N520DA

Part: WIRE — SHORTED (CABIN) · airframe 67,776 hrs · 51,220 cycles

FLOOR MOUNTED EMERGENCY LIGHT INOP IN FIRST CLASS. FOUND WIRE W1026-9006 SHORTED TO GROUND BETWEEN C/P D9059P AND DISCONNECT D9062. REPLACED WIRE. REPLACED POWER SUPPLY M9026 AND BATTERY PACK. SYSTEM TESTS GOOD.

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 66,687 hrs · 50,501 cycles

ON T/O AT 40 KTS NR 1 ENG APPEARED TO HAVE A COMPRESSOR STALL. EPR DROPPED SUDDENLY FROM 1.94 TO BELOW 1.7. AUTO PACK TRIP OCCURRED AND T/O WAS DISCONTINUED. RAN ENGINE TESTS PER PREFLIGHT HANDBOOK. UNABLE TO DUPLICATE.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 66,127 hrs · 50,129 cycles

LT OVERWING EMERG. LIGHTS INOP. RELAMPED LIGHTS.

Part: LINE — LEAKING (LT MLG DOOR) · airframe 65,160 hrs · 49,472 cycles

LOST SYS A HYD QTY AND PRESS DURING GEAR RETRACTION - FOUND LEFT GEAR DOOR ACTUATOR PRESSURE LINE LEAKING - REPLACED LINE

Part: BATTERY PACK — INOPERATIVE (R1 EXIT LIGHT) · airframe 64,875 hrs · 49,267 cycles

R1 EMERGENCY EXIT LIGHT INOP. REMOVED AND REPLACED LIGHT ASSY/ BATTERY PACK P/N 334701743, S/N OFF 4833, S/N ON 8676.

Part: LIGHT — DAMAGED (ROW 11) · airframe 64,843 hrs · 49,243 cycles

FOUND SEAT MOUNTED EMERGENCY LIGHT DAMAGED AND INOP AT 11D. REPLACED LIGHT ASSY.

Part: STRUCTURE — CORRODED (FUSELAGE) · airframe 63,748 hrs · 48,491 cycles

DURING ACCOMPLISHMENT OF SI 4-58560-12AD REINSP, FASTENER HOLE CORROSION WAS DISCOVERED IN THE UPPER, FWD HOLE ON BOTH THE LT AND RT SIDES OF THE HOLES SUBJECT TO THE SI INSP. HOLES WERE OVERSIZED TO 0.433 DIAM. W/ .0312 IN CUT. DAMAGE REPAIRED PER ERA 377433-14AD.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 63,748 hrs · 48,491 cycles

FOUND DURING MV-4 CORROSION VISIT NRC 156, 1 INCH CRACK IN LT AFT SERVICE DOOR OPENING FWD UPPER FRAME AT UPPER STOP. REPAIRED PER M/M 53-13-0 FIG 804.

Part: ANGLE — CRACKED (NR 4 SLAT) · airframe 63,748 hrs · 48,491 cycles

NR 4 SLAT ANGLE CRACKED AT I/B STOP PAD. INSTALLED REPAIR PER M/M 57-54-0 PG 816.

Part: ENGINE — STALLED (NR 2)

COMPRESSOR STALL NR 2 ENG ON T/O AT 300 FT. THREE LOUD POPS/BANGS, NO FUEL HEAT, NO NR 2 BLEED. IMMEDIATE RETURN FOR VISUAL LANDING. (INITIAL STALL WITH STEADY THROTTLE SETTING, LAST AT REDUCED THROTTLE SETTING). REPLACED C1 AND C2 FAN ASSYS.

Part: SKIN — CRACKED (BS 360-481)

FUSELAGE SKIN FS 360-481, STRG 4L SKIN LAP SPLICE, CRACK REPAIR. LFEC INSPECTION OF THE STRINGER 4L SKIN LAP SPLICE BETWEEN FS 360 AND 481 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN PANEL. INTERNAL HFEC INSPECTION CONFIRMED 14 CRACKS ALONG THE PANEL LENGTH. THE ENTIRE SKIN LAP SPLICE WAS CUT OUT AND REPLACED WITH AND EXTERNAL ALUMINUM DOUBLER PER ER/A 368137-14AD.

