N522US

Part: SKIN — SCRATCHED (FUSELAGE) · airframe 74,351 hrs · 31,922 cycles

FOUND A 7 INCH LONG SCRATCH IN FUSELAGE APPOXIMATELY 12 INCHES AFT OF L3 COCKPIT WINDOW LOWER AFT CORNER AND 10 INCHES BELOW LAP SEAM. BLENDED AND ACCOMPLISHED EDDY CURRENT. WITHIN LIMITS AND OK FOR SERVICE IAW SRM 53-00-01. HFEC 51-00-17 NO CRACKS.

Part: CONNECTOR — LOOSE (EMERGENCY LIGHTS) · airframe 73,841 hrs · 31,659 cycles

EMERGENCY LIGHTS ARE NOT LIGHTING IN THE AFT PART OF CABIN RESEATED CONNECTOR PLUG AT BATTERY PACK M734 IN AFT GALLEY OVERHEAD OPERATED LIGHTS ON AND OFF SEVERAL TIMES CKS NORMAL IAW AMM 33-51. OK FOR SVC.

Part: STRUCTURE — PUNCTURED (CARGO DOOR) · airframe 73,744 hrs · 31,606 cycles

ACS REPORTED FORWARD CARGO DOOR C1, AFT LOWER CORNER EDGE PUNCTURED .75 X .25. ACFT PREPARED FOR MX FERRY FOR MAJOR REPAIRS. ACFT CURRENTLY OUT OF SERVICE.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 72,806 hrs · 30,967 cycles

DOOR 4L EMERGENCY EXIT LIGHT INOPERATIVE. R & R BATTERY PACK, OPS CHECKED GOOD IAW AMM 33-51.

Part: SPAR CAP — CORRODED (HORIZONTAL STAB) · airframe 71,886 hrs · 30,333 cycles

REAR SPAR CAP CORRODED AT RT HORIZONTAL STAB STA 318.949, COMPLIED WITH ERA 506884-14 REV. ORIG STEPS 1-14 ON PRI ERA 506884-14 REV ORIG AND REV 1.

Part: SILL — CORRODED (CARGO DOORWAY) · airframe 71,879 hrs · 30,328 cycles

SMALL AREA OF CORROSION NR 2 CARGO DOOR LOWER SILL BS 1420. CLEANED AREA, REMOVED CORROSION PER SRM 53-60-15. AREA OUT OF LIMITS PER SRM 53-60-15. REMOVED FITTINGS FOR ACCESS. COMPLIED WITH PRI 506838-14 C/W ERA 506838-14 REV ORIG. REINSTALLED FITTINGS.

Part: CONNECTOR — DAMAGED (EMERGENCY LIGHT) · airframe 71,303 hrs · 30,056 cycles

DURING FLIGHT, EMERGENCY EXIT DOOR AND CELING LIGHTS COME ON AT DOOR 3 BOTH SIDES AND DOOR 2 RIGHT SIDE. EMERGENCY EXIT FLOOR LIGHTS COME ON IN FLIGHT FROM DOOR 3 FORWARD TO ROW 26. CYCLED EMERGENCY LIGHT SWITCH IN FLT DECK PER MC AND LIGHTS WENT OUT. FOUND DOOR 3L TEST SWITCH WIRE CONNECTOR SHORTED OUT RECONNECTED AND ADJUSTED WIRES. SWITCH OPS NORMAL OK FOR CONTINUED SERVICE.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 2,766 hrs · 1,623 cycles

EXIT LIGHT ABOVE L3 DOOR INOP. REPLACED BATTERY PACK PER AMM 33-51. OPS CHECK NORMAL.

Part: POWER SUPPLY — INOPERATIVE (EMERGENCY LIGHT) · airframe 67,806 hrs · 28,046 cycles

DURING A LINE CHECK, MX FOUND THE EMERGENCY PATH LIGHTS BETWEEN ROWS 22 AND 32 INOPERATIVE. MX REPLACED THE POWER SUPPLY. OPS CHECK WAS GOOD.

