB UPPER END, APPROX STA 1214. REPAIRED PER SRM 53-11-0.

Part: SNAP RING — FAILED (L 1 DOOR)

FWD 1L DOOR WOULD NOT OPEN AT GATE, REPEATED ATTEMPS DOOR FINALLY OPENED. FOUND SNAP RING MISSING ON UPPER ARM OF DOOR GUIDE PIN. INSTALLED SNAP RING AND OPERATION NORMAL.

Part: BATTERY — DISCHARGED (AFT AIRSTAIR)

AFT AIRSTAIR EMERGENCY LIGHT INOP. REPLACED BATTERIES. CKS NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

ON LAYOVER, FOUND AFT AIRSTAIR EMERGENCY LIGHT INOP. REPLACED BATTERY PACK OPERATION NORMAL.

Part: SKIN — GOUGED (FS 379)

DURING INSPECTION, AN APPROXIMATE 4.25 BY 3.25 CUTOUT WAS MADE IN THE SKIN TO REMOVE DAMAGE FROM GOUGE. MAINTAINING SCHEDULE OF THE A/C, A TIME LIMITED REPAIR WILL BE INSTALLED AND THE PERM REPAIR WILL BE ACCOMPLISHED AT NEXT HMV IN ACCORDANCE WITH B727 SRM 53-30-3, FIG 1.

Part: RIB — CRACKED (NR 7 LE SLAT)

UPON INSPECTION, A CRACK WAS FOUND IN THE LOWER FWD CORNER OF NR 10 RIB. REPAIRED PER MM 57-54-0, FOR NR 7 L/E SLAT.

Part: RIB — CRACKED (NR 7 LE SLAT)

UPON INSPECTION, RIB NR 11 FOUND CRACKED IN LWR FWD CORNER. REPAIRED PER MM 57-54-0, FOR NR 7 L/E SLAT.

Part: HEAT SHIELD — CRACKED (NR 7 LE SLAT)

UPON INSPECTION, A CRACK WAS FOUND IN HEAT SHIELD BETWEEN RIBS 11 AND 12, AND BETWEEN RIBS 12 AND 13. REPAIRED PER MM 57-54-0, FOR NR 7 L/E SLAT.

Part: RIB — CRACKED (NR 7 LE SLAT)

UPON INSPECTION BY MAINT. RIB NR 11 IN NR 7 L/E SLAT WAS FOUND CRACKED. REPAIRED PER MM 57-54-0.

Part: RIB — CRACKS (NR 7 SLAT)

FOUND CRACKS ON RIBS NR 13 AND NR 14 DURING SHOP INSPECTION OF NR 7 L/E SLAT. REPAIRED PER SRM 57-54-00.

Part: SKIN — CORRODED (BS 1010)

FOUND ON CV2 CHECK, CORROSION ON SKIN FOUND UPON REMOVAL OF STR SPLICE ON STA 1010 REF N/R 127. REPAIRED SKIN PER SRM 53-30-3 FIG 3A AND ID PER PS 900-5-1 FIG 4.

Part: GUSSET — CRACKED (FS 1273)

THE RT TORQUE BOX HORIZONTAL BEAM GUSSET AT FS 1273 WAS FOUND CRACKED. REPAIRS WERE ACCOMPLISHED PER S/B 53-0129.

Part: FLOORBEAM — CORRODED (BS 1166)

FOUND ON CV2 CHECK, FLOORBEAM STA 1166 LBL 47 WITH CORROSION DAMAGE. REPAIRED PER SRM 53-10-8.

Part: STRINGER — CORRODED (BS 1148/1166)

FOUND ON CV2 CHECK, CORROSION ON TOP OF STR 30 BETWEEN STA 1148 AND 1166 BL 0. REPAIRED AS PER SRM 53-10-3 AND ID PER PS 900-5-1 FIG 4.

Part: INTERCOASTAL — CORRODED (BS 680)

FOUND ON CV2 CHECK, CORROSION ON LWR LEG OF INTERCOSTAL AFT OF STA 680 I/B OF STR 26R. REPAIRED PER SRM 51-40-3.