Part: SKIN — CRACKED (BS 380-400)

INTERNAL HFEC INSPECTION OF THE LOWER FASTENER ROW OF THE LOWER SKIN PANEL OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 & FS 481, CONFIRMED TWO CRACKS BETWEEN FS 380 & 480. THE CRACKED AREA WAS ROUTED OUT OF THE SKIN LAP AND REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER PER B727 SRM 53-30-3, FIG 5 AND ER/A 368132-14AD.

Part: FRAME — SEVERED (BS 1090)

C3 DOOR FWD FRAME AT BS 1090 WAS FOUND SEVERED ABOVE S27R. A PARTIAL FRAME REPLACEMENT WAS MADE. NO SKIN CRACKING REPORTED. REPAIRED PER ERA 367579-14AD.

Part: RIB — CRACKED (NR 8 LE SLAT)

A 1 INCH CRACK IN L/E OF NOSE RIB NR 8 SLAT I/B SIDE OF O/B TRACK. REPAIRED PER M/M 57-54-0 PG 813.

Part: BATTERY PACK — WEAK (CABIN)

ON PREFLIGHT, CREW REPORTED AFT EMER EXIT LIGHT FLASHING. REPLACED BATT PACK, OPER OK.

Part: RIB — CRACKED (NR 4 LE SLAT)

FOUND ON C1 LETTER CK, NR 4 SLAT L/E NOSE RIB I/B SIDE OF ACTUATOR CRACKED .5 INCH. REPAIRED PER MM 57-54-0.

Part: ANGLE — CRACKED (BS 913)

FOUND ON C1 LETTER CK, STA 913 ANGLE CRACKED O/B END OF LT WHEEL WELL. REPAIRED PER MM 53-11-0.

Part: FRAME — CRACKED (PAX DOORWAY)

FOUND AT C1 LETTER CK, .5 INCH VISIBLE CRACK IN AFT ENTRY DOOR CUTOUT LT FRAME AT 2ND FROM UPPER STOP CASTING. REPAIRED PER SRM 53-10-9 FIG 11.

Part: FRAME — CRACKED (PAX DOORWAY)

DURING C-1 LETTER CHECK, .5 INCH VISIBLE CRACK IN AFT ENTRY DOOR CUTOUT LT FRAME AT SECOND FROM UPPER STOP CASTING. REPAIRED PER SRM 53-10-9.

Part: SWITCH — INOPERATIVE (COCKPIT)

RT PACK SWITCH FAULTY. INFLT BUMPED SWITCH TO INTERMEDIATE POS, CAUSING PACK TO NOT OPERATE AT FL 330. PAC APPEARED TO BE ON, BUT ACTUALLY WAS OFF. RESULT WAS DEPRESSURIZATION TO ABOVE 10,000 FT, CABIN ALT O2 DROPPED. CABIN ALT REGAINED IN STBY MODE AND SWITCH PHYSICALLY PUSHED UP. FOUND RT PACK SWITCH FAULTY, REPLACED AIR COND CONTROL PANEL. RAN PACS AND PRESSURIZED A/C TO 7 PSI. CABIN LK CK GOOD. STOWED AND RESET O2 SYSTEM.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

EMERGENCY LIGHT INOP ROW 12 TO 19.

Part: ANGLE — CRACKED (BS 1273)

THE GUSSET ANGLE AT FS 1273 ON THE RT VENTRAL STAIRWAY TORQUE BOX WAS FOUND WITH A TYPICAL CRACK. THE GUSSET ANGLE WAS REPLACED WITH A NEW PART PER BAC S/B 727-53-0129 AND DOCUMENTED PER ER/A 364503-14AD.

Part: FRAME — CRACKED (BS 1223)

FOUND ON B2 LETTER CHECK, .125 INCH CRACK IN LIGHTENING HOLE LT SIDE STA 1223. REPAIRED PER M/M 53-11-0.

