N544DA

Part: ENGINE — MALFUNCTIONED (NR 3) · airframe 62,405 hrs · 46,050 cycles

NR 3 ENGINE EGT LIMITED IN CLIMB POWER, EGT 590-595 AT 20 TAT CLIMB THRUST (ON T/O USING ALT 40 TAT CLIMB NR 3 EGT 610). AT 20 TAT CLIMB EPR = 1.88 HAD TO PULL NR 3 THROTTLE BACK TO 1.76 EPR TO KEEP EGT AT / BELOW 580. REPLACED NR 3 ENGINE PER 4T203AD.

Part: CHARGER — FAILED (CABIN) · airframe 60,601 hrs · 44,791 cycles

LEFT FORWARD OVERWING EMERGENCY EXIT LIGHT INOPERATIVE. REPLACED BATTERY PACK AND CHARGER ASSEMBLY, OPERATION NORMAL.

Part: CHARGER — FAILED (CABIN) · airframe 60,477 hrs · 44,710 cycles

LEFT OVERWING EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY CHARGER.

Part: LIGHT — UNSERVICEABLE (1L DOOR) · airframe 59,681 hrs · 44,247 cycles

EXIT SIGN ABOVE 1L DOOR DOES NOT ILLUMINATE WHEN EMERGENCY LIGHTS TESTED. REPLACED LIGHT ASSY

Part: SEAL — TORN (1-L DOOR) · airframe 59,044 hrs · 43,837 cycles

ON CLIMBOUT A LOUD SQUEAL DEVELOPED FROM FORWARD LEFT DOOR. NOISE WAS TOO LOUD TO CONTINUE FLIGHT. DECENDED TO 10,000 FTAND CHANGED CABIN TO 2.0 PSID. NOISE STOPPED. CA RPD L1 DOOR SEAL.

Part: CLIP — CRACKED (STA 1263) · airframe 59,031 hrs · 43,830 cycles

FOUND ON E2 LETTER CK SKIN CLIP CRACKED FWD STA 1263 ABOVE STR 12R. REPAIRED PER B727 DAL DRD 53-10-4D FIG 803D.

Part: WEB — CRACKED (STA 1214 R/H) · airframe 59,031 hrs · 43,830 cycles

FOUND ON E2 LETTER CK R/H INBD VERT TORQUE BOX WEB CRACKED AT UPPER END STA 1214 R/H. REPAIRED PER MM 53-11-000-8.

Part: LIGHT — INOPERATIVE (CARGO DOOR) · airframe 58,308 hrs · 43,326 cycles

EMERGENCY LIGHT ON AFT CARGO DOOR INOPERATIVE. REPLACED LIGHT RACK

Part: BATTERY PACK — DISCHARGED (LT OVERWING) · airframe 58,295 hrs · 43,318 cycles

LT OVERWING EMERGENCY EXIT LIGHT FLASHING. REMOVED AND REPLACED BATTERY PACK.

Part: BATTERY — DISCHARGED (CABIN) · airframe 57,785 hrs · 42,963 cycles

DURING STBY PWR CK LT SIDE OVERWING EXIT LIGHTS FAILED TO ILLUMINATE. REPLACED BATTERY PACK. ALL CHECKS NORMAL.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 57,785 hrs · 42,963 cycles

ON L/O FOUND C-2 DOOR EMERGENCY FLOOD LIGHT INOP. REPLACED SAME.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 57,453 hrs · 42,740 cycles

FUSELAGE / STRINGER / FS 440 / STRG. 27L : SPLICE REPAIR. STRINGER 27L WAS FOUND CORRODED AT FS 440. THE CORRODED SECTION OF STRINGER WAS CUT AWAY TO REMOVE ALL DAMAGED. THE DAMAGED SECTION WAS REPAIRED WITH TWO (2) ALUMINUM REPAIR ANGLES INSTALLED PER ER/A 379468-14, REV A.

Part: SKIN — CRACKED (NR 3 LE FLAP) · airframe 55,952 hrs · 41,701 cycles

NR 3 KRUEGER FLAP CRACKED AT O/B LIP HINGE CUTOUT. TPA D-2 LTR CHK. INSTALLED DOUBLER PER M/M 57-53-0, NR 2A.

