N727US

ATA 5510

Part: BEAM — CORRODED (HORIZONTAL STAB) · corrosion level 2 · airframe 72,087 hrs · 38,682 cycles

WHILE AT C-CHECK IN KBQK, FOUND THE LT HORIZONTAL STABILIZER, UPPER SURFACE, OUTBOARD TRAILING EDGE BEAM TO BE CORRODED ABOVE THE #6 ELEVATOR HINGE. CUT OUT THE DAMAGED SECTION OF THE LH BEAM BETWEEN STATIONS 136.50-173.21, THEY FABRICATED A NEW BEAM SECTION FROM BAC 1520-1158. PICKED UP HOLES, CLEANED, TREATED, PRIMED, AND INSTALLED THE SPLICE REPAIR SECTION OF THE LT HORIZONTAL UPPER TRAILING EDGE BEAM IAW SRM 55-10-6 AND 51-30-2, NO OTHER DEFECTS NOTED AT THIS TIME

ATA 5712

Part: RIB — CRACKED (LT WING) · airframe 72,087 hrs · 38,682 cycles

WHILE AT C- CHECK IN KBQK, DURING A HFEC INSPECTION OF THE RH RIB CHORD AT STATION BL 70.5 PER AD 14-04-09 S/B 57-0112 R5,A CRACK WAS FOUND IN HOLE MARKED ON THE RH SIDE AT STATION BL 70.5. STOP DRILLED CRACK, PERFORMED A HFEC INSPECTION OF ALL EXISTING HOLES, NO OTHER CRACKS FOUND AT THIS TIME, INSTALLED LARGE REPAIR KIT (65C33202-98) ON RT SIDE AT RBL 70.5,BS 760.95 IAW S/B 57- 0112 R5 AND SRM 51-30-2.

ATA 5311

Part: FRAME — DAMAGED (ZONE 200) · airframe 69,970 hrs · 37,616 cycles

DISCREPANCY WHILE AT C-CHECK AT COMMERCIAL JET IN KDHN THE FOLLOWING DAMAGE WAS FOUND AT STATION 783 WL 213RBL AND LBL63 HAVE PILOT HOLES WITH NO PITCH FROM EXISTING HOLES, CHAFE DAMAGE AND A DRILL STRIKE ON THE INBOARD FREE FLANGE OF THE FRAME. CORRECTIVE ACTION: COMMERCIAL JET IN KDHN FABRICATED 4 EACH FREEZE PLUGS FROM 7075-T651, A CIRCULAR FILLER FROM 7075-T6 .090, STRAP FROM 7075-T6 .071 AND A REPAIR DOUBLER FROM 7075-T6 .071 IAW AEI EO# EO12870, TREATED AND PRIMED PARTS AND INSTALLED PARTS IAW AEI EO NO EO12870. WORK APPROVED BY AEI 8110-3 DATED 2/15/2021 BY ROLF D. HAMERQUIST DERT-636371-NM

ATA 7200

Part: ENGINE — FOD (NR 3) · airframe 69,816 hrs · 37,544 cycles

DISCREPANCY: CREW REPORTED THAT AFTER DEPARTURE FROM KLRD AND CLIMBING THROUGH 10000 FEET, THE NR 3 ENGINE FAILED WITH ASSOCIATED VIBRATIONS. THEY DECLARED AN EMERGENCY AND PERFORMED THE ENGINE FIRE, SEVERE DAMAGE OR SEPARATION CHECKLIST AND LANDED AT THE DEPARTURE AIRPORT WITHOUT FURTHER INCIDENT. CORRECTIVE ACTION: USA JET MAINTENANCE IN KLRD INSPECTED THE ENGINE AND FOUND ALL FOUR STAGES OF THE TURBINE SECTION TO HAVE FOD. THEY REMOVED AND REPLACED THE NR 3 ENGINE, IAW USA JET GMM VOLUME 4 CHAPTER 72.01.1 TO 72.01.26. ALL OPERATIONS AND LEAKS NORMAL DURING ENGINE TRIM RUN.

ATA 5311

Part: ANGLE — CRACKED (FUSELAGE) · airframe 69,548 hrs · 37,405 cycles

DISCREPANCY: DURING MAINTENANCE INSPECTION PER AEI SUPPLEMENT SID# 50-601 REV F, TASK AEI-FC-5-3, A CRACK WAS FOUND ON FAILSAFE ANGLE OF THE FRAME LOCATED AT STA. 480. THE CRACK STARTED ON THE FASTENER THAT ATTACH THE ANGLE TO FRAME S-17L. CORRECTIVE ACTION: USA JET MTX. AT KYIP PERFORM A HFEC INSPECTION ON ALL OPEN HOLES COMMON TO THE REPAIR PER BOEING NDT MANUAL, TRIMMED OUT EXISTING ANGLE PER AEI EO10363, FABRICATED A-2 REPAIR ANGLE FROM 0.125” 7075-0 ALUMINUM AND A -1 FILLER FROM 0.100” 7075-T6 ALUMINUM. INSTALLED -1 FILLER AND -2 REPAIR ANGLE AT BS 480 WET WITH BMS5-95 SEALANT USING HL62PB6-X HI-LOKS AND HL79-6 COLLARS ON EXITING HOLES AND HL18PB6-X HI-LOKS WITH HL70-6 COLLARS ON NEW HOLES PER SRM 51-30-2 AND AEI EO10363, APPROVED BY 8110-3 DATED MARCH 09, 2020.