Part: TAB — DELAMINATED (LT ELEVATOR) · airframe 73,440 hrs · 70,600 cycles

LT ELEVATOR CONTROL TAB DELAMINATED APPROX 8 SQUARE INCHES. R & R RT ELEVATOR CONTROL TAB IAW AMM 27-30-03. ADJUSTMENT/TEST GOOD IAW MM 27-30-03-201 CORRECTED BY COOK 284650 STA DHN 10JAN11. REQUIRED INSP COMPLETED.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHT) · airframe 66,941 hrs · 27,518 cycles

DURING A LINE CHECK, MX FOUND THE EMERGENCY EXIT LIGHT AT DOOR 2 LT INOPERATIVE. MX REPLACED THE BATTERY AND POWER SUPPLY. OPS CHECK WAS GOOD.

Part: GATE — CORRODED (R1 DOOR) · corrosion level 2 · airframe 66,941 hrs · 27,518 cycles

DURING M-CHECK FOUND CORROSION ON R1 DOOR LOWER GATE. REPAIRED IAW SRM 51-40-02, SRM 52-11-38-004.

Part: BULKHEAD WEB — DAMAGED (NR 2 PYLON) · airframe 66,941 hrs · 27,518 cycles

DURING M-CHECK FOUND DAMAGE TO BULKHEAD WEB IN NR 2 PYLON MID SPAR BULKHEAD FITTING FWD FACE. REPAIRED IAW ERA 484910-14.

Part: SKIN — DENTED (BS 620 S16L) · airframe 66,941 hrs · 27,518 cycles

DURING M-CHECK FOUND DENT AND SCRATCH ON FUSELAGE SKIN AT BS 620 S16L. REPAIRED IAW ERA 484243-14.

Part: FLOOR SUPPORT — CORRODED (BS 345-377) · airframe 66,941 hrs · 27,518 cycles

CORROSION ON CABIN FLOOR SUPPORT BEAM FROM STA 345-377 BL'0'. REMOVED CORROSION FROM FLOOR SUPPORT BEAM BL'0' BTW STA 345-377 IAW SRM 51-10-02. ORIGINAL MAT. .063" MAT LOSS .016 FOUND TO BE OUT OF LIMITS IAW SRM 53-10-51 FIG 101. REMOVED FLOOR SUPPORT BEAM IAW SRM 51-40-02. LOCATED, DRILLED, AND INSTALLED NEW FLOOR SUPPORT BEAM IAW SRM 51-40-05 & 51-40-02.

Part: FLOOR SUPPORT — CORRODED (BS 405) · airframe 66,941 hrs · 27,518 cycles

CORROSION ON CABIN FLOOR SUPPORT BEAM STA 405 RBL24 STA BFM. REMOVED CORROSION DIM. L=2.5" W=.800" D=.071" FOUND TO BE OUT LIMITS IAW SRM 53-00-51. REMOVED FLOOR SUPPORT BEAM STA 365-440 RBL24 IAW SRM 51-40-02, REMOVED FLOOR BOX BEAM IAW SRM 51-40-02 LOCATED AND DRILLED FAB FLOOR SUPPORT ASSY IAW SRM 51-40-05. INSTALLED FLOOR SUPPORT & FLOOR BOX BEAM IAW SRM 51-40-02.

Part: FLOORBEAM — CORRODED (BS 377) · airframe 66,941 hrs · 27,518 cycles

CORROSION ON CABIN FLOORBEAM STA 377,BL'0' TO LBL18 AND AT RBL13. RII: Y BLENDED AREA ORG .125 L=3" X W=1.2" X D=.035 REMAINING .090 OUT OF LIMITS IAW SRM 53-00-51, FIG 101 SHEET 1,2,3 DETAIL II,III. REMOVED SPLICES AT STA 377 RBL32 & LBL34 IAW SRM 51-40-02. REMOVED 'T' CORD AT STA 377 RBL32 TO LBL34 IAW SRM51-40-02. FABRICATED "T" CORD & SPLICES AT RBL32 & LBL34, TREATED & PRIMED IAW SRM 51-20-01. TOP COATED "T" CORD & SPLICES IAW AMM 53-01-02. INSTALLED "T" CORD & SPLICES & STRAP IAW SRM 53-00-51 FIG 201. RII COMPLETED BY SAN 280957 MAE QC 110.

