N535DA

Part: WARNING SYSTEM — ACTIVATED (NR 3 ENGINE) · airframe 60,378 hrs · 44,755 cycles

NR 3 ENG FIRE INDICATION ON CLIMB THROUGH 10500. INDICATION CLEARED UPON RETARDING THROTTLE TO IDLE. CA- FND FUEL HEAT MANIFOLD BAD, REPLACED SAME. RAN ENG., ALL CHECKS GOOD.

Part: ISOLATION VALVE — CHAFED (RT DEICE SYSTEM) · airframe 59,910 hrs · 44,420 cycles

WHILE TROUBLESHOOTING WING ANTI-ICE PROBLEM FOUND RIGHT BLEED AIR ISOLATION VALVE WIRING CHAFING ON PNUEMATIC DUCT BETWEEN THE VALVE AND THE AFT PACK VALVE. WHILE INSTALLING PNUEMATIC DUCT FOUND WIRE BUNDLE FOR LEFT BLEED ISOLATION VALVE CHAFED. REPAIRED WIRING HARNESS, VALVE OPERATES NORMAL. REPLACED DAMAGED PNEU DUCT, LEAK CKS OK.

Part: LIGHT — FAILED (COCKPIT) · airframe 59,585 hrs · 44,194 cycles

ON APPROACH INTO SDF, F/O UNDER GLARESHIELD FLOOR LIGHT GOT BRIGHTER THEN ALL THREE FLOUR LIGHTS INOP WITH ELECTRIC SMELL. TURNED OFF FLOUR LIGHTS AND SMELL WENT AWAY. REPLACED LIGHT ASSY.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 59,576 hrs · 44,186 cycles

CENTER CABIN OVERHEAD EMERGENCY LIGHT BETWEEN OVERWING EXITS INOP. REPLACED BATTERY PACK, OPS NORMAL.

Part: ACTUATOR — FAILED (NR 6 KRUGER FLAP) · airframe 59,426 hrs · 44,080 cycles

SYSTEM A HYD LOSS IN FLIGHT WENT TO ZERO. FOUND NUMBER 6 LEADING EDGE KRUEGER FLAP ACTUATOR FAILED. REPLACED ACTUATOR.

Part: ANGLE — CRACKED (RT WING) · airframe 58,956 hrs · 43,766 cycles

FOUND AT F-1 LETTER CHECK, NR 8 SLAT ACT I/B AND O/B SUPPORT DOUBLERS CRACKED. REPAIRED PER MM 57-20-21.

Part: STIFFENER — CRACKED (RT WING) · airframe 58,956 hrs · 43,766 cycles

FOUND AT F-1 LETTER CHECK, NR 7 O/B SLAT TRACK I/B SPAR STIFFENER CRACKED. REPAIRED PER MM 57-20-21.

Part: WIRE — BROKEN (OIL TRANSMITTER) · airframe 58,766 hrs · 43,636 cycles

NUMBER 3 OIL TEMP WAS FLUCTUATING UP TO THE UPPER PEG. OIL QTY WAS SLOWLY DECREASING TO 1.4, OIL PRESS WAS NORMAL AT 50 PSI. ENG WAS SHUTDOWN IN FLT. ALL OTHER PARAMETERS WERE NORMAL. FOUND BROKEN WIRE AT CANNON PLUG TO OIL TEMP TRANSMITTER. REPAIRED BROKEN WIRE AND REPLACED CANNON PLUG. RAN ENGINE, NO OIL LEAKS.

Part: HARNESS — DAMAGED (NR 3 ENGINE) · airframe 58,475 hrs · 43,438 cycles

FOUND NUMEROUS LONGITUDINAL SPLITS ON INSULATION OF ALL 3 GEN FEEDER CABLES IN MID PYLON AREA OF NR 3 ENG. REPLACED CABLES FROM SPLICES IN RT 48 SECTION TO FIREWALL DISCONNECT WITH NEW TYPE CABLES BMS 13-58 DL (P/N 012210733) PER BOEING SERVICE LETTER 727-SL-24-026-A.

Part: SKIN — CRACKED (FUSELAGE) · airframe 58,387 hrs · 43,376 cycles

LFEC INSPECTION OF THE STRINGER 26L SKIN LAP SPLICE BETWEEN FS 480 & 680 INDICATED CRACKS IN THE LOWER FASTENER ROW OF THE LOWER SKIN. INTERNAL MFEC INSPECTION CONFIRMED 4 CRACKS ALONG THE PANEL LENGTH. THE SKIN LAP WAS TRIMMED OFF ALONG THE PANEL LENGTH AND REPAIRED WITH AN EXTERNAL ALUMINUM DOUBLER PER ER/A 369647-14AD, REV A.

Part: SKIN — CRACKED (BS 384)

4 INCH CRACK IN FUSELAGE SKIN AT FS 384 2 .5 INCH ABOVE STR 25R AND .25 INCH CRACK IN FUSE SKIN 2 INCH AFT OF ABOVE CRACK. REPAIR PER SRM 53-30-3 TIME LIMITED.

