N523DA

Part: TORQUE BOX — CRACKED (FS 1263) · airframe 67,681 hrs · 52,132 cycles

FUSELAGE / VENTRAL STAIRWAY / RH TORQUE BOX STRUCTURE / FS 1263 : CRACK REPAIR THE VENTRAL STAIRWAY ACTUATOR ON THE RH TORQUE BOX AT FS 1263 WAS FOUND PULLED THROUGH THE UPPER WEB OF THE TORQUE BOX, RESULTING IN CRACKING DAMAGE TO THE UPPER WEB, SIDE WEB, AND UNDERLYING STIFFENERS. THE DAMAGE TO THE UPPER WEB WAS REMOVED WITH A CUTOUT AND REPAIRED WITH AN ALUMINUM DOUBLER. ALL OTHER MEMBERS REPLACED. THE REPAIR WAS ACCOMPLISHED PER ER/A 384097-14AD.

Part: BATTERY — DISCHARGED (CABIN) · airframe 67,569 hrs · 52,053 cycles

LT SIDE OVERWING EMERGENCY LIGHTS DID NOT ILLUMINATE DURING LAYOVER TEST. REPLACED BATTERY PACK PER M/M. CKS OK.

Part: BATTERY — DISCHARGED (CABIN) · airframe 67,494 hrs · 52,002 cycles

AFT OVERHEAD ISLE EMERGENCY LIGHT INOP. REPLACED BATTERY OPS CHECK GOOD.

Part: CHARGER — INOPERATIVE (CABIN) · airframe 67,454 hrs · 51,968 cycles

OVERWING EMERGENCY EXIT LIGHTS INOP IN EMERGENCY MODE. REMOVED AND REPLACED CHARGER ON RIGHT SIDE, BATTERY ON LEFT SIDE AND EMERGENCY LIGHT ASSEMBLY ON RIGHT OVERWING EXIT.

Part: SKIN — CRACKED (FUSELAGE) · airframe 67,153 hrs · 51,744 cycles

DURING LAYOVER, MAINTENANCE FOUND A 1 INCH LONG CRACK IN THE FUSELAGE SKIN BETWEEN TWO FASTENERS AT S-30 BETWEEN FS 990 AND 1009. THE SUBJECT CRACK WAS REMOVED AND AN EXTERNAL DOUBLER INSTALLED. THE REPAIR INCORPORATED AN EXISTING REPAIR INSTALLED PER PREVIOUS ER/A 331904-14 AT S-29L.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 67,145 hrs · 51,738 cycles

LEFT OVERWING EMERGENCY EXIT LIGHT INOP. REPLACED BATTERY RACK.

Part: BATTERY — DISCHARGED (CABIN) · airframe 67,145 hrs · 51,738 cycles

EMERGENCY EXIT LIGHT OVER AFT RT DOOR INOP. REPLACED BATTERY AND RACK. ALSO SECURED GROUND.

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 67,123 hrs · 51,721 cycles

THE LT BOX SKIN OF THE VERTICAL STABILIZER WAS FOUND WITH A CRACK EMANATING FROM A FASTENER COMMON TO THE REAR SPAR LOCATED 1 INCH ABOVE THE FUSELAGE SKIN INTERFACE. THE CRACK WAS STOP DRILLED AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 383575-14, REV A.

Part: ANGLE — CRACKED (NBR 6 SLAT) · airframe 67,116 hrs · 51,715 cycles

FOUND ON E1 LETTER CK. 1 INCH CRACK AT COVE SKIN ATTACH ANGLE NBR 6 SLAT BELOW ACTUATOR ROD REPAIRED PER M/M 57-54-000-8 FIG 805A,

Part: ANGLE — CRACKED (RT WING 5 SLAT) · airframe 67,116 hrs · 51,715 cycles

FOUND ON E1 L/C 1.25 INCH CRACK NBR 5 SLAT COVE SKIN ATTACH ANGLE AT INBD END REPAIRED PER M/M57-54-000-8 FIG 805A

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 67,116 hrs · 51,715 cycles

FOUND ON E-1 LETTER CK SKIN CRACKED AT BASE OF VERTICAL STAB RT SIDE ABOVE FWD END OF NUMBER 2 ENG CUTOUT AT STR 10. REPAIR PER MM 55-30-000-8.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 66,623 hrs · 51,370 cycles

FOUND FORWARD BULLNOSE EMERGENCY EXIT LIGHT INOP. REPLACED BATTERY PACK.