Part: SKIN — DAMAGED (NR 7 SLAT) · airframe 66,941 hrs · 27,518 cycles

RT WING SLAT NR 7 T/E WEDGE, APPROX 36" FROM INBD EDGE IS DAMAGED. REMOVED DAMAGED SKIN AND CORE AND BONDED NEW CORE, INTERNAL DOUBLER FILLER, AND EXTERNAL DOUBLER IAW SRM 51-70-10, REPAIR NR4, FIG 200. COMPLETED BY SAN 489916, STAMP 91.

Part: FLOORBEAM — CORRODED (BS 365) · corrosion level 2 · airframe 66,941 hrs · 27,518 cycles

CORROSION ON CABIN FLOORBEAM UPPER CHORD AT STA 365 FROM RBL 63-BL'0'. BLENDED AREA DIM. L=5' W=2" D=.060" FOUND TO BE OUT OF LIMITS IAW SRM 53-00-51, REMOVED OLD REPAIR IAW SRM 51-40-02. FAB, LOCATED, & DRILLED T-CHORD BEAM IAW SRM 51-40-05 & 53-00-51, INSTALLED REPAIR UPPER CHORD AT STA 365RBL 0 TO RBL 63 IAW SRM 51-40-02 & SRM 53-00-51 REPAIR 3. RII COMPLETED.

Part: WEDGE — DAMAGED (NR 7 SLAT) · airframe 66,941 hrs · 27,518 cycles

RT WING, SLAT NR7, T/E WEDGE, APPROX 36" FROM OTBD EDGE IS DAMAGED. REMOVED DAMAGED SKIN AND CORE AND BONDED NEW CORE INTERNAL DOUBLER FILLER AND EXTERNAL DOUBLER IAW SRM 51-70-10 REPAIR NR 4, FIG 202. PAINTED AREA IAW MM 51-21-10. RII COMPLETED BY SAN 489916, STAMP 91.

Part: WEDGE — DAMAGED (NR 8 SLAT) · airframe 66,941 hrs · 27,518 cycles

RT WING SLAT NR 8 T/E WEDGE APPROX 36" FROM INBD EDGE IS DAMAGED. RII: Y. REMOVED INNER SKIN, CORE AND EXTERNAL SKIN. FABRICATED NEW SKIN AND CORE AND BONDED IAW SRM 51-70-10 REPAIR NR4, FIG 202. PAINTED IAW MM 51-21 -10. RII COMPLETED BY SAN 489916 STAMP 91.

Part: FLOORBEAM — CORRODED (BS 1640) · corrosion level 2 · airframe 66,941 hrs · 27,518 cycles

DURING "M" CHECK FOUND CORROSION ON FLOORBEAM AT BS 1640. REPAIRED IAW SRM 51-40-02 & SRM 53-00-01, FIG 201.

Part: WEB — CORRODED (BS 1718) · corrosion level 2 · airframe 66,941 hrs · 27,518 cycles

DURING "M" CHECK FOUND CORROSION ON FLOOR WEB AT BS 1718 BL 0 TO RBL 31. REPAIRED IAW SRM 51-40-02, SRM 53-60-51 REPAIR NR 2.

Part: FLOORBEAM — CORRODED (BS 345) · corrosion level 2 · airframe 66,941 hrs · 27,518 cycles

DURING M-CHECK FOUND CORROSION ON FLOORBEAM UPPER CHORD BS 345 BL 0 TO LBL 18. REPAIRED IAW SRM 53-00-51 REPAIR NR 5.

Part: WEB — CORRODED (BS 1360-1380) · corrosion level 2 · airframe 66,941 hrs · 27,518 cycles

DURING M-CHECK, FOUND CORROSION ON WEB AT STRINGER 27R BETWEEN BS 1360 & BS 1380. REPAIRED IAW SRM 51-40-02.

Part: SKIN — DENTED (BS 660-680) · airframe 66,941 hrs · 27,518 cycles

DURING M-CHECK FOUND DENT IN LOWER FUSELAGE SKIN BETWEEN BS 660 & BS 680 STRINGER 23L & STRINGER 24L. REPAIRED IAW SRM 53-00-01 FIG 201, SRM 51-42-11.