Part: MECHANISM — FAILED (NLG DOOR)

LOUD BANG DURING INITIAL GEAR RETRACTION ON T/O FROM SJC. FOLLOWED BY EXCESSIVE VIBS. RED GEAR DOOR LIGHT ILLUMINATED. ON FRONT PNL AS WELL AS AMBER NOSE GEAR LIGHT ON S/O PNL. GEAR EXTENDED NORMALLY. PER EMERGENCY CK-OUT. UPON ARR INTO SFO, MAINTENANCE FOUND FWD NOSE GEAR DOOR CONTROL ROD END SEPERATED FROM CONTROL ROD ASSY. REMOVED AND REPLACED CONTROL ROD ASSY. OPS CK OK.

Part: COMPRESSOR — STALLED (NR 2 ENGINE)

AS POWER WAS INCREASING TO TAKEOFF SETTING NR 2 ENGINE HAD A HARD COMPRESSOR STALL. A HEAVY VIBRATION AND RUMBLING NOISE WAS HEARD/FELT FROM NR 2 ENGINE. MAXIMUM CROSSWIND WAS LESS THAN 3 KTS. REPLACED NR 2 ENGINE.

Part: VALVE — FAILED (RT PACK)

ENG RUNNING ESS PWR SEL ON ENG 1, BOTH PACKS ON. APU GEN/FIELD BREAKER OPENED WITH ASSOCIATED AMBER LIGHTS, 1-3 BTBS OPEN WITH LIGHTS. PACKS TRIPPED, SMOKE, HOT PACK SMELL AND LOSS ELECT. RETURNED TO GATE. ELECT FAULT PANEL UNDEREXCITED SYS 1-3. LIGHTS ILLUMINATED, PACK VALVE C/B TRIPPED. REMOVED AND INSTALLED RT PACK VALVE. RAN ENGS. SWAPPED PWR, ALL CKS NORMAL.

Part: SILL — CORRODED (CARGO DOOR)

FUSELAGE C2 DOOR SURROUND LOWER SILL OUTBD CHORD, CORROSION REPAIR. THE OUTBOARD CHORD OF THE C2 DOOR OPENING LOWER SILL WAS FOUND CORRODED ON THE OUTBD FLANGE BETWEEN FS 950F+11 AND FS 960. THE CORROSION WAS BLENDED AWAY WITH A MAXIMUM DEPTH OF .075. THE DAMAGE WAS REPAIRED WITH AN ALUMINUM STRAP PER ER/A 367596-14, REV A.

Part: SKIN — DENTED (LT HORIZ STAB)

BULGE AT LT HORIZONTAL STABILIZER UPPER SKIN 6 IN FWD OF ELEVATOR 2ND FROM O/B HINGE(MARKED). INSTALLED DOUBLER PER SRM 55-20-3.

Part: FRAME — DAMAGED (BS 990)

FOUND DURING MV2 CORROSION VISIT NRC 213, CUT AND REMOVE FLOOR SUPPORT RAIL ABOVE STRINGER 29 LT STA 980 FOR ACCESS TO FRAME REPAIR (STA 990) REF NRC 128. REPAIRED PER SRM 53-10-5, WORKED WITH NRC 128, 93, 94.

Part: DOUBLER — CRACKED (NR 3 LE SLAT)

A 1 INCH CRACK IN DOUBLER NR 3 SLAT RIB O/B OF ACT. REPLACED DOUBLER PER MM 57-54-0 FIG 804.

Part: STRINGER — DAMAGED (BS 990)

FOUND DURING MV2 CORROSION VISIT NRC 128, CUT FRAME STA 990 TO ACCESS REPAIR OF STR 29 LT REF NRC 89. REPAIRED PER M/M 53-12-0 FIG 805. WORKED WITH NRC 93, 94, 213.

Part: STRINGER — CRACKED (BS 1000)

FOUND DURING MV2 CORROSION VISIT NRC 89, 1 IN CRACK STR 29 LT AT STA 1000. REPLACED STR 29 LT STA 980 TO STA 1007 PER SRM 53-10-11 FIG 3. WORKED WITH NRC 93, 94, 128, 213.

Part: FRAME — CRACKED (BS 620)

THE AFT FRAME OF THE C1 CARGO DOOR OPENING WAS FOUND WITH A 1 INCH CRACK IN THE FRAME WEB BELOW THE LOWER DOOR STOP FITTING. THE CRACK WAS ROUTED OUT OF THE WEB AND REPAIRED WITH A DOUBLER PER ER/A 367202-14.

Part: SKIN — CRACKED (BS 360-481)

FUSELAGE SKIN FS 360-480 STRINGER 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 13 TOTAL CRACKS. THE ENTIRE SKIN LAP WAS CUTOUT ALONG THE LENGTH OF THE PANEL AND REPAIRED WITH AN EXTERNAL DOUBLER PER ER/A 367136-14AD, REV A.