Part: WIRE — BROKEN (CABIN) · airframe 66,250 hrs · 51,132 cycles

EMERGENCY LIGHTS OUT, ROWS 12 - 19. REPAIRED BROKEN WIRE.

Part: BATTERY — DISCHARGED (CABIN) · airframe 65,580 hrs · 50,736 cycles

L2 DOOR EMERGENCY EXIT OVERHEAD LIGHT BATTERIES DEAD. REPLACED BATTERIES.

Part: CONTROL UNIT — OVERHEATED (COCKPIT) · airframe 64,092 hrs · 49,769 cycles

ON DESCENT, LIGHT SMOKE NOTICED BELOW PILOT''S L-2 WINDOW. WINDOW HEAT TURNED OFF AND SMOKE STOPPED.

Part: STRINGER — CRACKED (FUSELAGE) · airframe 64,047 hrs · 49,736 cycles

STRINGER 18A LT AT STA 940 HAS A 3/4 INCH VISIBLE CRACK FROM RADIUS BLOCK LOWER BOLTS AND A 1 INCH CRACK FROM RADIUS BLOCK UPPER BOLTS. REPAIRED PER M/M 53-12-000-8 AND ERA 380727-14 ORIGINAL ISSUE. TIME LIMITED LEVEL 2 REPAIR RESTRICTIONS APPLY. REINSPECT REPAIR AT EVERY LETTERCHECK AND COMPLY WITH PERMANENT REPAIR AT NEXT HMV NOT TO EXCEED 15,220 CYCLES FROM 4-17-01

Part: STRINGER — CRACKED (FUSELAGE) · airframe 64,047 hrs · 49,736 cycles

STRINGER 18A RT STA 940 CRACKED 1 INCH. REPAIRED PER MM 53-12-000-8 TIME LIMITED I REPAIR

Part: SKIN — CORRODED (FUSELAGE) · airframe 62,602 hrs · 48,637 cycles

THE FUSELAGE SKIN AT FS 1050 AND STRINGER 28R WAS FOUND WITH TWO AREAS OF CORROSION. THE CORROSION WAS REMOVED WITH TWO 8 X 1 INCH CUTOUTS IN THE SKIN. THE CUTOUTS WERE REPAIRED WITH A SINGLE EXTERNAL ALUMINUM DOUBLER INSTALLED PER ER/A 378309-14, REV A.

Part: WEB — CRACKED (FUSELAGE) · airframe 62,598 hrs · 48,634 cycles

FOUND ON C2 LETTER CK, 1.25 INCH CRACK STA 1303 RT WEB ABOVE THE S-DUCT. A .75 INCH CRACK IN STA 1303 LT WEB ABOVE THE S-DUCT. REPAIRED PER B727 DRD 53-10-4D FIG 802D.

Part: ANGLE — CRACKED (VERTICAL STAB) · airframe 62,598 hrs · 48,634 cycles

FOUND ON C2 LETTER CK,1 INCH CRACK IN BULKHEAD TO STR ATTACH ANGLE INSIDE VERT STAB AT STR 9L. REPAIRED PER MM 55-30-0.

Part: BATTERY PACK — MALFUNCTIONED (CABIN) · airframe 62,427 hrs · 48,408 cycles

RT WING EMERGENCY LIGHT FWD BLINKS. REPLACED RT FWD BATTERY PACK, CHECKS GOOD.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 62,161 hrs · 48,062 cycles

CENTER AISLE OVERWING EMERG EXIT LIGHT INOP. REPLACED BATTERY PACK.

