N775NC

Part: SKIN — DENTED (FUSELAGE) · airframe 76,137 hrs · 72,482 cycles

DURING LIGHTNING STRIKE INSPECTION, FOUND DENT ON LOWER LT SIDE OF FUSELAGE APPROX 16 IN OTBD OF VHF 2 COMM ANTENNA. REPAIRED IAW SRM 53-04-3, FIG 8.

Part: LIGHT — BROKEN (CABIN) · airframe 76,001 hrs · 72,338 cycles

DURING LINE CHECK, MX FOUND THE EMERGENCY ESCAPE LIGHTING AT 7D TO BE BROKEN. MX R & R THE LIGHT ASSY AND RETURNED THE ACFT TO SERVICE.

Part: SLIDE — LOW PRESSURE (R1 DOOR) · airframe 75,692 hrs · 71,981 cycles

DURING LINE CHECK, MAINTENANCE FOUND THE 1R DOOR SLIDE PRESSURE AT ZERO. MAINTENANCE REPLACED THE DOOR SLIDE AND RETURNED THE AIRCRAFT TO SERVICE.

Part: LANYARD — MISROUTED (R1 DOOR SLIDE) · airframe 75,558 hrs · 71,817 cycles

DURING LINE CHECK, MAINTENANCE FOUND THE R1 DOOR SLIDE LANYARD TO BE IMPROPERLY ROUTED. MAINTENANCE REINSTALLED THE LANYARD AND RETURNED THE AIRCRAFT TO SERVICE.

Part: CONNECTOR — LOOSE (CABIN) · airframe 3,859 hrs · 3,526 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE OVERHEAD EMERGENCY ESCAPE LIGHTING IN THE REAR OF THE CABIN WAS INOPERATIVE. MAINTENANCE FOUND A LOOSE CONNECTION AT THE LIGHT HOUSING ASSEMBLY, TIGHTENED THE CONNECTION AND THE SYSTEM RETURNED TO NORMAL OPERATION.

Part: BATTERY PACK — DISCHARGED (CATWALK) · airframe 3,859 hrs · 3,526 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE EMERGENCY PATHWAY LIGHTING FOR THE CATWALK IN THE TAIL COMPARTMENT WAS DIM. MAINTENANCE REPLACED THE BATTERY PACK AND THE LIGHTS. RETURNED TO AN OPERATIONAL CONDITION.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 2,953 hrs · 2,636 cycles

EMERGENCY EGRESS AISLE LIGHTS TO DIM, ROWS 9 THROUGH 12. REPLACED BATTERY PACK, CHECKS OK.

Part: FLOORBOARD — CRACKED (CABIN) · airframe 59,863 hrs · 61,087 cycles

CENTER AISLE FLOORBOARD 60D HAS 11 INCH CRACK. P/N 9923615-11 IPC 53-21-00-03G ITEM 200. STA MSP 14SEP11 ATA 5322 ENTR 555596 S POS: CN TASK HRS: 0002.0 TASK ELAPSE TIME HRS: 0002.0 RII: N. REPLACED AISLE FLOORBOARD 60D, ROBBED FROM A/C 9871 PER DC9 AMM 53-20-01.

Part: SKIN — CHAFED (VERTICAL STAB) · airframe 73,589 hrs · 69,813 cycles

VERTICAL STAB LT SKIN CHAFED AFT OF LEADING EDGE. REMOVED AND REPLACED LT SKIN PN H5912130-71 PO 1130960 IAW DC-9 SRM 51-30-1, 51-30-2 AND 51-30-5 P-243.

Part: INTERCOSTAL — BENT (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT ACC COMPT BETWEEN STA 1314 AND 1326 LT SIDE INTERCOSTAL IS BENT AND ATTACH CLIP AFT END IS CRACKED. REMOVED INTERCOSTAL, REFORMED, INSPECTED, NO CRACKS NOTED, REMOVED ATTACH CLIP AT AFT END, FABED NEW CLIP FROM MAT ID 2024-T3 .032, LOCATED, DRILLED, TREATED, PRIMED AND INSTALLED NEW CLIP AND INTERCOSTAL IAW DOUGLAS DRAWING 9917701 AND SRM 51-30-2, 51-30-5, 51-30-4, 51-10-3.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

6C/281 MAIN PASSENGER CABIN STA 1184 RBL 22 ELEVATOR CONTROL CABLES PULLEY BRACKET MOUNT SUPPORT AFT SIDE OF PULLEY CRACKED. REMOVED SUPPORT, STOP DRILLED CRACK, NDT VERIFIED CRACKS CONTAINED. FABRICATED AND INSTALLED REPAIR PARTS FROM NR 1120665. ALL WORK DONE IAW DC-9 SRM 53-01 PG 16 SHEET 4, 51-30-5 AND 51-30-1. .050 AND .025 7075T6 P-245 REQUIRED INSPECTION COMPLETED BY Q-948 490448.

