N509DA

Part: LIGHT — INOPERATIVE (CABIN) · airframe 73,816 hrs · 49,618 cycles

IRR- AFT AIRSTAIR OVERHEAD EMERGENCY LITE ASSY INOP. CA- RPLD SAME.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 73,376 hrs · 49,339 cycles

DURING MORNING EMERGENCY LIGHTS TEST, WHEN SELECTED ON, LIGHTS ILLUMINATED THEN WENT DIM AND FINALLY OFF. REPLACED BATTERY PACKS. S/N OFF 73729, 32333, 24513, 10662, 12950, YA8852, 4671, 72867, 3467, 7428, 65522, 9956. MAN P/N OF ALL WAS 9008-3-5A

Part: HEATER — MALFUNCTIONED (CARGO BAY) · airframe 72,789 hrs · 48,950 cycles

FOUND ON ARRIVAL WHILE UNLOADING PASSENGER BAGS AFT BAG BIN WALL OVERHEATED AND DISCOLORED. FOUND THE BAG BIN WALL OVERHEATED. REPLACED HEATER ASSY.

Part: LIGHT — INOPERATIVE (LT OVERWING) · airframe 72,242 hrs · 48,596 cycles

LEFT AFT OVERWING EMERGENCY LIGHT INOP. REPLACED BATTERY PACK, CHECKS GOOD.

Part: FRAME — CRACKED (FUSELAGE) · airframe 72,203 hrs · 48,569 cycles

THE FUSELAGE FRAME AT FS 825.92 WAS FOUND CRACKED AT STR 16L. THE CRACK WAS REMOVED AND REPAIRED PER ERA 334351-14 AT HMV.

Part: SKIN — CRACKED (FUSELAGE) · airframe 72,203 hrs · 48,569 cycles

CRACKS WERE FOUND AT THE UPPER AND LOWER HINGE CUTOUTS OF THE L1 DOOR. THE SKIN AND BONDED DOUBLER WERE CRACKED AT BOTH LOCATIONS AND THE BEAR STRAP WAS CRACKED AT THE UPPER HINGE LOCATION ONLY. THE CRACKS WERE REMOVED AND REPAIRED PER ERA 334353-14 AT HMV.

Part: SKIN — CORRODED (FUSELAGE) · airframe 72,203 hrs · 48,569 cycles

CORROSION DAMAGE WAS FOUND ON THE FUSELAGE SKIN BETWEEN FS 700 AND 720 BETWEEN STRINGERS 28L AND 28R. ERA 334399-14AD AUTHORIZES THE CORROSION TO BE REMOVED AND REPAIRED PER SRM 53-30-3, FIGURE 1 AT HMV.

Part: FRAME — CRACKED (FUSELAGE) · airframe 72,203 hrs · 48,569 cycles

THE WEB OF THE FS 761L FRAME WAS FOUND CRACKED RIGHT AT THE FLOOR LINE. ERA 334347-14 AUTHORIZES THE DAMAGE AT THIS ONE LOCATION TO BE REPAIRED PER EO 4-61904-3AD. THE DAMAGE WAS FOUND AT HMV.

Part: SKIN — WORN (NR 5 SLAT) · airframe 72,203 hrs · 48,569 cycles

UPPER SURFACE IS WORN ON NR 5 SLAT. BURNISHED WEAR AREA, MADE STAINLESS DOUBLER. INSTALLED DOUBLER PER MM 727 57-54-0 FIG 81.

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 72,203 hrs · 48,569 cycles

TEMP REPAIR ON VERTICAL STAB RT SIDE AT FUSELAGE SKIN. REPAIRED AREA PER M/M 55-30-0 FIG 801.

Part: ATTACH FITTING — CORRODED (AIR COND BAY) · airframe 72,203 hrs · 48,569 cycles

FWD AIR CONDITIONER BAY DOOR ATTACH TEE WAS REPAIRED PER MM 53-30-1, DUE TO CORROSION.

Part: ANGLE — WORN (TE FLAP) · airframe 72,203 hrs · 48,569 cycles

AFT CHORD ANGLE WORN AT I/B AFT FLAP TRACK. REPAIRED PER MM-57-52-0 FIG 802, ON S/O A34364.

Part: STIFFENER — CRACKED (FUSELAGE) · airframe 72,203 hrs · 48,569 cycles

THREE CRACKS WERE FOUND IN THE LBL 26.83 VERTICAL STIFFENER ON THE FORWARD SIDE OF THE FS 1183 BULKHEAD. THE CRACKS WERE FOUND BETWEEN WL 243 AND WL 263. EACH CRACK WAS APPROX 2 INCHES LONG. THE STIFFENER WAS REPAIRED PER ERA 334327-14AD AND S/B 727-53-0192. THE DAMAGE WAS FOUND AT HMV.