Part: SKIN — CRACKED (BS 481-681)

FUSELAGE SKIN FS 481-681 STRINGER 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 PANEL. INTERNAL HFEC INSPECTION CONFIRMED 4 CRACKS IN CONSECUTIVE FRAME BAYS. THE SKIN LAP WAS CUTOUT ALONG THE ENTIRE PANEL LENGTH AND REPAIRED WITH AND EXTERNAL ALUMINUM DOUBLER PER ER/A 367137-14AD.

Part: PANEL — DELAMINATED (NR 2 SPOILER)

FOUND AREA OF DELAMINATION ON NR 2 SPOILER UPPER SURFACE. REPAIRED PER SRM 57-50-6.

Part: WEB — CRACKED (BS 1303)

FOUND ON D2 LETTER CK, 2 EA .5 INCH CRACKS STA 1303 VERT WEB ABOVE S-DUCT RT SIDE. REPAIRED PER SRM 53-10-4.

Part: WEB — CRACKED (BS 1243)

FOUND ON D2 LETTER CK, RT VERTICAL TORQUE BOX WEB CRACKED .1562 INCH AT LIGHTENING HOLE STA 1243 RT. ROUTED OUT DAMAGED AREA PER MM 53-11-0.

Part: ANGLE — CRACKED (BS 1273)

FOUND ON B2 LETTER CK, HORIZONTAL TORQUE BOX ANGLE CRACKED RT STA 1273. REPLACED ANGLE PER SRM 53-10-10.

Part: BATTERY — DISCHARGED (CABIN)

R-2 DOOR EMER EXIT SIGN INOP. REPLACED BATT OPS CK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING S/C, FOUND AFT EMERG EXIT SIGN INOP WHEN TESTING EMERG LIGHTS. REPLACED BATTERY PACK.

Part: TUBE — BROKEN (NR 2 LE SLAT)

ON TAXI OUT, -A- SYS HYD FAILED. REPLACED NR 2 L/E SLAT LINE.

Part: BULB — FAILED (CABIN)

ON FAA RAMP INSPECTION ONE EMER TRACK LIGHTING BULB INOP. REPLACED LAMP AND OK.

Part: FLOORBEAM — CORROSION (BS 344)

CORROSION ON TOP SIDE OF FLOORBEAM STA 344 FROM BL 0 TO LBL 39. REMOVED DAMAGED SECTION OF BEAM, FABRICATED AND INSTALLED A REPLACEMENT CHORD SECTION PER SRM 53-10-8, FIG 11.

Part: WINDOW — FAILED (CABIN)

ON CLIMBOUT, AT 27,000 PASSENGER CABIN WINDOW AT ROW 2A CRACKED AND CABIN PRESSURE WAS MAINTAINED AT 7.6 PSI. FLT WAS CONTINUED AT FL200 AND CABIN PRESS AT 6.0 PSI. ON ARRIVAL PBI FOUND OUTER WINDOW PANE BROKEN, INNER PANE INTACT. REPLACED 2A WINDOW, INSPECTED SURROUNDING AREA, NO PROBLEMS FOUND.

Part: TORQUE BOX WEB — CRACKED (BS 1213)

FOUND ON B2 LETTER CHECK, .1875 INCH CRACK UPPER END OF TORQUE BOX WEB STA 1213 ABOVE STAIRWAY CLOSEOUT PANEL. REPAIRED PER MM 53-11-0.

Part: ANGLE — CRACKED (NR 6 LE SLAT)

FOUND ON B2 LETTER CHECK, NR 6 SLAT COVE SKIN SUPPORT ANGLE CRACKED INBOARD END. REPAIRED PER MM 57-54-0.

Part: PASSENGER DOOR — BENT (FWD ENTRY)

AC LOG ITEM Z60966002 RT CORNER OF FORWARD ENTRY DOOR IS BENT UP. REPAIRED PER MM 52-11-01 FIG 804.

Part: WEB — CRACKED (BS 1323)

DURING B-1 LTR CHECK, FOUND 48 SEC TORQUE BOX WEB IS CRACKED AT LIGHTENING HOLE, STA 1323 LT. REPAIRED PER MM 53-11-0.

Part: TRANSVERSE BEAM — CRACKED (BS 1263)

THERE IS DAMAGE TO THE LOWER TORQUE BOX STATION 1263 TRANSVERSE BEAM FWD SIDE. 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: WEB — CRACKED (TORQUE BOX)

FOUND DURING A-2 LETTER CHECK, CRACK IN LT TORQUE BOX SKIN .5 INCH LONG AT UPPER RIVET ROW ABOVE FWD LIGHTENING HOLE. ALSO,A .125 INCH CRACK AT UPPER FWD LIGHTENING HOLE LT SIDE VERT STAIRWAY. REPAIRED PER B727 MM 53-11-0 PG 832.