Part: FLOOR PANEL — CRACKED (MAIN CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN PASSENGER CABIN FLOOR PANEL NR 86LT SIDE IS CRACKED 2 PLACES. CUT OUT DAMAGE SECTION 25 INCHES BY 9 INCHES. NO DEFECTS IAW NDT SPM 06-10-06. FABRICATED AND INSTALLED FILLER .020 7075-T6 AND DOUBLER .032 7075-T6 IAW ERA 491735-14. P-226 REQUIRED INSP COMPLETED.

Part: FLOOR PANEL — CRACKED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PANEL NR 85 HAS CRACK INBD AFT END. CUTOUT DAMAGE 2 INCHES BY 1.25 INCHES NO DEFECTS PER NDT SPM 06-10-01. FABRICATED AND INSTALLED FILLER AND DOUBLER FROM .020 7075-T6 PO NR 1120495 IAW DC-9 SRM 53-01 FIG 4, P225. REQUIRED INSPECTION COMPLETED PEMCO Q919.

Part: CHANNEL — DENTED (FLOOR PANEL) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PANEL NR 77 HAS 5 HAT CHANNELS DISBONDED AND IEA HAS DENT. REMOVED HAT CHANNELS IAW SRM 51-10-4. LOCATED AND DRILLED HOLES IN DISBONDED HAT CHANNELS AND INSTALLED HAT CHANNELS IAW SRM 51-30-2 AS PER ENGINEERING. REQUIRED INSPECTION COMPLETED PEMCO Q919.

Part: FLOOR SUPPORT — CRACKED (MAIN DECK) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PANEL 66 HAS 5EA HAT CHANNELS CRACKED. REMOVED AND REPLACED 5 HAT CHANNELS IAW SRM 51-30-2. UPON INSP FOUND 2 CRACKS. CUTOUT DAMAGED AREA 2 INCH BY 1 1/2 INCH. NDT HFEC INSP IAW NDT SPM06-10-01. NO CRACKS NOTED. FABRICATED AND INSTALLED 1 DOUBLER AND 1 FILLER IAW SRM 53-23-00 FIG 5. TAGGED REPAIR IAW PS 900-5-1 NR 4 P245.

Part: SKIN — DAMAGED (FLOOR PANEL) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PANEL 73 HAS 1 HOLE ON TOP SKIN. CUT OUT DAMAGE (1") IAW SRM 53-01 FIG, 4. NDT VERIFIED NO CRACK NOTED IAW NDT SPM 06-10-01. ORIG MAT OF PANEL 73 IS .020" 7075-T6 IAW SRM 53-23-0. FABRICATED DOUBLER FROM .032" 7075T6 AND INSTALLED IAW SRM 53-01 FIG 4.

Part: STRUCTURE — CHAFED (BS 1190 L17R) · airframe 73,589 hrs · 69,813 cycles

AFT ACC COMPT STA 1190 L17R HOLE CHAFED IN FR OB OF VALVE. CUT OUT DAMAGED AREA 2.5 INCH BY 1 INCH. NO DEFECTS PER NDT SPM 06-10-01.001. FIB FILLER FROM PART NR 9958233-27 AND DOUBLERS FROM.063 7075-T6 PART NR SR09530035-25. INSTALLED YAW DC9 SUM 5304 FIG 4.

Part: FLOOR SUPPORT — CRACKED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PANEL 73 HAS BTM SIDE HAS 1 HAT CHANNEL CRACKED APPROX 1/2 IN. CUT OUT DAMAGED HAT CHANNEL (2 INCH LENGTH) IAW SRM 53-05 FIG 1. RECEIVED AND TRIMMED CHANNEL AND INSTALLED IAW SRM 53-05 FIG 1. TAGGED REPAIR IAW DPS 900-5-1 NR 4.