Part: ENGINE — LEAKING (NR 3) · airframe 55,928 hrs · 41,683 cycles

OIL QUANTITY DECREASED RAPIDLY ON NR 3 ENG. RATE WAS APPROX 1 GAL PER 5 MIN UNTIL REACHING ZERO. ENG CHANGE IN PROGRESS.

Part: FLAP TRACK — CORRODED (TE FLAP) · airframe 55,773 hrs · 41,577 cycles

TYPICAL CORROSION WAS FOUND ON THE LOWER SURFACE OF THE NR 4 AND NR 5 FLAP TRACKS AND ON THE UPPER SURFACE OF THE MLG AT THE INTERFACE OF THE FLAP TRACK AND THE MLG SUPPORT BEAM. THE CORROSION WAS MACHINED OR SPOTFACED FOR REMOVAL PER THE GUIDANCE OF BAC S/B 727-57-0178 AND PER ER/A 369800-14AD.

Part: WIRE — DISCONNECTED (CABIN)

EMERGENCY EXIT LIGHT OVERRIDE SWITCH AT AFT FLIGHT ATTENDANT STATION INOP. FOUND ONE WIRE DISCONNECTED FROM AFT ATTENDANT EMERGENCY LIGHT SWITCH. RESECURED WIRE TO SWITCH, OPERATION NOW NORMAL.

Part: ENGINE — MALFUNCTIONED (NR 1)

ON CLIMB-OUT, NR 1 ENG OIL FILTER BYPASS LIGHT ILLUMINATED. S/D ENG PER POM. OIL FILTER FOUND CLEAN. REPLACED SAME, ENGINE RUN CHECKS GOOD.

Part: RIB — CRACKED (NR 1 LE SLAT)

FOUND ON D1 LETTER CK, NR 1 SLAT L/E NOSE RIB CRACKED 1.5 INCH AT I/B SIDE OF ACTUATOR. REPAIRED PER MM 57-54-0.

Part: STIFFNER — CRACKED (LT LE SPAR)

FOUND ON D1 LETTER CK, NR 4 SLAT I/B TRACK I/B SPAR STIFFENER CRACKED. REPAIRED PER MM 57-20-21.

Part: CASTING — CRACKED (LT TE SPAR)

FOUND ON D1 LETTER CK, NR 4 SLAT ACTUATOR I/B MOUNT CASTING CRACKED. REPLACED CASTING.

Part: SKIN — CRACK (LT LE SLAT)

LOWER SKIN CUT TO FACILITATE MAINTENANCE. REPAIRED PER M/M 57-54-0 FIG 801.

Part: RIB — CRACKED (LT WING)

RIB CRACKED. REPAIRED RIB PER M/M 57-54-0.

Part: BATTERY PACK — DISCHARGED (CABIN)

OVERWING RT SIDE EMERGENCY EXIT LIGHTS INOP. REPLACED BATTERY PACK AND OPS CK GOOD.

Part: BATTERY — DISCHARGED (CABIN)

FLASHLIGHT HAD NO CHARGE. REPLACED BATTERY, OPS CK GOOD.

Part: ANGLE — CRACKED (BS 870)

FOUND ON C2 LETTER CK, RT KEEL BEAM SUPPORT ANGLE CRACKED AT STA 870. REPLACED ANGLE PER SRM 53-10-9.

Part: BULKHEAD BEAM — CRACKED (BS 1183)

FUSELAGE BULKHEAD FS 1183 LBL 18 VERTICAL BEAM, REPAIR FOR CRACK. A .75 INCH TYPICAL CRACK WAS FOUND IN RADIUS OF THE LBL 18 VERTICAL BEAM LOWER END ON THE FS 1183 BULKHEAD. THE CRACKED BEAM WAS REPAIRED PER BAC S/B 727-53-0202. THE REPAIR WAS DOCUMENTED PER ER/A 365782-14AD.

Part: FUEL CONTROL — FAILED (NR 3 ENGINE)

NR 3 ENG DID NOT RESPOND TO THROTTLE MOVEMENT DURING DESCENT, FLAMEOUT, FUEL FLOW WAS ZERO. EGT AND EPR WERE ZERO AND NOT RESPONDING. N1 AND N2 DISPLAYED WINDMILLING INDICATION, THIS LASTED FOR 2 TO 3 MINUTES. PRIOR TO COMMENCING THE ENG FAILURE FOLLOW UP CHECKLIST THE ENG BEGAN RESPONDING NORMALLY. REPLACED NR 3 ENGINE FUEL CONTROL AND FUEL PUMP.