ATA 5320

Part: CHANNEL — CORRODED (STA 470, LBL 43) · corrosion level 2 · airframe 68,522 hrs · 36,561 cycles

DISCREPANCY: DURING INSPECTION AT KYIP MAINTENANCE FOUND PRESSURE SEAL ZEE CHANNEL CORRODED AT STA 870, LBL 43. CORRECTIVE ACTION: AIRCRAFT FERRIED TO KSFB FOR REPAIR. MAINTENANCE AT KSFB REMOVED AND REPLACED CORRODED ZEE CHANNEL WITH NEW I/A/W B727 SRM 51-10-1, 51-10-2, AND 51-30-2.

ATA 2130

Part: SPRING — FAILED (RELIEF VALVE) · airframe 68,269 hrs · 36,775 cycles

CREW REPORTED DURING CRUISE, AT FL200, CABIN PRESSURE BEGAN TO INCREASE RAPIDLY. CABIN ALTITUDE WARNING HORN SOUNDED. RECALL ACTION ITEMS COMPLETED, AND EMERGENCY PROCEDURES CHECKLIST FOLLOWED. EMERGENCY DECLARED AND RAPID DESCENT TO 10,000 FEET COMPLETED. AT 10,000 FEET, CABIN WAS PRESSURIZING TO 8,500 FEET. DUE TO FUEL REMAINING INSUFFICIENT TO CONTINUE TO DESTINATION AIRPORT, DECISION MADE TO RETURN TO DEPARTURE AND CANCELLED EMERGENCY. REMAINDER OF FLIGHT UNEVENTFUL. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE OPS CHECKED PRESSURIZATION CONTROL IAW AMM 21-31-00, PG. 201-202, STEPS 1, 2, 3 AND PG. 501-504 STEPS 1, PARA A-D. OPS CHECKED GOOD. PERFORMED OPS CHECK OF PRESSURE CONTROLLER IAW MM 21-30-00, FAILED THE OPS CHECK. ALL OTHER CHECKS & STEPS OPS CHECKED GOOD. FOUND PRESSURE SURGES IN FLIGHT WITH LEFT PACK ON. MAINTENANCE CLEANED THE WATER SEPARATOR IAW MM 21-55-51, AND MM 21-55-41. OPS AND LEAK CHECKED GOOD. INSPECTED THE LT WATER SEPARATOR BYPASS VALVE & 35° CONTROL VALVE IAW AMM 21-50-01. CHECKED GOOD. NO DEFECTS NOTED. FOUND MAIN DISTRIBUTION MANIFOLD RELIEF VALVE OSCILLATING WITH BOTH PACS ON. REPLACED THE RELIEF VALVE SPRINGS IAW MM 21-21-11. OPS CHECKED GOOD. THE AIRCRAFT WAS RETURNED TO SERVICE.

ATA 5740

Part: FITTING — CORRODED (LT WING) · airframe 66,371 hrs · 35,809 cycles

DURING C-CHECK DISCOVERED CORROSION ON THE LT AFT BOTTLE PIN FITTING & BUSHING. COMPLETED REPAIR OF LT AFT BOTTLE PIN FITTING BY INCREASING THE COUNTER BORE & REPLACING THE BUSHING IAW SERVICE BULLETIN 727-57-0175 R3 PAGE 20 PART III STEP “E” FIGURE 9.

ATA 5315

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 66,371 hrs · 35,809 cycles

DURING C-CHECK DISCOVERED CORROSION ON THE FLOORBEAM AT STATION 1030, RBL55 LOWER SURFACE UNDER TOP CAP. COMPLETED FLOORBEAM REPAIR AT STATION 1030, RBL 50-55 IAW SRM 53-10-8 FIGURE 3 PAGES 18 - 23.

ATA 5330

Part: SKIN — CRACKED (FUSELAGE) · airframe 66,371 hrs · 35,809 cycles

DURING C-CHECK DISCOVERED A CRACK ON THE BELLY SKIN & A CORRODED FLOORBEAM AT STATION 729. REPAIRED CORRODED FLOORBEAM & BELLY SKIN IAW SRM 53-30-3 FIGURE 6 SHEET 1 53-30-3 FIGURE 3 SHEET 4 & 51-30-2 PAGE 2-3 PARAGRAPH 4.

ATA 5730

Part: SKIN PANEL — CORRODED (RT WING) · airframe 66,371 hrs · 35,809 cycles

DURING C-CHECK DISCOVERED CORROSION ON THE RT UPPER SURFACE SKIN OF WING AT WING STATION 727.5 TOWARD THE LE. CORROSION REMOVED ON UPPER SURFACE OF RT WING WITHIN LIMITS IAW SRM 57-30-01 PAGE 2 FIGURE 1 SHEET 2. INSTALLED REPAIR DOUBLER IAW SRM 51-10-2 & DWG 57-15128-1.