Part: FLOORBEAM — CRACKED (BS 775 RBL 52) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 775 RBL 52 FLOORBEAM CRACKED. REMOVED FLOORBEAM IAW DC9 SRM 51-30-1, 51-30-2, 51-30-05. RECEIVED NEW FLOORBEAM CFE PN NR 9915527 -506. LOCATED, DRILLED AND DEBURRED IAW DOUGLAS DRAWING 9915527. TREATED AND PRIMED IAW SRM 51-10-3. INSTALLED FLOORBEAM IAW SRM 51-30-1, 51-30-2, 51-30-5. REQUIRED INSPECTION COMPLETED.

Part: WEB — CRACKED (BS 700-780) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVER WING RBL-44 BETWEEN STA 740 AND 770 WEB TO CENTER TANK ANGLE CRACKED. NDT MARKED ENDS OF CRACK PER NDT SPM 06-10-01. GAINED ACCESS AND REMOVED DAMAGED SECTION OF ANGLE FROM STA 700-780 RBL 44. RECEIVED NEW ANGLE. INSTALLED NEW ANGLE IAW SRM 51-10-4, 51-30-5 AND CAP SEALED IAW SRM 51-20-0 P-239 16 MAY 11.

Part: SKIN — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FUSELAGE EXTERIOR LT SIDE AIR STAIRS CUTOUT AFT LOWER CORNER HAS APPROX 2 INCH CRACK IN FUSELAGE SKIN. NDT VERIFIED CRACK. TRIMMED OUT SKIN WITH DIMENSIONS OF 1.5 IN BY 1.70 IN IAW DWG NR SR09530031. HFEC INSPECTED IAW NDT SPM 06-10-01.001.CRACK TO BE CONTAINED AND NO CRACK IN DOUBLER. FABRICATED DOUBLER AND FILLERS. INSTALLED IAW DWG NR SR09530031 AND SRM 51-30-5.

Part: FRAME — CRACKED (BS 734 L18R) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 734 RIGHT LONG 18 MAIN FRAME CRACKED. REMOVED AND INST NEW FRAME PART NR 9923406-502 IAW 51-30-5, DWG 3924863.P-226. REQUIRED INSPECTION COMPLETED.

Part: VANE — CHAFED (LT WING TE FLAP) · airframe 73,589 hrs · 69,813 cycles

LEFT WING MOVEABLE VANE INBD EDGE CHAFED AT LOWER END PARTS RACK 82B. -5 ZEE ANGLE AND -21 ANGLE FOUND TO BE OUT OF LIMITS IAW DC-9 SRM 57-01 FIG 1. FABRICATED -21 ANGLE IAW DC9 SRM 51-10-02 MTL.032 2024 T3. TREATED AND PRIMED IAW DC-9 SRM 51-10-3. RECV NEW -5 ZEE ANGLE PN 09-2700-3-2766. INSTALLED -5 AND-21 ANGLES IAW DC-9 SRM 51-30-02, 51-30-08. TOP COATED IAW DC-9 SRM 51-10-3.

Part: ACCESS PANEL — DAMAGED (RT WING) · airframe 73,589 hrs · 69,813 cycles

RIGHT WING FUEL ACCESS 1472A LANDING HAS 1 MIS DRILLED HOLE. REAMED HOLE TO .435. FABRICATED FREEZE PLUG. INSTALLED IAW ERA 491735-14 P-226.

Part: FRAME — GOUGED (BS 1136 BULKHEAD) · airframe 73,589 hrs · 69,813 cycles

AFT WET AREA-STA 1136 LEFT LONG 4 PYLON BULKHEAD FRAME GOUGED. BLEND GOUGE 1" BY 4" ORIG .050 REMOVED .012 REMAINING .038. FOUND OUT OF LIMITS PER SRM 53-01.FAB AND INSTALLED 2 ANGLES FROM .040 7075-0 IAW SRM 53-02 FIG 2 SHEET 4. HEAT TREATED ON TRAVELER 2547NO1681.

Part: FRAME — CRACKED (BS 753) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 753 RIGHT LONG 18 MAIN FRAME CRACKED. REMOVED MAIN FRAME AT STA 753 RIGHT LONG 18. RECEIVED NEW FRAME P/N 97-5300-3-0024. INSTALLED NEW FRAME IAW SRM 51-30-5 P226.