Part: DOOR — CRACKED (CARGO COMPT)

AT FL 350 CABIN STARTED CLIMBING AT 650 FPM. CARGO HEAT OUTFLOW AND MAIN OUTFLOW VLV'S CLOSED. LT PACK WENT TO FULL CLOSED AND WOULD NOT CHANGE. NO DUCT OVERHEAT OR PACK TRIP OFF LIGHT, ALSO NO PRESS FAILURE LIGHTS. FOUND C-3 CARGO DOOR FWD LWR CORNER CRACKED. REPLACED DOOR.

Part: ANGLE — CRACKED (NR 3 LE SLAT)

FOUND ON A-1 LETTER CHECK, 1.5 INCH CRACK IN NR 3 L/E SLAT LWR COVE SKIN ANGLE. REPAIRED PER M/M 57-54-0.

Part: BULB — FAILED (AFT GALLEY)

AFT GALLEY DOOR EXIT LIGHT INOP. RELAMPED, OPERATION NORMAL.

Part: CHORD — CRACKED (NR 2 TE MIDFLAP)

DURING SHOP VISIT, A CRACK AND TEMPORARY REPAIR DOUBLER WAS FOUND ON AFT CHORD OF NR 2 MIDFLAP. INSTALLED PERMANENT REPAIR PER MM 57-53-0.

Part: CHORD — CRACKED (NR 2 TE MIDFLAP)

DURING SHOP VISIT, A CRACK WAS DISCOVERED ON AFT CHORD AT I/B DRIVE ROD CUTOUT, OF NR 2 MIDFLAP. REPAIRED PER MM 57-52-0.

Part: LE SKIN — WORN (NR 3 TE MIDFLAP)

DURING SHOP INSP, NR 3 MIDFLAP WAS FOUND WITH I/B L/E SKIN WORN. REPAIRED LEADING EDGE PER MM 57520, BY REMOVING DAMAGED AREA AND INSTALLING A DOUBLER AND FILLER.

Part: COWLING — CRACKED (NR 2 ENGINE)

DURING A SHOP INSPECTION, THE UPPER FRAME ANGLE WAS FOUND TO BE CRACKED. A REPAIR WAS INSTALLED PER THE S.R.M. 54-10-3. FOR NR 2 ENGINE LEFT FORWARD COWL PANEL.

Part: SKIN — WORN (NR 4 TE FLAP)

DURING SHOP INSP, NR 4 MIDFLAP L/E SKIN WORN AT O/B END OF FLAP. REPAIRED PER MM 57520 BY REMOVING DAMAGED AREA AND INSTALLING A DOUBLER AND FILLER.

Part: FRAME — MISDRILLED (FS 760.95)

DURING THE ACCOMPLISHMENT OF DAL EO 4-58560-3AD, IT WAS NOTICED BY MAINTENANCE THAT THE FRAME REINFORCEMENT STRAP ON THE OUTER CHORD OF STA 760.95 FRAM, WAS DOUBLE DRILLED AT THREE LOCATIONS PRIOR TO THIS HEAVY MAINTENANCE VISIT. MAINTENANCE OVERSIZED THE HOLES TO CLEAN UP THE DAMAGE. THE UPPER TWO OVERSIZED HOLES ARE THROUGH THE STRAP AND FRAME AND ARE 0.500 INCH AND 0.437 INCH DIAMETER. THE LOWER HOLE IS ONLY THROUGH THE STRAP AND IS 0.437 INCH DIAMETER. NO DAMAGE HAS BEEN DONE TO THE SKIN.

Part: SKIN — CORRODED (FS 700-720)

BELLY SKIN, CORROSION AT STA 700 TO 720, O/B OF S-28L AD 91-09-09, 94-05-04. SKIN CORROSION AT STA 700 TO 720, O/B OF S-28L HAS PROMPTED REQUEST FOR AN EXTENSION OF AN EXISTING DOUBLER IN THAT AREA TO COVER THE ADDED DAMAGE REMOVAL, APPROXIMATLY 2 BY 2 INCHES. THE ERA WILL INCORPORATE THE ADDED CUT OUT INTO THE PREVIOUS REPAIR.