Part: SKIN — CRACKED (FUSELAGE) · airframe 72,203 hrs · 48,569 cycles

A CRACK WAS FOUND IN THE STR 4L LAP JOINT BETWEEN FS 420 AND FS 440. THE CRACK WAS CUT OUT AND REPAIRED PER ERA 334325-14AD AT HMV.

Part: SPAR — CRACKED (TE FLAP) · airframe 72,203 hrs · 48,569 cycles

AFT SPAR RAIL CRACKED. REPAIRED PER MM 57-52-0 FIG 802, ON S/O A34369.

Part: STRINGER — CRACKED (LT WING) · airframe 72,203 hrs · 48,569 cycles

LT WING TANK TOP SKIN STR 9 CRACKED AT RIB STA 629. REPAIRED PER 57-13-0 PAGE 801 FIG 802.

Part: SKIN — DAMAGED (DAMAGED) · airframe 72,203 hrs · 48,569 cycles

C/W SRM 53-11-0 PERMANENT REPAIR STA 910 LT SIDE. REMOVED 2 HYDRAULIC LINES FOR ACCESS. REMOVED ANGLE PER SRM 53-10-4D STEP 1. REMOVED FASTENERS, CLIP AND FILLER PER SRM 53-10-4D. BEGAN DRILLING PARTS FOR BS 910 PER SRM 53-10-4D. FINISHED DRILLING REPAIR PARTS PER SRM 53-10-4D. OK TO INSTALL. STARTED INSTALLING FASTENERS AT 910. DRILLED UP REPAIR PARTS FOR BS 9135. REPAIR COMPLETED ON NR 1200.

Part: RIB — CRACKED (NR 5 SLAT) · airframe 72,203 hrs · 48,569 cycles

RIB CRACKED AT LWR RADIUS NR 5 SLAT TRACK SUPPORT BOX. REMOVED SLAT TRACK. REMOVED DAMAGE, FABRICATED REPAIR DOUBLER AND FILLER PER MM 57-54-0 FIG 808. OK TO INSTALL DOUBLER AND FILLER. INSTALLED REPAIR PER MM 57-54-0 FIG 808 AND BEGAN INSTALLING SLAT TRACK. COMPLETED INSTALLING SLAT TRACK.

Part: VALVE — INOPERATIVE (LT PACK)

CABIN ALTITUDE CLIMBS AT 1000-300 FPM. DUCT PRESS INDICATES LT 45 RT 22 PSI. SWAPPED BLEED SOURCE AND CYCLED PACK SWITCH, NO EFFECT. FOUND LEFT PACK FWD PACK VALVE INOP. REPLACED SAME. ALSO, REPLACED RT BLEED HI PRESS VALVE. LEAK CKS GOOD.

Part: LIGHT — INOP (AFT AIRSTAIR)

AFT OVERHEAD AIRSTAIR DOOR EMERGENCY LIGHT INOP. REPLACED LIGHT ASSY AND BATTERY'S OPS NOW OK.

Part: SKIN — CRACKED (BS 660-680)

LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 480 & 680 INDICATED A CRACK IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED A SINGLE CRACK BETWEEN FS 660 & 680. THE CRACK WAS ROUTED OUT OF THE SKIN LAP AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER B727 SRM 53-30, FIG 5 AND ER/A 368263-14AD.

Part: ANGLE — CORRODED (NR 2 ENGINE)

ON HUSH-KIT MOD, FOUND RT NR 2 AFT MOUNT CHORD ANGLE CORRODED BEYOND MFG SPECS. REPLACED RT CHORD ANGLE WITH ONE OF NEW MFG.

Part: WIRE — DAMAGED (NR 1 ENGINE)

ON HUSH-KIT MOD, FOUND NUMEROUS LONGITUDINAL SPLITS ON INSULATION OF ALL 3 GEN FEEDER CABLES IN MID PYLON AREA. REPLACED CABLES FROM SPLICES IN LT 48 SEC TO FIREWALL DISCONNECT WITHNEW TYPE CABLES BMS 13-58 D. P/N 012210733 PER BOEING SERVICE LETTER 727-SL-24-026-A.