Part: FLOOR SUPPORT — CORRODED (BS 237-302) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 237-302 BL0 FLOOR SUPPORT HAS CORROSION REMOVED AND REPLACED FLOOR SUPPORT IAW SRM 51-30-05. CORROSION FOUND TO BE OUT OF LIMITS IAW SRM 53-01 FIG 1.

Part: INTERCOSTAL — CRACKED (BS 148-160) · airframe 73,589 hrs · 69,813 cycles

COCKPIT BETWEEN STA 148 AND STA 160 LOWER INTERCOSTAL CRACKED AT FWD WIRE CONDUIT. REMOVED WEB ATTACH PLATE AND 2 BRACKETS TO FOM. REMOVED INTERCOSTAL IAW SRM 51-30-2. FABRICATED REPAIR ANGLES FROM 3011/2H .063 PO NR 0722363 IAW SRM 53- 05-51-10-2. INSTALLED ANGLES IAW SRM 51-30-5. RESTORED ACCESS P239. REQUIRED INSP COMPLETED.

Part: CUSP WEB — CRACKED (MAIN CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN BETWEEN STA 1044 AND 1060 LT CUSP WEB CRACKED SEVERAL PLACES. CUTOUT DAMAGE AREA 4.5 INCH BY 29.875 INCH. NO DEFECTS PER NDT SPM 06-10-01. FAB AND INSTALLED REPAIR FROM .032 INCH 7075-T6 IAW DWG SG09530019.P226. REQUIRED INSP.

Part: SEAT TRACK — CORRODED (BS 200-285) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 200-285 RBL 22, SEAT TRACK HAS CORROSION. REMOVED CORROSION FROM SEAT TRACK IAW 53-01 FIG 1 OUT OF LIMITS RECEIVED NEW TRACK P/N 27726100. REMOVED AND REPLACED SEAT TRACK IAW DC-9 SRM 51-30-05. REQUIRED INSPECTION.

Part: PULLEY BRACKET — CHAFED (AIRSTAIR DOOR) · airframe 73,589 hrs · 69,813 cycles

AFT ACC COMPT STA 1303 LT PULLEY MOUNT BRACKET AT AIRSTAIR DOOR CUT OUT CHAFED. REMOVED AND REPLACED LT ELEVATOR CONTROL CABLE PULLEY MOUNT BRACKET AT STA 1303 IAW DC-9 SRM 51-30-01. TENSIONED LT ELEVATOR CONTROL CABLES 3B, 4B, IAW MM 27-30-00. FINAL RIGGING TO BE ACCOMP ON CARDS 2730-6398LT AND RT P128 REQUIRED INSP.

Part: FRAME — DAMAGED (BS 908 L29R/L) · airframe 73,589 hrs · 69,813 cycles

AFT CARGO COMPT FRAME REPAIR ANGLE HAS SEVERAL IMPROPERLY INSTALLED FASTENER'S SOME PULLED THROUGH AND TOOLING GOUGE'S IN UPPER FWD FLANGE AT STA 908 BETWEEN LONG S29L-29R. REMOVED DAMAGED FRAME REPAIR IAW SRM 51-30-5. FABRICATED AND INSTALLED NEW FRAME SECTION AND SPLICES IAW SRM 53-03 FIG 2A.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

KEEL AREA BETWEEN MAIN GEAR DOORS LANDING FOR PANEL 5501NW HAS CORROSION SEVERAL PLACES. REMOVED CORROSION OUT OF LIMITS IAW DWG 9923459. LOCATED, DRILLED, TREATED, PRIMED, TOP COATED AND INSTALLED NEW WEB SKIN PART NR 9923459-35 ON IAW SRM 51-10-4, 51-10-3, 51-30-1, 51-30-2 PER DWG 9923457.

Part: STRINGER — DAMAGED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FWD CARGO STA 535 L24L HAS 1 MISS DRILLED HOLE IN RECEIVED .063 7075-T6 IAW SRP DC-9-53-10-04-801-663A-A. FABRICATED, LOCATED AND DRILLED REPAIR ANGLE IAW SRM AND SPM 51-10-4, 51-10-2 AND DC9-A-53-10-04-801-663A-A. TREATED AND PRIMED IAW SRM 51-10-3. INSTALLED IAW SRM 51-30-5.