Part: RIB — CRACKED (VERT FIN)

DURING HMV, FOUND ON VERTICAL FIN 4TH RIB DOWN FROM ACCESS HOLE STA 6.372 RIB NR 6 CHORD ANGLE CRACKED AT STR 7 LEFT. REPAIRED PER M/M 55-30-0 PG 802.

Part: RIB — CRACKED (NR 8 LE SLAT)

DURING HMV, FOUND NR 8 SLAT, RIB NR 13 WAS CRACKED IN RADIUS. REPAIRED PER M/M 57-54-0 FIG 805.

Part: RIB — CRACKED (NR 6 LE FLAP)

FOUND ON HMV RIB WEB AT TAI, TUBE CRACKED AT NR 6 SLAT INBOARD WEB. REPAIRED RIB PER M/M 57-54-0, FIG 805.

Part: RIB — CRACKED (NR 4 LE SLAT)

DURING HMV, FOUND NR 4 SLAT HAS CRACK AT ACTUATOR ATTACH O/B RIB. REPAIRED PER MM 57-54-0 FIG 804.

Part: RIB — CRACKED (NR 3 LE SLAT)

DURING HMV, FOUND NR 3 SLAT HAS CRACK IN LOWER SURFACE OF NR 3 RIB FROM I/B END. REPAIRED PER MM 57-54-0 FIG 805.

Part: ACTUATOR MOUNT — CRACKED (NR 4 LE FLAP)

FOUND AT HMV, NR 4 SLAT MAIN ACTUATOR MOUNT CRACKED AT PREVIOUSLY REPAIRED AREA. REPAIRED PER M/M 57-54-0, FIG 804A.

Part: ANGLE — CRACKED (NR 6 LE FLAP)

FOUND DURING HMV - NR 6 SLAT, CRACKED ANGLE BETWEEN DE-ICE TUBE AND FARTHEST ROLLER TRACK. REPAIRED PER M/M 57-54-0, FIG 812.

Part: FRAME — OVERSIZED HOLES (FS 760.95)

DURING ACCOMPLISHMENT OF EO 4-61904-3AD, SEVERAL HOLES IN THE INBOARD FRAME FLANGE AT FS 760.95, BOTH RT AND LT SIDES WERE OVERSIZED THROUGH THE STRAP, FRAME, AND MODIFICATION ANGLE. ONE HOLE ON THE LEFT HAND SIDE HAS BEEN OVERSIZED TO 0.403 DIA AND REQUIRES THE INSTALLATION OF A BUSHING.

Part: BEAM — CRACKED (FWD ENTRY DOOR)

DURING HMV, FOUND FWD ENTRY DOOR LOWER HORIZONTAL BEAM CRACKED AT AFT CORNER. REPAIRED PER M/M 52-11-01 PG 805.

Part: BRACKET — CRACKED (NR 6 LE FLAP)

DURING HMV, FOUND NR 6 KRUEGER FLAP ACTUATOR BRACKET IS CRACKED AT I/B LOWER FWD CORNER. REPAIRED PER M/M 57-20-21.

Part: SKIN — CRACKED (LT ELEVATOR)

DURING HMV, FOUND LT ELEVATOR SKIN CRACKED APPROX 1.5 INCH CRACK IN UPPER SKIN I/B END NEAR LEADING EDGE. REPAIRED PER SRM 55-20-3.

Part: RIB — CRACK (BS 760.95)

DURING THE ACCOMPLISHMENT OF EO 4-58560-3AD, A CRACK WAS DETECTED IN A FASTENER HOLE IN THE VERTICAL FLANGE OF THE RIB CHORD AT BS 760.95. REMOVAL OF THE CRACK IN THE RIB CHORD RESULTED IN THE INADVERTENT OVERSIZING OF THE FUSELAGE SKIN AT THIS LOCATION, AS WELL AS AN ADJACENT FASTENER. THE BS 760.95 FRAME WAS NOT OVERSIZED.

Part: WEB — CRACKED (VERT STAB)

AT HMV, FOUND LOWER LEFT CORNER CRACKED VERT WEB INSIDE VERT STAB AT STA 1303. REPAIRED PER SRM 53-10-4 FIG 17.

Part: WEB — CRACKED (VERT STAB)

AT HMV, FOUND LOWER RT CORNER CRACKED VERT WEB INSIDE VERT STAB STA 1303. REPAIRED PER SRM 53-10-4 FIG 17.