Part: WIRE — DAMAGED (NR 3 ENGINE)

ON HUSH-KIT MOD, FOUND NUMEROUS LONGITUDINAL SPLITS ON INSULATION OF ALL 3 GEN FEEDER CABLES IN MID PYLON AREA. REPLACED CABLES FROM SPLICES IN RT 48 SEC TO FIREWALL DISCONNECT WITHNEW TYPE CABLES BMS 13-58 DL P/N 012210733 PER BOEING SERVICE LETTER 727-SL-24-026-A.

Part: POWER SUPPLY — INOPERATIVE (ROW 27)

EMERGENCY ESCAPE PATH LIGHTING FROM ROW 27 BACK WAS INOP. FOUND SHORTED WIRE AT FLOOR DISCONNECT. REPAIRED WIRING AND REPLACED BATTERY POWER SUPPLY.

Part: LENS — MISSING (CABIN)

EMERGENCY TRACK LIGHTING 10C MISSING BULB/FROM 27 TO REAR OF ACFT EMERGENCY TRACK LIGHTING INOP. REPAIRED SHORTED WIRE IN FLOOR AND RELAMPED 10C.

Part: SKIN — CORRODED (BS 1050-1080)

SEVERAL EXISTING SKIN DOUBLER REPAIRS WERE LOCATED ON THE BELLY SKIN PANEL BETWEEN STRINGERS 26L & 26R AND BETWEEN FS 1010 AND 1080. THE REPAIRS WERE FOR CORROSION CUTOUTS. TO IMPROVE THE CONDITION OF SKIN AND ELIMINATE ADDITIONAL CORROSION, THE SKIN WAS CUT AT FS 1080 BETWEEN STRINGERS 26L & 26R AND THE SECTION REMOVED TO FS 1010. A NEW SECTION OF SKIN WAS SPLICED IN WITH ALUMINUM SPLICE STRAPS PER ER/A.

Part: BULKHEAD CHORD — CORRODED (BS 950)

FOUND DURING MV2 CORROSION VISIT NRC 221, CORROSION ON LOWER CHORD OF STA 950 BULKHEAD JUST O/B OF STR 29 RT. REPAIRED PER SRM 53-10-9 FIG 12.

Part: WEB — CRACKED (BS 1243)

ROUTED OUT .125 INCH CRACK IN 48 SECTION TORQUE BOX WEB RT SIDE AT LIGHTNING HOLE FWD OF STA 1243 PER M/M 53-11-0 PG 828.

Part: BATTERY PACK — DISCHARGED (CABIN)

LAYOVER FOUND L-2 AND R-2 SLIDE EMERGENCY LIGHTS INOP. REPLACED M983 SLIDE LIGHT BATTERY PACK, OPN CKS OK.

Part: SKIN — CORRODED (BS 490)

THE SKIN WAS FOUND CORRODED BETWEEN FS 480 AND 500 AT STRINGER 28R. THE CORROSION WAS CUTOUT RESULTING IN A 16.75 LONG X 3.25 WIDE CUTOUT. THE CUTOUT WAS REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER, INSTALLED PER PROCEDURES OUTLINED IN B727 SRM 53-30-3, FIG 3 AND DOCUMENTED PER ER/A 365500-14, REV B .

Part: SKIN — CORRODED (BS 1055)

THE FUSELAGE SKIN AT FS 1055 AND STRINGER 29L WAS FOUND WITH CORROSION RESULTING IN A 2 X 3 CUTOUT TO REMOVE THE DAMAGE. THE CUTOUT WAS ADJACENT TO TWO OTHER EXISTING SKIN REPAIRS. ONE OF THE EXISTING REPAIRS WAS REMOVED AND REPLACED WITH A NEW EXTERNAL ALUMINUM DOUBLER TO INCORPORATE PREVIOUS DAMAGES AND TO OVERLAP AN EXISTING REPAIR. ALL REPAIRS WILL BE REMOVED AT NEXT MV AND A NEW SKIN INSTALLED.

Part: SKIN — CORRODED (BS 990)

THE FUSELAGE SKIN AT FS 990 AND STRINGER 28R WAS FOUND CUTOUT TO REMOVE CORROSION OVER A 2 X 3 AREA. THE CUTOUT WAS ADJACENT TO AN EXISTING REPAIR INSTALLED TO REPAIR ANOTHER SKIN CORROSION CUTOUT. THE EXISTING REPAIR WAS REMOVED AND A NEW EXTERNAL ALUMINUM DOUBLER AND TRIPLER WAS INSTALLED TO REPAIR BOTH CUTOUTS. THE REPAIR WAS ACCOMPLISHED PER ER/A 231173-14, REV D.