Part: EXHAUST PIPE — CRACKED (MLG WW)

WHILE PERFORMING A POST-REMOVAL INSPECTION OF A GTCP85-98CK APU EXHAUST PIPE (3850089-1), A 10 INCH CIRCUMFERENTIAL CRACK WAS NOTED ON THE PLENUM MOUNTING FLANGE. CAUSE FOR CRACK IS UNKNOWN. EXHAUST PIPE WAS MODIFIED BY ALLIED SIGNALTO SATISFY REQUIREMENTS OF EO 4-69905-3AD (AD 95-07-03). THE AD REQUIRED THE INSTALLATION OF AN EXHAUST HUB TO IMPROVE CONTAINMENT CAPABILITY IN CASE OF T-WHEEL FAILURE. TIME SINCE LAST SVI FOR APU: 1664 HOURS. EXHAUST PIPE IS SUBJECT TO REPAIR OR REPLACEMENT BY ALLIED SIGNAL.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY TRACK LIGHTING REMAINED ILLUMINATED WITH SWITCH IN OFF POSITION. REPLACED BATTERY.

Part: WEB — CRACKED (BS 1243)

VENTRAL STAIR TORQUE BOX STRUCTURE WEB AT STA 1243 LT HAS LIGHTENING HOLE CRACKED. STOP DRILLED CRACK, REPAIRED PER MM 53-11-00 PG 828.

Part: FLAP — CRACKED (NR 2 TE MIDFLAP)

THE NR 2 MIDFLAP LOWER AFT CHORD ANGLE WAS FOUND CRACKED AT 3 LOCATIONS DURING SHOP INSPECTION, 19, 35, AND 56 FROM IB END OF FLAP. ALL THREE LOCATIONS WERE REPAIRED PER 727 MM 57-52-0 BY INSTALLING A DOUBLER PER THE INSTRUCTIONS AFTER STOP DRILLING CRACKS.

Part: MIDFLAP — CRACKED (NR 3 TE MIDFLAP)

THE I/B MIDFLAP AFT LOWER CHORD WAS FOUND CRACKED 21 AND 43 FROM I/B END OF FLAP DURING SHOP INSPECTION. THE CHORD ANGLE WAS REPAIRED PER MM 57-52-0 BY INSTALLING A DOUBLER.

Part: BLKHD STIFFENER — CRACKED (BS 1183)

A CRACK WAS FOUND IN THE VERTICAL STIFFENERS AT BOTH RBL AND LBL 36.83 ON THE FORWARD SIDE OF THE 1183 BULKHEAD. THE CRACKS ARE APPROXIMATELY .5 LONG AND ARE LOCATED AT WL 240. THE BEAM WILL BE REPAIRED PER RELEVANT OPERATIONS OF EO 4-59821-3.

Part: STRINGER — CRACKED (WS 656.50)

RIGHT WING STRINGER TO RIB AT WS 656.50 STR 5 HAS CRACK FROM HOLE AND ALONG ANGLE. STARTED DRILLING REPAIR PER M/M 57-13-0. DISCONNECTED LINE AT WS 686.5 AND COMPLETED DRILLING. REINSTALLED VENT LINE AND WIRE CLAMPS.

Part: FLOORBEAM — CORRODED (BS 400)

CABIN FLOORBEAM CORRODED STA 400 RBL 30 AT NUTCLIP HOLE. REPAIRED FLOORBEAM PER MM 53-20-11 PG 802.

Part: FRAME — CORRODED (FUSELAGE)

CORROSION AT ACCESS PANEL 3448R SUPPORT FRAME. REMOVED CORROSION AS PER SRM 51-10-6 ON WEB, WITHIN LIMITS AS PER SRM 53-10-1 FIG 1. TREATED AND PAINTED AS PER PS 900-2-5. REMOVED CORROSION AS PER SRM 51-10-6 FROM T-ANGLE. CORROSION OUT OF LIMITS AS PER SRM 53-10-1 FIG 1. MANUFACTURED NEW T-ANGLE PER SRM 53-10-1 FIG 804. REPAIRED PER MM 53-30-1.