Part: POWER SUPPLY — INTERMITTENT (CABIN) · airframe 62,083 hrs · 47,962 cycles

FWD CTR AISLE EMERGENCY LIGHT WON''T TEST. REPLACED RACK, CHECKS OK.

Part: LIGHT — INOPERATIVE (OVERWING) · airframe 61,915 hrs · 47,752 cycles

RIGHT FWD OVRWING EMERGENCY EXIT LIGHT INOP. REPLACED BATTERY RACK M655, OPS CHECKS GOOD.

Part: SLIDE — DISCHARGED (PAX DOOR) · airframe 61,837 hrs · 47,653 cycles

L2 DOOR SLIDE LOW PRESSURE. REPLACED SAME.

Part: BATTERY PACK — DISCHARGED (ROW 16)

EMERGENCY LIGHT BATTERY PACK RACK ROW 16 OVERHEAD TEST BAD. REPLACED BATTERY PACK RACK.

Part: POWER SUPPLY — INOPERATIVE (ROW 4)

EMERGENCY EXIT SIGN AT ROW 4 FAILED TO ILLUMINATE DURING TEST BY CREW MEMBER. REPLACED POWER SUPPLY.

Part: SKIN — CRACKED (BS 481-681)

FUSELAGE SKIN FS 481-68, STRG 4R, SKIN LAP SPLICE, CRACK REPAIR. LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 481 AND 681 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 8 CRACKS ALONG THE PANEL. THE SKIN LAP WAS CUTOUT ALONG THE PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 367156-14AD.

Part: SKIN — CRACKED (BS 420-440)

FUSELAGE SKIN FS 420-440 STRINGER 4L, SKIN LAP SPLICE, CRACK REPAIR. LFEC INSPECTION OF THE STRINGER 4L SKIN LAP SPLICE BETWEEN FS 360 AND 481 INDICATED A CRACK IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED A SINGLE CRACK BETWEEN FS 420 AND 440. THE CRACK WAS ROUTED OUT AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER B727 SRM 53-30-3, FIG 5 AND DOCUMENTED PER ER/A 367158-14AD.

Part: SKIN — CRACKED (BS 360-481)

FUSELAGE SKIN FS 360-481 STRG 4R SKIN LAP SPLICE, CRACK REPAIR. LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 360 AND 481 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 6 CRACKS IN 3 SEPARATE FRAME BAYS. THE SKIN LAP WAS CUTOUT ALONG THE ENTIRE PANEL LENGTH AND REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER PER ER/A 367155-14AD.

Part: SKIN — CRACKED (BS 680-740)

FUSELAGE SKIN FS 680-740, STRINGER 4R, SKIN LAP SPLICE, CRACK REPAIR. LFEC INSPECTION OF THE STRINGER 4R SKIN LAP SPLICE BETWEEN FS 680 AND 740 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL HFEC INSPECTION CONFIRMED 45 CRACKS ALONG THE PANEL. THE SKIN LAP WAS CUTOUT ALONG THE ENTIRE LENGTH OF THE PANEL AND REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER PER ER/A 367157-14AD.

Part: STRINGER — CRACKED (VERT STAB)

VERT FIN STR 10L CRACKED AT STA 180.600. INSTALLED DOUBLER PER M/M 55-30-0.

Part: FRAME — CRACKED (PAX DOORWAY)

FOUND AT B-2 LETTER CK, .5 INCH CRACK AFT ENTRY DOOR CUTOUT LT FRAME AT 2ND FROM UPPER STOP CASTING. REPAIR PER SRM 53-10-9.