Part: SLIDE — RUPTURED (EXIT DOOR 3L) · airframe 50,203 hrs · 21,099 cycles

DURING SLIDE SHOP TEST, INFLATABLE SUB ASSEMBLY SEAM RUPTURED AT NORMAL OPERATING PRESSURE. NEW INFLATABLE SUB ASSEMBLY WAS INSTALLED.

Part: ANNUNCIATOR — SMOKE (COCKPIT) · airframe 48,190 hrs · 20,335 cycles

UPON ARRIVAL TO GATE, FLIGHT CREW NOTICED SMOKE COMING FROM THE LANDING GEAR CONTROL HANDLE OPENING. FIRE EQUIPMENT WAS CALLED OUT. AFTER SHUTDOWN OF ENGINE, APU, AND UTILITY BUSSES, THE SMOKE STOPPED. MAINTENANCE REPLACED THE LEFT LANDING GEAR DOWN ANNUNCIATION AND THE PROXIMITY SWITCH ELECTRONICS UNIT. LANDING GEAR INDICATION NORMAL.

Part: FSEU — MALFUNCTIONED (LE FLAPS)

DURING FINAL APPROACH, L/E FLAP ASSYM ANNUNCIATED. FLIGHT CREW DECLARED AN EMERGENCY AND PERFORMED AN UNEVENTFUL LANDING. MAINTENANCE REMOVED AND REPLACED NR 1 FSEU.

Part: FSEU — MALFUNCTIONED (LE FLAPS)

DURING FINAL APPROACH, L/E FLAP ASSYM AND LEADING EDGE CAUTION LIGHT ILLUMINATED. GO-AROUND ACCOMPLISHED FOLLOWED BY UNEVENTFUL LANDING. MAINTENANCE REPLACED NR 2 FSEU.

Part: FITTING — CORRODED (BS 580)

DURING TRANSITION CHECK, FOUND CORROSION ON THE THIRD FROM FORWARD FITTING AT THE FORWARD CARGO DOOR THRESHOLD AT FS 580. REPLACED FITTING PER SRM 51-10-00.

Part: FITTING — CORRODED (BS 610)

DURING TRANSITION CHECK, FOUND CORROSION ON THE SECOND FROM AFT FITTING AT THE FORWARD CARGO DOOR THRESHOLD FS 610. REPLACED FITTING PER SRM 51-10-00.

Part: FITTING — CORRODED (BS 570)

DURING TRANSITION CHECK, FOUND CORROSION ON THE SECOND FROM FORWARD FITTING AT THE FORWARD CARGO DOOR THRESHOLD FS 570. REPLACED FITTING PER SRM 51-10-00.

Part: FLOORBEAM — CORRODED (BS 1680)

DURING TRANSITION CHECK, FOUND CORROSION ON TOP OF FLOORBEAM AT SEVERAL LOCATIONS FROM LBL 54 TO RBL 24, FS 1680. REPAIRED PER EA 55-151991.

Part: FLOOR BEAM — CORRODED (FS 1681)

DURING P-CHECK, FOUND CORROSION ON THE BS 1681 FLOOR BEAM UPPER CHORD AT LBL 32. REPAIRED CHORD (P/N 146N5091) PER EA 55-102159.

Part: OUTFLOW ACT — MALFUNCTIONED (CABIN)

DURING CLIMB, BOTH AUTO PRESSURE CONTROLLERS WERE INOPERATIVE WITH CABIN AUTO INOPERATIVE STATUS MESSAGE. AIRCRAFT RETURNED TO MSP. REPLACED OUTFLOW VALVE ACTUATOR. SYSTEM CHECK WAS NORMAL.

Part: BLEED VALVE — FAILED (NR 2 ENGINE)

DURING CLIMB, THE NR 2 COMPRESSOR STALLED TWICE. TWO LOUD BANGS AND A BRIGHT FLASH WERE OBSERVED. NO ABNORMAL ENGINE INDICATIONS WERE OBSERVED. AIRCRAFT WAS RETURNED TO MEM WHERE TROUBLESHOOTING FOUND THE 2.5 BLEED VALVE SEIZED. THE ENGINE WAS REPLACED.