Part: FRAME — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT CARGO COMPT AFT FACE OF FRAME 1108 SPLICE UNDERNEATH OF UPPER FLANGE HAS CORROSION BETWEEN LONG 27L AND L28L. REMOVED SPLICE IAW 51-30-5. TOOLING MARK ON SPLICEOUT OF LIMITS IAW SRM 53-01 FIG 1. RECEIVED MAT .063 7075-0. RECEIVED FROM HEAT TREAT ON TRAVELER 2547NO1607. LOCATED, DRILLED AND DEBURRED NEW SPLICE IAW SRM 51-10-4. TREATED AND PRIMED IAW SRM 51-10-3. INSTALLED SPLICE IAW SRM 51-30-5.

Part: SKIN — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FUSELAGE EXTERIOR SKIN BETWEEN STA 1151 AND 1167L29L AND L29R PREVIOUS REPAIR HAS CORROSION AROUND DRAIN HOLE. REPAIR HAS CORROSION THAT REQUIRES BLENDING. CANT BLEND ON REPAIR OUT OF LIMITS. REMOVED REPAIR DOUBLER. REQUEST NDT FOR CRACKS, NO CRACKS NOTED ZETEC A2700. FAB REPAIR DOUBLER FROM .0712024-T3 AND FILLER .063 7075-T6. INSTALLED DOUBLER AND FILLER IAW DC9 SRM 53-04 12B SH 1.

Part: LONGERON — DAMAGED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FWD CARGO STA 535 L24R HAS 1 HOLE IN LONGERON LOWER LEG. TRIMMED OUT DAMAGED AREA. NDT VERIFIED DAMAGE NO LONGER EXISTS. FABRICATED REPAIR DOUBLER FROM 7075 T6 .063. DRILLED AND DEBURRED, ALODINE AND PRIMED AND INSTALLED IAW SRM 51-10-3, 51-30-2 AND 51-30-5.

Part: PANEL — CRACKED (NR 1 PYLON) · airframe 73,589 hrs · 69,813 cycles

NR 1 ENG PYLON T/E PNL LANDING HAS A CRACK FWD OTBD END COMING PAST PREVIOUSLY REPAIRED STOP DRILL HOLE AT UPPERSIDE. REMOVED PREVIOUS REPAIR DOUBLER PER DC9 SRM 51-30-2. DRILLED STOP HOLE, FABRICATED NEW REPAIR DOUBLER PER DC-9 SRM 54-01 FIG 2 SHEET 3. MATERIAL ID .032 TITANIUM PER SRM 54-20-0 FIG 2 SHEET 1. PASSIVATED PER SRM 51-10-3. INSTALLED NEW REPAIR PER SRM 54-01 FIG 2 SHEET 3.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 579 RIGHT LONG 17 FRAME CRACKED. CUT OUT DAMAGE IAW DC-9 SRM 53-03 FIG 32. 1 1/4 INCH BY 3 3/4 INCH NDT VERIFY NO DAMAGE REMAINS. FABRICATED -29 FILLER .063 7075T6 IAW 53-03 FIG 32. FABRICATED -33 ANGLE .071 7075-0 PO 1120609. HEAT TREATED ON TRAVELER 216DA956. RECEIVED REPAIR ANGLE SR095300-5. INSTALL IAW 53-03 F32.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 522 RIGHT LONG 17 FRAME CRACKED. CUT OUT DAMAGE IAW DC9 SRM NR 53-03 F32 NDT VERIFY NO CRACK REMAINS. FAB FILLER IAW 53-03 FIG 2 MAT .063 7075T6.FAB DRILL UP ANGLE -5 .O71 70750. HEAT TREATED ON TRAVELER 216DA956. RECEIVED REPAIR ANGLE SR09530095-5 AND DRILL IAW 53-03 F.32 FAB -7.100 7075T6 IAW 53-03 F1 INSTALL REPAIR IAW 53-03 FIG 32. INSTALLED ID TAG PER DPS 900-5-1 NR 4.