Part: SKIN — CRACKED (BS 990)

L1 DOOR SURROUND BEAR STRAP WAS FOUND CRACKED IN THE LWR AFT CORNER OF THE DOOR. CRACK WAS TRIMMED OUT THRU THE SKIN, BONDED DOUBLER AND BEAR STRAP. REPAIRED PER ERA 331987-14.

Part: FRAME — CRACKED (BS 380)

A CRACK WAS FOUND IN THE FRAME AT FS 380 AND WL 280, JUST ABOVE THE R1 DOOR CUTOUT. REPAIRED PER ERA 331909-14.

Part: FRAME — CORROSION (BS 95-960)

CORROSION WAS FOUND ON THE O/B FLANGE OF THE O/B CHORD OF THE C2 DOOR SILL. APPROX 0.060 OF MATERIAL FROM THE UPPER SURFACE OF THE FLANGE WAS REMOVED. REPAIRED PER ERA 331905-14.

Part: ANGLE — CRACKED (NR 5 LE SLAT)

NR 5 SLAT ANGLE CRACKED AT O/B SIDE OF ACTUATOR ATTACH RIB. REMOVED PANELS 6501, 6573 AND 6502 FOR ACCESS. REPAIRED PER MM 57-54-0, FIG 804. INSTALLED PANELS 6501, 6573 AND 6502.

Part: RIB — CRACKED (NR 7 LE SLAT)

NR 7 SLAT O/B ACTUATOR ATTACH RIB HAS BEEN STOP DRILLED TWICE INDICATING THAT CRACK HAS CONTINUED TO GROW. REMOVED ACCESS PANELS TO RIB. FABRICATED DOUBLER. OK TO INSTALL DOUBLER. INSTALLED DOUBLER PER MM 57-54-0 FIG 804. REPAIR OK PER M/M. OK TO CLOSE SLAT PANEL. CLOSED SLAT ACCESS PANELS.

Part: BULKHEAD ANGLE — CORRODED (BS 740)

FWD B/B STA 740 BLKH LWR ANGLE/CORRODED LOC BETWEEN STA 27R AND 28R. NOTE, FOUND DURING OK TO INST STG 27R REPAIR N/R 1349. BEGAN REMOVING ANGLE, CONT REMOVING ANGLE. REMOVED ANGLE BEGAN INSTALLATION OF NEW ANGLE. DRILLED UP NEW ANGLE. DRILLED UP ANGLE DOUBLER PER M/M 53-11-0, FIG 826. OK TO INSTALL. BEGAN INSTALLATION OF ANGLE. COMPLETED INST OF ANGLE.

Part: FORMER — BENT (BS 970)

FORMER BENT AND DAMAGED, STA 970, ABOVE 26L. REMOVED DAMAGE PER SRM 53-10-4. FABRICATED REPAIR PER SRM 53-10-4. DYE CHECKED REMOVED AREA FOR CRACKS, NO CRACKS FOUND PER PS 900-6-3. INSTALLED REPAIR DOUBLER PER SRM 53-10-3.

Part: SKIN — REPAIRED (NR 3 TE MIDFLAP)

DURING SHOP VISIT, THE COVE SKIN WAS FOUND CRACKED 31 FROM IB END OF FLAP. THE SKIN WAS REPAIRED PER 727 MM 57-52-0, FIG 809, BY REMOVING THE DAMAGE AND INSTALLING A DOUBLER AND FILLER.

Part: ANGLE — CRACKED (NR 3 TE MIDFLAP)

THE MIDFLAP REAR CHORD ANGLE WAS FOUND CRACKED 37 AND 31 FROM IB END DURING SHOP VISIT. THE ANGLE WAS REPAIRED PER 727 MM 57-52-0 BY INSTALLING A DOUBLER.

Part: ANGLE — REPAIRED (NR 3 TE MIDFLAP)

DURING SHOP VISIT, THE REAR CHORD ANGLE WAS FOUND CRACKED 17 AND 22 FROM IB END OGF FLAP. THE ANGLE WAS REPAIRED PER 727MM 57-52-0 BY INSTALLING A DOUBLER.