Part: SPAR — CRACKED (RT ELEVATOR)

THE REAR SPAR OF THE RT ELEVATOR WAS FOUND WITH A .1875 INCH TYPICAL CRACK AT CENTER HINGE BRACKET SHEAR PLATE. THE CRACK WAS STOP DRILLED PER THE REQUIREMENTS OF AD 96-06-05 AND S/B 727-55-0089. THE REPAIR WAS DOCUMENTED PER ER/A 365499-14AD WHICH ESTABLISHES A RE-INSPECT OF THE REAR SPAR WITHIN 1600 CYCLES AND TERMINATING MODIFICATION WITHIN 3200 CYCLES.

Part: WEB — CRACKED (BS 1223)

FOUND ON F-1 LETTER CHECK NRC NR 61, TWO 1 INCH CRACKS, LOWER TORQUE BOX LT WEB UPPER EDGE ABOVE LIGHTENING HOLE STA 1223. INSTALLED DOUBLER PER M/M 53-11-0 PG 832.

Part: STRINGER — CORRODED (BS 995)

STRINGER 29R FS 995 CORRODED BEYOND LIMITS. REPAIRED PER SRM 53-10-11 FIG 3.

Part: BATTERY PACK — DISCHARGED (BS 950)

AFT LT OVERWING EMER SLIDE LIGHT INOP. REPLACED BATT, OPS OK.

Part: SKIN — DENTED (BS 1205)

FUSELAGE SKIN FS 1205-1215, STRINGER 23R AND REPAIR FOR SKIN DENTS. THE FUSELAGE SKIN WAS FOUND WITH TWO DENTS BETWEEN FS 1205 AND 1215 JUST ABOVE STRINGER 23R. THE DENTS WERE CUTOUT AND AN EXTERNAL SHEET METAL DOUBLER WAS INSTALLED PER ER/A 363791-14.

Part: CHARGER — INOPERATIVE (CABIN)

EMERGENCY EXIT LIGHTS INOP. REPLACED BATTERY PACK AND CHARGER.

Part: BATTERIES — DISCHARGED (CABIN)

IRREG EMERGENCY LIGHT ABOVE BOTTOM STEP OF THE AIRSTAIRS INOP. REPLACED BATTERIES.

Part: BATTERY PACK — DISCHARGED (CABIN)

IRREG/ LEFT WING, FWD EXTERIOR LIGHT FOR OVERWING ESCAPE PATH INOP. REPLACED BATTERY PACK M1086.

Part: BATTERY — DISCHARGED (CABIN)

LEFT FWD EXTERIOR EMERGENCY LIGHT FOR OVERWING ESCAPE PATH INOP. REPLACED BATTERY PACK.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY EXIT LIGHTS INOP. CHARGED BATTERY PACKS, TESTS OK.

Part: LIGHT — INOPERATIVE (CABIN)

FOUND ON S/C 21D EMERGENCY TRACK LIGHT INOP AND LIGHT COVER MISSING. RELAMPED 21D, OPS CKS GOOD. INSTALLED LIGHT COVER, CKS OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

EMERGENCY EXIT SIGN LIGHTS OVER RT OVERWING EXITS DID NOT TEST PROPERLY. REPLACED BATTERY PACK, OPN CKS OK.

Part: FRAME — CRACKED (C3 DOOR CUTOUT)

THE UPPER LEG OF THE C3 DOOR CUTOUT FWD FRAME IS CRACKED AT STA 1090, OUTBOARD OF S-27R. REPAIRED PER DAL ER/A 304414-14AD.

Part: SKIN — CORRODED (BS 1040-1080)

FOUND CORROSION ON THE INTERNAL SKIN BETWEEN STA 1040-1080 AT STR 28L. THE CORROSION WAS BLENDED WITH A MAXIMUM DEPTH OF 0.012 INCH BETWEEN STR 28L AND THE OUTBOARD INTERCOSTAL. STR 28L WAS ALSO FOUND CORRODED. SPLICED NEW SECTIONS IN AT STA'S 1040, 1060, AND 1080 PER B727 SRM 53-10-3, FIG. 1. THE SKIN WILL BE REPAIRED PER B727 SRM 53-30-3, FIG. 4.

Part: TRANSVERSE BEAM — CRACKED (BS 1273)

THERE IS A 2.5 INCH CRACK IN THE ANGLE OF BOTH THE TRANSVERSE BEAM AND THE GUSSET OF THE TORQUE BOX AT FS 1273. THESE AREAS OF THE TORQUE BOX ARE THE SUBJECT OF AD 94-07-08, WHICH REQUIRES INSPECTION PER S/B 53-0129. THIS REPLACEMENT DOES NOT TERMINATE THE REPETITIVE INSPECTION REQUIREMENTS. TERMINATING ACTION WILL BE PROVIDED BY EO 4-61071-3.