Part: FLOOR PANEL — CRACKED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN-FLOOR PANEL 35 HAS 1 HAT CHANNEL CRACKED IN 2 PLACES. REMOVED CRACKED HAT CHANNEL IAW SRM DC-9 51-30-2. INSTALLED NEW HAT CHANNEL IAW SRM DC9 53-01 FIG 4 PART NR 2912282 LOT NR 1120523, P-245 Q-948 490448 10 MAY 11.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 503 FRAME CRACKED AT L17R 2 FASTENERS. AT FRAME 503 L17R CUT OUT DAMAGED SECTION 3 3/4 IAW DC-9 SRM 53-03 FIG 32 NDT VERIFIED DAMAGE REMOVED. FABRICATED 1EA -33 ANGLE FROM 7075-0 0.071. HEAT TREATED ON PEMCO TRAVELER NR 2547NO1585TO 7075-T6. FABRICATED 1 -29 FILLER MAT .063 7075-T6. RECEIVED -5 ANGLE FABRICATED 2 -7 DOUBLERS FROM 100 7075-T6. ADDED WEIGHT 9.7 OZ. INSTALLED IAW DC-9 SRM 53-03 FIG 03 FIG 32.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 541 FRAME AT L17R CRACKED AT FASTENER. CUT OUT DAMAGE AREA 1 1/4 BY 3 3/4 IAW 53-03 FIG 32. NDT VERIFY DAMAGE REMOVED. FAB -33 FILLER IAW 53-03 F.32. MATERIAL .071 7075-0 AND DRILL UP. HEAT TREATED ON TRAVELER 216DA956. RECEIVED ANGLE PN SR09530095-5. DRILL UP IAW 53-03 F.32. FAB 2 MAT 100 7075T6. INSTALLED REPAIR IAW 53-03 FIG 32. ID TAG PER DPS 900-5-1 NR 4 ADD WEIGHT 7.9 OZ

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 200 TO 247 LBL 22 SEAT TRACK HAS CORROSION. REMOVED CORROSION FROM MAIN CABIN FLOOR TRACK STA 200 TO 247 LBL22 IAW DC9 SRM 51-10-3. FOUND TO BE OUT OF LIMITS IAW DC9 SRM 53-03 FIG 4B-1. REMOVED AND REPLACED LBL 22 SEAT TRACK STA 200 TO 302 IAW DC9 SRM 51-30-01.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FWD WET AREA STA 218 LEFT SIDE CUSP WEB CRACKED ON BOTTOM SIDE UNDER Z-ANGLE. REMOVED AND REPLACED SECTION OF CUSP WEB FROM ST 218 TO 237 PER DWG NR 94 FS 481230 SRM 51-10-2, 51-10-4,51-30-2, 51-30-05. FABRICATED NEW WEB FROM .020 7075 T6 LOT NR 1120495 IAW SRM 53-13-2.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 560 RIGHT LONG 17 FRAME CRACKED. AT FRAME 560L 17R CUT OUT DAMAGE SECTION 1 1/4 BY 3 3/4 IAW DC9 SRM 53-03 FIG 32. NDT VERIFIED DAMAGE REMOVED. FABRICATED 1-33 ANGLE FROM 7075-0 .071. HEAT TREATED ON PEMCO TRAVELER NR 2547 NR 1585 TO 7075-T6. FABRICATED 1-29 FILLER MAT .063 7075-T6. RECEIVED -5 ANGLE. FABRICATED 2-7 DOUBLERS FROM 100 7075-T6. INSTALLED REPAIR IAW DC9 SRM 53-03 FIG 32.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 503 FRAME AT L17L CRACKED AT FASTENER CUT OUT DAMAGED SECTION 1 1/4 BY 3 3/4 IAW DC9 SRM 53-03 FIG 32. NDT VERIFIED DAMAGE REMOVED. FABRICATED 1-32 ANGLE FROM 7075-0.071. HEAT TREATED ON PEMCO TRAVELER NR 2547 NO 1585 TO 7075-T6. FABRICATED 1-29 FILLER MAT .063 7075-T6. RECEIVED ANGLE -5. FABRICATED 2-7 DOUBLER FROM .100 7075-T6. INST REPAIR IAW DC-9 SRM 53-03 FIG 32. INSTALLED PER DPS 900-5-1 NR 4.