Part: ANGLE — REPAIRED (NR 3 TE MIDFLAP)

DURING SHOP VISIT, THE NR 3 MIDFLAP, SN DL15, WAS FOUND WITH A CRACKED REAR CHORD ANGLE. THE ANGLE WAS REPAIRED PER 727 MM 57-52-0, FIG 802 BY INSTALLING A DOUBLER.

Part: STRINGER — CRACKED (VERT STAB)

FOUND .75 INCH CRACK IN VERT STAB STRINGER 8R AT THIRD BULKHEAD ABOVE CRAWLWAY OPENING FIN STA 133.8. REPAIRED PER MM 55-30-0 FIG 803.

Part: WEB — CRAKCED (BS 1235)

FOUND .375 INCH CRACK RT VERT WEB UPPER LIGHTENING HOLE STA 1235, .5 INCH CRACK RT VERT WEB UPPER LIGHTENING HOLE STA 1243. REPAIRED PER MM 53-11-0 P 828.

Part: BATTERY PACK — DISCHARGED (CABIN)

ON L/O, FOUND LEFT FWD OVERWING EMERGENCY LIGHT INOP. REPLACED BATT PACK, OPS CK NML.

Part: SEQUENCE VALVE — CRACKED (RT MLG)

EXPERIENCED COMPLETE A-SYSTEM HYDRAULIC LOSS UPON GEAR RETRACTION AFTER TAKEOFF. REPLACED MAIN GEAR LOCK OPERATED SEQUENCE VALVE.

Part: RIB — CRACKED (BS 760.95)

WING, RIB, BL 70.5, STA 760.95, UPPER RIB CHORD, REPAIR FOR CRACKED FASTENER HOLES. WHILE ACCOMPLISHING AND MANDATED INSPECTIONS OF THE BL 70.5 RIB CHORD AT STA 760.95, SEVERAL FASTENER HOLES SHOWED CRACK INDICATIONS. THE CRACKED HOLES WERE OVERSIZED TO ELIMINATE THE CRACKS, BUSHED AS REQUIRED, AND A REPAIR INSTALLED SIMILAR TO THE REPAIR IN BAC S/B 727-57-112, REV 5. THE DEVIATIONS TO THE S/B WERE GRANTED AMOC AND DOCUMENTED IN ER/A 363384-14AD, REV A.

Part: BATTERY — DISCHARGED (CABIN)

EMERGENCY LIGHT OVER AFT AIRSTAIR INOP. REPLACED BATTERY.

Part: BATTERY PACK — DISCHARGED (CABIN)

OVERWING RT CTR EMERG LIGHT INOP. REPLACED BATT PACK AT M956, OPS CHKS GOOD.

Part: BATTERY — DISCHARGED (CABIN)

RT WING EXT EMERGENCY LIGHT INOPERABLE. REPLACED RACK AND BATTERY. ALL CHECKS NORMAL

Part: DOUBLER — CRACKED (BS 1263)

THE AFT VENTRAL STAIRWAY TORQUE BOX RIGHT HAND HORIZONTAL WEB HAS A .5 INCH CRACK IN A PREVIOUS REPAIR DOUBLER INSTALLED BY ER/A 06896-14, AT STA 1263 ON APPROXIMATELY BL 20.5. THIS DOUBLER WILL BE REMOVED AND THE WEB WILL BE TRIMMED IN A RECTANGULAR FASHION. A NEW DOUBLER WILL BE INSTALLED. THE WEB IS MANUFACTURED FROM 0.032 CLAD 7075-T6.

Part: SKIN — CRACKED (BS 1060)

FOUND CRACK AT STA 1060, ON STRINGER 28R. REPAIRED PER DELTA ER/A 303739-14.

Part: SKIN — CORRODED (BS 1030)

DURING INSPECTION, FOUND FUSELAGE SKIN BULGED AT STATION 1030, STRINGER 28R. REPAIRED IN ACCORDANCE WITH B727 SRM 53-30-3, FIG 1.