Part: SKIN — CRACKED (BS 345)

THREE CRACKS WERE FOUND IN THE SKIN AND DOOR SURROUND STRUCTURE IN THE LOWER AFT CORNER OF THE L1 DOOR CUTOUT. EACH CRACK IS 4 INCHES IN LENGTH AND IS THROUGH THE SKIN, BONDED DOUBLER, AND BEAR STRAP. THE DAMAGE WAS CUTOUT AND AN EXTERNAL DOUBLER AND TRIPLER WAS INSTALLED. THIS REPAIR WAS APPROVED BY FAA/DER FORM 8110-3, DER DESIGNATION SO-775, DTD 6-21-97.

Part: LIGHT — CORRODED (CABIN)

RT EXTERIOR EMERGENCY EXIT LIGHT AT OVERWING HATCH INOP. CLEANED CORROSION ON LIGHT SOCKET CONTACTS. CHECKS NORMAL.

Part: SKIN — CRACKED (RUDDER)

A .375 INCH CRACK IN LOWER RUDDER SKIN LT SIDE BELOW 'A' IN DELTA. REPAIRED PER SRM 55-20-3.

Part: BATTERY PACK — DISCHARGED (CABIN)

EXTERIOR EMERGENCY LIGHT ON C2 DOOR FAIRING INOPERATIVE. REPLACED BATTERY PACK RACK M957.

Part: SWITCH — FAILED (RT MLG DOOR)

RT GEAR DOOR LIGHT STAYED ON AFTER TAKEOFF AND RED DOORS LIGHT AT GEAR HANDLE. CYCLED GEAR DOOR. OPENED NORMALLY. FORWARD RT GEAR DOOR INDICATION TO MCO AND PACKARD PER MEL 32-00-01. REPLACED SWITCH ON GEAR DOOR. OPS TEST OK. REMOVED MCO/PLAC.

Part: ROD END — BROKEN (WS 950)

WHEN SPEEDBRAKES APPLIED ON LANDING, AIRCRAFT ROLLED TO RIGHT. FOUND NR 2 LEFT OUTBD SPOILER NOT DEPLOYING. FURTHER INVESTIGATION FOUND ROD END BROKEN REF IPC 27-10-0- 22B ITEM 5. MAINT FROM ATL REPLACED ROD END AND OPS CHECK OK.

Part: SKIN — CORRODED (BS 1183)

DURING THE ACCOMPLISHMENT OF THE AFT LAV SERVICE PANEL REWORK PER EO 4-69078-3AD, THE INTERNAL BONDED DOUBLER WAS FOUND CORRODED. ALSO, THE LOWER CORNER OF THE OVERLAPPING SKIN AT APPROX STA 1183 STR 20L HAS TOOLING DAMAGE ON THE SKIN. ACCOMPLISHED REPAIRS PER DL ERA 303349-14 REV, B.

Part: SKIN — CORROSION (BS 708-720)

THE FUSELAGE SKIN (2024-T3 CLAD) WAS FOUND TO HAVE CORRODED JUST O/B OF STR 28L, FROM STA 708 TO 720. THIS DAMAGE WILL REQUIRE A CUTOUT MEASURING 12 INCHES LONG BY 1.5 WIDE EXTENDING FROM STA 708 TO 720. THIS DAMAGE IS 9.5 TO THE LEFT OF AN EXISTING EXTERNAL SKIN REPAIR PER ER/A 221033-14AD. ALSO, THE SKIN CLIP WAS FOUND TO BE CORRODED BETWEEN STR 28L AND 27L AT STA 720 ON THE FWD SIDE OF THE FRAME. ACCOMPLISHED REPAIRS PER DL ERA 303354-14AD REV A.

Part: SKIN — CRACKED (L1 DOOR)

THE L-1 PASSENGER DOOR WAS FOUND WITH TWO CRACKS IN THE UPPER FWD CORNER. THESE CRACKS RESULTED IN TWO CUT OUTS, 2 INCH BY 1.25 INCH AND 2.5 INCH BY 1.5 INCH, EIGHT INCHES APART. ONE DOUBLER REPAIR WILL BE USED FOR BOTH CRACKS. THE DOOR SKIN IS MADE FROM 0.045 CLAD 2024-T42. ACCOMPLISHED REPAIRS PER DL ERA 303353-14.