Part: ATTACH BRACKET — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT ACC COMPT STA 1314 RT INTERCOSTAL SUPPORT BEAM LOWER END ATTACH BRACKET CRACKED. REMOVED CRACKED BRACKET. FABRICATED NEW BRACKET FROM BAC1505-100437 7075 T6 .100. DRILLED AND DEBURED AND ALODINED AND PRIMED AND INST IAW DC9 SRM 51-10-3 AND 51-10-4.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 465 FRAME AT L17R CRACKED AT FASTENER. CUT OUT DAMAGE IAW DC-9 SRM 53-03 FIG 32 1 1/4 BY 3 3/4. NDT VERIFY NO DAMAGE. FABRICATED FILLER IAW 53-03 FIG 32.063 7075T6 IAW 53003 FIG 32. FABRICATED -33 ANGLE .071 7075T0 HEAT TREATED ON TRAVELER 216DA956. RECEIVED REPAIR ANGLE SRO9530095-5. INSTALLED IAW 53-03 AND 32. INSTALLED ID TAG PER DSP 900-5-1 NR 4.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN PASSENGER CABIN STA 313 BL O-LBL 22 FLOOR PANEL SUPPORT IS CRACKED. REMOVED CRACKED FLOOR PNL SUPPORT FROM MAIN PASS CABIN STA 313 BL O-LBL 22. ORIG MAT .050 2024-T3. RECEIVED MAT .050 2024-T3. FABRICATED NEW FLOOR PNL SUPPORT OUT OF .050 2024-T3. LOCATED DRILLED, DEBURRED FASTENER HOLES. TREATED, PRIMED INSTALLED NEW FLOOR PNL SUPPORT AT STA 313 BL O-LBL 22 IAW DC9 SRM 53-13-2, 51-10-2, 51-10-4, 51-10-3, 51-30-2.

Part: WINDOW FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN BETWEEN STA 734 AND 753 RT WINDOW FRAME CRACKED AT FASTENER UPPER FWD END. FABRICATED, LOCATED, DRILLED DEBURRED AND INSTALLED DOUBLER AND FILLER AT MAIN CABIN IAW DC9-A-56-20-02-801-663A-A. MATERIAL VERIFICATION DOUBLER .063 7075-T6 LOT NR 1135900 FILLER .040 2024-T3 LOT NR 1120191 IAW DC9-A-56-20-02-801-663A-A. HFEC INSP IAW DC-9 NDT SPM 06-10-01.

Part: CARGO TRACK — CORRODED (CARGO BAY) · airframe 73,589 hrs · 69,813 cycles

FWD CARGO BETWEEN STA 218 AND 370 RIGHT SIDE TIE DOOR TRACK HAS CORROSION UPPER AND LOWER SURFACE. REMOVED FWD CARGO RIGHT SIDE TIEDOWN TRACK BETWEEN STA 218 AND 370. OUT OF LIMITS IAW SRM DC9 53-01 FIG 1. RECEIVED NEW TIEDOWN TRACK PN130607 TRAVELER 2547NO1608. LOCATED AND DRILLED, DEBURRED AND TRIMMED IAW SRM DC-9 51-10-4. INSTALLED TIEDOWN TRACK IAW SRM DC-9 51-30-1.

Part: FLOOR PANEL — CORRODED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PNL NR 26 HAS CORROSION SPOT TOP SURFACE OF PNL AS MARKED. MAT LOSS OUT OF LIMITS IAW DC9 SRM 53-01. REMOVED DRAIN AND INSTALLED NEW PNL IAW DC9 SRM 51-30-01. OBTAINED MAT FOR NEW PNL SKIN AND HAT CHANNELS MAT ID .032 7075-T6 AND CHANNEL. ASSEMBLED NEW PNL NR 26 IAW ER NR 490844-14MA AND DC-9 SRM 51-10-3, 51-10-4, 51-30-1 AND TAGGED IAW DPS 900-5-1 NO 4 P-226. REQUIRED INSPECTION COMPLETED BY Q-919 483541 07 MAY 11.

Part: VERTICAL SUPPORT — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 775 LBL 44 VERTICAL SUPPORT CRACKED UNDER FLOOR. REMOVED VERTICAL FLOOR SUPPORT IAW SRM DC-9 51-30-2 AND 51-30-5. CUSTOMER FURNISHED SUPPORT PN 3925812U1. LOCATED, DRILLED, DEBURRED IAW SRM DC-9 51-10-4. INSTALLED NEW PART IAW SRM DC-9 51-30-1 AND 51-30-5.

Part: FLOOR PANEL — CORRODED (COCKPIT) · airframe 73,589 hrs · 69,813 cycles

COCKPIT FLOOR PNL 14A HAS CORROSION ON UPPER SURFACE ALSO HAS 1 PUNCTURE THROUGH. REMOVED COCKPIT FLOOR. CORROSION ON SURFACE AND 1 PUNCTURE IAW SRM DC-9 51-30-1. FABRICATED LOCATED, DRILLED, DEBURRED, COUNTERSUNK FLOOR PANEL AND THREE EA HAT CHANNELS .025 7075-T6 LOT NR 1170665 IAW DC-9 SRM 51-10-4 AND DWG NR 9957826 ERA 491732-14MA.