Part: CLIP — CORRODED (FS 500)

FOUND ON CV2 CHECK, CORROSION ON SKIN CLIP AT STA 500 BETWEEN STR 28R AND 27R. REPAIRED PER M/M 53-11-0.

Part: FORMER — CRACKED (FS 480)

FOUND ON CV2 CHECK, 1 INCH CRACK ON STATION 480 FORMER ABOVE STRINGER 27L. REPAIRED PER SRM 51-40-3.

Part: CLIP — CORRODED (FS 500)

FOUND ON CV2 CHECK, CORROSION ON AFT SIDE OF FORMER AT STATION 500, JUST INBD OF 27R. REPAIRED AS PER M/M 53-11-0 AND CHECKED LIMIT PER SRM 53-10-1.

Part: CLIP — CORRODED (FS 1030)

FOUND ON CV2 CHECK, CORROSION AT SKIN CLIP STA 1030 BETWEEN S29R AND 28R. REPAIRED PER M/M 53-11-0 AND IDENT PR 8.7 900-5-1 FIG 4.

Part: SEAT TRACK — CORRODED (FS 344)

FOUND ON CV2 CHECK, CORROSION ON L/T INBD SEAT TRACK JUST AFT OF STA 344. REPAIRED PER M/M 53-20-11.

Part: SEAT TRACK — CORRODED (FS 340)

FOUND ON CV2 CHECK, CORROSION ON L/T OUTBD SEAT TRACK JUST AFT OF STA 344. REPAIRED PER M/M 53-20-11.

Part: STIFFENER — CRACKED (FS 1400)

FOUND ON CV2 CHECK, CRACK IN STIFFENER STA 1400 OVERHEAD OF NR 2 ENGINE COMPARTMENT SECTION. REPAIRED PER SRM 54-10-3 AND IDENTIFIED PER PS 900-5-1 FIG 4.

Part: BRACKET — CRACKED (NR 6 LE SLAT)

FOUND ON CV2 CK, .5 INCH VISIBLE CRACK ON NR 6 L/E FLAP ACTUATOR O/B ATTACH BRACKET IN LOWER RADIUS. REPAIRED PER M/M 57-20-21 PAR 12.

Part: FOREFLAP — CRACKED (NR 4 TE FLAP)

FOUND ON CV2 CHECK, 1 INCH CRACK ON NR 4 FOREFLAP ABOVE NR 7 FLAPTRACK. REPAIRED AS PER SRM 57-50-4.

Part: FLANGE — CRACKED (BS 1342.4)

FOUND ON CV2 CHECK, CRACKED FLANGE STA 1342.4 WHERE LOWER EDGE OF FWD COWLS MATES WITH FUSELAGE AT PREVIOUS REPAIR (6 O'CLOCK POSITION). REPAIRED PER M/M 53-11-0 PG 801 IDENTIFY REPAIR AS PERMANENT REPAIR PER PS 900-5-1 NR 4.

Part: RIB — CRACKED (NR 5 SLAT)

FOUND ON CV2 CHECK, (1) .25 INCH VISIBLE CRACK ON NR 5 SLAT L/E RIB O/B OF ACTUATOR ROD. (2) 2.0625 INCH CRACKS ON NR 5 SLAT L/E RIB I/B OF ACTUATOR ROD. REPAIRED PER M/M 57-54-0 PAR 3.

Part: FOREFLAP — CRACKED (NR 3 TE FLAP)

FOUND ON CV2 CHECK, 1 INCH CRACK ON NR 3 FOREFLAP ABOVE NR 6 FLAPTRACK CARRIAGE. REPAIRED AS PER SRM 57-50-4.

Part: NOSE RIB — CRACKED (NR 7 SLAT)

FOUND DURING C-2 LETTER CHECK, NR 7 SLAT I/B ACTUATOR NOSE RIB CRACKED .1250 INCH. REPAIRED PER B727 MM 57-54-0 PG 803.

Part: SKIN — PUNCTURE (NR 1 ENG COWL)

DURING SHOP INSPECTION, NR 1 ENGINE NOSE COWL OUTER SKIN WAS FOUND WITH PUNCTURE DAMAGE AT 7 O'CLOCK POSITION. REPAIRED PER SRM 54-30-3.