Part: FRAME — CRACKED (BS 784)

FOUND CRACK IN THE INBOARD FLANGE OF STA 784 FRAME JUST ABOVE THE MAIN CABIN FLOOR. REPAIRED PER B727 S/B 727-53-0197.

Part: TRUNNION FITTING — CORRODED (RT MLG)

FOUND CORROSION ON THE INNER FACE OF THE FWD TRUNNION BEARING SUPPORT FITTING ON THE RT MLG. REPAIRED PER MM 57-43-0.

Part: SUPPORT — CORRODED (FLAP TRACK)

FOUND CORROSION ON THE FLAP TRACK SUPPORT IN LARGE BEARING BORE. REPAIRED PER M/M 57-42-0, PG 806.

Part: ANGLE — CORRODED (FWD CARGO)

FOUND CORROSION AT ANGLE UNDER AND AROUND THE HINGES FOR PANEL 3348. REPAIRED PER MM 53-30-1, PG 807 TO 808.

Part: SKIN — DENTED (C3 DOOR)

FOUND A DEEP, SHARP RADIUS DENT AND GOUGE IN THE C-3 DOOR EXTERIOR SKIN APPROX 15 INCHES LONG, 8 INCHES ABOVE THE HANDLE CUTOUT. REPAIRED PER SRM 52-00-3, FIG 3.

Part: TRUNNION — CORRODED (LT MLG)

FOUND CORROSION ON LEFT GEAR FWD TRUNNION FACE. REPAIRED PER M/M 57-43-0 PG 803.

Part: TRACK — CORRODED (NR 4 TE FLAP)

FOUND CORROSION ON THE NR 4 FLAP TRACK FWD SUPPORT FITTING INSIDE THE BORES. REPAIRED PER M/M 57-42-0.

Part: BATTERY — DISCHARGED (AFT AIRSTAIR)

DURING LAYOVER, FOUND AFT AIRSTAIR EMERGENCY EXIT LIGHTS INOP. REPLACED BATTERY PACK OPERATION NORMAL.

Part: FLOW CONTL VLV — FAILED (LEFT)

UNABLE TO MAINTAIN CABIN ALTITUDE IN CLIMB, REGAINED PRESSURIZATION BY CHECK LIST, FL 180 CABIN ALT CLIMBING OFF, LANDING PIT. REPLACED LEFT FLOW CONTROL VALVE AND RETURNED TO SERVICE.

Part: SKIN — CORROSION (BS 720)

CORROSION WAS FOUND ON THE RAM AIR ACTUATOR ACCESS DOOR CUTOUT AT THE FWD LT CORNER. THE CORROSION WAS CUT OUT. REPAIARED PER DL ERA 302764-14.

Part: ANGLE — CRACKED (VERT STAB)

FOUND DURING E-2 LETTER CHECK, VERTICAL STAB FORMER ATTACH ANGLE CRACKED AT FIN STA 157.2 AND STR8 LEFT. REPAIRED PER M/M 55-30-0 PAR 2.

Part: STRINGER — CRACKED (VERT STAB)

FOUND DURING E-2 LETTER CHECK, VERT STAB STRINGER CRACKED AT FIN STA 110.4 AND STR 10 LEFT. REPAIRED PER M/M 55-30-0 PAR 3.

Part: FLOW CNTL VLV — FAILED (CABIN)

RIGHT PACK FAILED IN FLIGHT AT FL 250. AIRCRAFT LOST PRESSURIZATION, LT PACK ON MCO. REPLACED AFT FLOW CONTROL VALVE, OPERATION NORMAL.

Part: EEL BATTERY PACK — DISCHARGED (CARGO DOOR)

RT AFT CARGO DOOR EMERG LIGHT INOP. REPLACED BATT PACK M957. OPS CK GOOD.