Part: RIB — CRACKED (NR 4 LE SLAT)

DURING HMV, FOUND NR 4 SLAT RIB CRACKED O/B RIB OF O/B TRACK. REPAIRED PER MM 57-54-0.

Part: RIB — CRACKED (NR 8 LE FLAP)

FOUND DURING HMV - NR 8 SLAT NR 13 RIB IS CRACKED IN RADIUS. FABRICATED REPAIR PER M/M 57-54-0, FIG 805.

Part: SKIN — CRACKED (BS 1090)

THE FUSELAGE SKIN AT STA 1090 IS CRACKED IN TWO PLACES. A .75 INCH CRACK EXISTS ALONG STR 1 AND A .25 INCH CRACK EMANATES FROM THE FIRST FASTENER HOLE RIGHT OF THE CENTERLINE. THIS FASTENER HOLE IS THE FORWARD MOST FASTENER FOR THE DOGHOUSE FAIRING ATTACH ANGLE. THESE 2 CRACK SITES ARE .75 INCH APART CIRCUMFERENTIAL, AND THE CRACKS RUN LONGITUDINALLY. ACCOMPLISHED REPAIRS PER ERA 232051-14AD.

Part: RIB — CRACKED (NR 3 LE SLAT)

DURING HMV, FOUND NR 3 SLAT, RIB NR 9 CRACKED IN RADIUS. REPAIRED PER M/M 57-54-0 FIG 805.

Part: ANGLE — CRACKED (NR 6 LE FLAP)

FOUND DURING HMV, NR 6 SLAT, CRACKED ANGLE BETWEEN DE-ICE TUBE AND FARTHEST ROLLER TRACK. REPAIRED CRACK PER M/M 57-54-0, FIG 812.

Part: WEB — CRACKED (NR 6 LE SLAT)

DURING HMV, FOUND NR 6 SLAT I/B WEB AT DE-ICE TUBE CRACKED. REPAIRED ANGLE PER M/M 57-54-0 FIG 805.

Part: RIB — CRACKED (NR 3 LE SLAT)

DURING HMV, FOUND NR 3 SLAT, RIB NR 7 CRACKED IN RADIUS. REPAIRED PER M/M 57-54-0 FIG 805.

Part: RIB — CRACKED (NR 3 LE SLAT)

DURING HMV, FOUND NR 3 SLAT, RIB NR 6 CRACKED IN RADIUS. REPAIRED PER M/M 57-54-0 FIG 805.

Part: RIB — CRACKED (NR 8 LE SLAT)

DURING HMV, NR 8 SLAT, RIB NR 6 FOUND CRACKED IN RADIUS. REPAIRED PER M/M 57-54-0.

Part: FITTING — CORRODED (LT WING)

DURING HMV, FOUND LT AFT WING ATTACH BODY FITTING WAS CORRODED AT 6 O'CLOCK POSITION. REPAIRED PER SRM 57-10-7.

Part: RIB — CRACKED (VERTICAL STAB)

FOUND ON HMV, 4TH RIB DOWN FROM HOLE STA 6 STR 8L CRACKED. FABRICATED REPAIR PER M/M 55-33-0 PG 803.

Part: RIB — CRACKED (VERTICAL FIN)

DURING HMV, FOUND VERTICAL FIN INTERIOR STATION 1303 RIB CRACKED AT BOTTOM. DYE CHECKED AND REPAIRED PER SRM 53-10-4.

Part: DOUBLER — DAMAGED (GRND AIR CONNECT)

DURING HMV, FOUND TEMPORARY REPAIR DOUBLER ON PNEUMATIC GROUND AIR CONNECTOR CUTOUT AFT INBOARD CORNER. FABRICATED NEW DOUBLER PER M/M 53-30-0 PGS 803 AND 804.

Part: COWL — WORN (NR 2 ENGINE)

DURING HMV, NR 2 ENGINE RT AFT COWL PANEL WAS FOUND WITH TOP SIDE SKIN RIVETS ALONG LONGERON ARE SHORT OF EDGE DISTANCE. ALSO, TOP EDGE OF COWL IS WORN. REPAIRED PER SRM 54-10-3 FIG 6.

Part: EEL — INOPERATIVE (CABIN)

AFT STRIP OF CABIN EMERGENCY FLOOR LIGHTS INOP. REPAIRED SHORT AT FLOOR STRIP AND REPLACED POWER SUPPLY. OPERATION NORMAL.