Part: ACTUATOR BRACKET — CRACKED (NR 5 LE FLAP)

FOUND ON D-1 LETTER CK, .5 INCH CRACK IN NR 5 L/E FLAP ACTUATOR I/B SUPPORT BRACKET. REPAIRED PER MM 57-20-21.

Part: ANGLE — CRACKED (BS 870)

FOUND A 1.5 INCH CRACK AT LOWER END OF RT KEEL BEAM ANGLE, STATION 870. REPLACED ANGLE PER SRM 53-10-9.

Part: HYD LINE — CRACKED (B-HYD SYST)

ON T/O, A-SYS HYD QTY DECREASED TO 1.8 GAL. SHORTLY THEREAFTER THE B-SYS STARTED TO DECREASE AND B-HYD PUMPS WERE TURNED OFF. FOUND THE RIGID HYD LINE FOR THE B-SYS MODULE CRACKED. REPLACED WITH A LIKE LINE, SERVICED SYS AND OPS CK OK.

Part: PACK VALVE — MALFUNCTIONED (RT PACK)

A/C WOULD NOT MAINTAIN PRESSURIZATION WITH SINGLE PACK. OPS CARGO HEAT VALVE CLOSED. REPLACED RT FWD PACK VALVE. REPLACED EQUIPMENT COOLING. SHUT OFF VALVE. PRESSURIZED A/C. CKS NORMAL.

Part: SKIN — CORROSION (BS 950)

CORROSION WAS FOUND IN THE FUSELAGE SKIN APPROXIMATELY 2 INCHES AFT OF STA 950F, AT S-28R. DAMAGE REMOVAL RESULTED IN A 4.125 INCH INBD/OUTBD BY 6.0 INCH FWD/AFT CUT-OUT. THE SKIN IS FABRICATED FROM CLAD 2024-T3 AND WAS MEASURED AT 0.150 INCH THICK. REPAIRED PER DL ERA 302750-14.

Part: STIFFENER — CRACKED (BS 1183)

FOUND ON CV-2 CK, .125 INCH VISABLE CRACK EXTENDING FROM LOWER O/B RADIUS BLOCK AT VERTICAL STIFFENER STA 1183 LBL 8. REPAIRED PER M/M 53-11-0 PAR 9.

Part: FRAME — CRACKED (LT AFT SERV DOOR)

FOUND ON CV-2 CK, LT AFT SERVICE DOOR (S/N 593) HAS A .5 INCH CRACK IN THE UPPER HINGE CUTOUT OF THE FWD FRAME. REPAIRED PER SRM 52-40-2 FIG 4.

Part: MOUNT — CRACKED (NR 2 SLAT ACT)

FOUND ON CV-2 CHECK, NR 2 SLAT ACTUATOR MOUNT CRACKED AT UPPER O/B LOBE. REPAIRED PER M/M 57-42-0 PG 812.

Part: SKIN — CRACKED (NR 5 LE SLAT)

FOUND ON CV2 CHECK, .25 INCH CRACK IN NR 5 SLAT COVE SKIN AT CUTOUT FOR I/B STOP PAD. REPAIRED PER SRM 57-50-3 FIG 23.

Part: SHIM — MIGRATED (TE FLAP)

DURING INSPECTION, A LAMINATED SHIM INSTALLED ON THE LEFT WING, INBD T/E FLAP, INBD TRACK WAS FOUND TO HAVE MIGRATED GREATER THAN THE 0.25 LIMIT SPECIFIED PER DAL SI 4-58662-12AD. IN COMPLIANCE WITH AD 90-07-05, THE MIGRATED SHIM WILL BE RELOCATED AND THE ATTACHMENTS WILL BE RETORQUED.

Part: SLAT — CRACKED (NR 7)

A .375 INCH CRACK EMANATING FROM I/B STOP PAD NR 7 SLAT. FOUND DURING C-1 LETTER CHECK, TPAMM 3-24-95. REPAIRED PER MM 57-54-0 PG 816.

Part: TUBE — CRACKED (NR 2 ENGINE)

DURING CRUISE, B-SYSTEM HYDRAULIC QTY WENT TO 0. FOLLOWED ABNORMAL PROCEDURES LANDED SEA. FOUND LINE FROM NR 2 CASE DRAIN AT TEMP SWITCH CRACKED. INSTALLED TEMPORARY LINE FOR RETURN TO SERVICE THEN SCHEDULED INSTALLATION OF REPLACEMENT LINE.