Part: WEB — CRACKED (NR 8 SLAT)

FROM MV-2 ATL, I/B WEB IS CRACKED ON NR 8 SLAT. FABRICATED AND INSTALLED DOUBLER PER M/M 57-54-0 FIG 814.

Part: STIFFENER — CRACKED (NR 8 LE FLAP)

THE INBOARD ACTUATOR ATTACH RIB STIFFENER ON THE NR 8 SLAT ACTUATOR WAS FOUND CRACKED. THE DAL MFG PART NUMBER FOR THE INBOARD AND OUTBOARD STIFFENERS IS (57-0367-002). BOTH THE INBOARD AND OUTBOARD ATTACH RIB STIFFENERS WILL BE REPLACED PER EO 4-59271-3AD. THIS ER/A DOES NOT PROVIDE TERMINATING ACTION FOR EO 4-59271-3AD. OPERATIONS 570 AND 590 HAVE BEEN COMPLIED WITH FOR THE NR 8 SLAT ONLY.

Part: BRACKET — MISINSTALLED (NR 1-2-8 LE FLAP)

THE NR 1, NR 2 AND NR 8 SLAT ACTUATOR MOUNT BRACKETS WERE FOUND WITH GAPS EXCEEDING THE 0.01 LIMIT SET BY SI 4-59271-12. THE GAPS AT THE MOUNT BRACKETS ARE THE SUBJECT OF S/B 727-57-0130. SHIMS WILL BE INSTALLED IN ACCORDANCE WITH THE SERVICE BULLETIN. THE BRACKETS WERE NOT FOUND TO BE CRACKED. THIS ER/A DOES NOT TERMINATE THE INSPECTION REQUIREMENTS OF SI 4-59271-12. ACCOMPLISHMENT OF EO 4-59271-3AD IS STILL MANDATORY PRIOR TO THE ACCUMULATION OF 60,000 FLIGHT CYCLES.

Part: ACTUATOR BOLTS — LOOSE (NR 13 SPOILER)

AT MV-2 VISIT, FOUND NR 13 SPOILER ACT LUGS LOOSE RT WING. REPAIRED MOUNT BOLTS WHERE THEY ATTACH TO VERTICAL ANGLES ON REAR SPAR PER MM 57-42-0.

Part: SKIN — CRACKED (SERVICE DOOR)

DURING SHOP INSP, A CRACK WAS FOUND AT THE LOWER HINGE CUTOUT. THE CRACK WAS ROUTED OUT AND A STEEL DOUBLER WAS INSTALLED AS PER SRM 52-40-2 FIG 4, FOR LT AFT SERVICE DOOR.

Part: EEL MODULE — BROKEN (CABIN)

EMERGENCY FLOOR TRACK MISSING IN FLOOR TRACK AT SEAT 10 C. REPLACED EMERGENCY PATH LIGHT HOLDER MODULE AND BULB, OPERATION NORMAL.

Part: STIFFENER — CRACKED (ATTACH RIB)

WHILE WORKING ON A HYDRAULIC LEAK ON THE NR 7 SLAT ACTUATOR ATTACH RIB STIFFENER WAS FOUND CRACKED. THE DAL MFG (P/N 57-0367-001) ON THE STIFFENER. THIS ER/A WILL REPLACE THE OUTBD ATTACH RIB STIFFENER PER EO 4-59271-3AD.

Part: COVE ANGLE — CRACKED (NR 8 SLAT)

DURING F-1 LTR CHECK, FOUND NR 8 SLAT COVE ANGLE CRACKED BELOW ANTI-ICE DUCT. REPAIRED PER M/M 57-54-0.

Part: EXCHANGER — FAILED (RT PACK)

ON CLIMBOUT FL 2,900 CABIN WARNING HORN CAME ON, CABIN ALT ROSE 12,000 TO 13,000 FT. MADE EMEMERGENCY DESCENT, RETURNED TO ATL. FOUND RIGHT PACK HEAT EXCHANGER BURST AND LEAKING. REPLACED HEAT EXCHANGER OPERATION NORMAL.