Part: ATTACH ANGLE — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT WET AREA APB RT SIDE NR 4 FORMER OTBD END LOWER ATTACH ANGLE CRACKED. REMOVED DAMAGED ANGLE IAW DC-9 SRM 51-30-01, 51-30-02, 51-30-05. REC'V NEW ANGLE PN NR 99158-232. LOCATED, DRILLED, DEBURRED IAW DC-9 SRM 51-10-05. TREATED AND PRIMED IAW DC-9 SRM 51-10-03. INSTALLED ATTACH ANGLE IAW DC-9 SRM 51-30-01, 51-30-05.

Part: PAN — CRACKED (WINDOW) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN BETWEEN STA 1022 AND 1041 LEFT SIDE WINDOW PAN CRACKED ON TOP AND BOTTOM AFT CORNERS. REMOVED DAMAGED ANGLES IAW DC-9-A-56-20-02-801-663A-A. MATERIAL FABBED DOUBLER .063 PART NR 7075-T6 LOTNR 1135036, FILLER .040 2024-T3 IAW DC9 SRM 51-10-4 DC-9A-56-20-02801-663A-A. ADDED WEIGHT 600 GRAMS ID TAGS IAW DPS 900-5-1 NO 4 SCALE.

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT ACC COMPT STA 1275 L7L CANTED FR CRACKED. REMOVED CRACKED ANGLE. OBTAIN NEW ANGLE PN NR SR09530086-31. DRILLED AND DEBURRED, ALODINED AND PRIMED AND INSTALLED ANGLE IAW DC9 SRM 51-10-5, P-226 07 MAY 11 Q-919 483541 07 MAY 11.

Part: ATTACH BRACKET — DAMAGED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 218 RBL 46 HAS DRILL START IN FLOORBEAM ATTACH BRACKET. REMOVED FLOORBEAM ATTACH BRACKET FROM MAIN CABIN STA 218 RBL 46 IAW DC9 SRM 51-30-06. FABRICATED, LOCATED, DRILLED AND DEBURRED NEW BRACKET PER DRAWING NR 3912075 USING EXTRUSION 2911391. INSTALLED NEW FLOORBEAM BRACKET IN MAIN CABIN STA 218 RBL 46 IAW DC9 SRM 51-30-5.

Part: FLOOR PANEL — CORRODED (COCKPIT) · airframe 73,589 hrs · 69,813 cycles

COCKPIT FLOOR PANEL NR 14 HAS CORROSION SEVERAL PLACES. REMOVED FLOOR PANEL NR 14B. REMOVED CORROSION FROM PANEL IAW DC9 SRM 51-10-3. ORIG THICKNESS OF PANEL IS .025 IAW DWG 9957826. REMOVED .017 .008 REMAINING IAW SRM 51-01. MATERIAL IS OUT OF LIMITS. OBTAINED MATERIAL TO FAB NEW PANEL USING 7075-T6 .025. FABRICATED PANEL, LOCATED AND DRILLED HOLES. DEBURRED, TREATED IAW SRM 51-30-1, 51-10-3. INSTALLED PANEL IAW DC-9 SRM 51-30-1.

Part: FLOOR PANEL — TORN (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PNL NR 79 HAS TORN SPOT ON TOP EDGE OF PNL. OUT OF LIMITS PER SRM 53-01 FIG 1 SHEET 1. FABRICATED PNL FROM .025 7075T6 PER ERA 491734-14MA. TREATED AND PRIMED PER SRM 51-10-2. STENCILED PER ERA 491734-14MA. ID THE REPAIR PER PS900-5-1 NR 4. INSTALLED HAT TO PNL PER ERA 491734-14 MA.

Part: CARGO TRACK — CORRODED (CARGO BAY) · airframe 73,589 hrs · 69,813 cycles

AFT CARGO RT SIDE TIE DOWN TRACK HAS CORROSION IN UPPER SURFACE FROM BS 851 TO 1068. REMOVED CORROSION ON RT TIEDOWN TRACK OUT OF LIMITS PER SRM 53-05 FIG 4C. REMOVED PER SRM 51-30-1 AND 51-30-5. FABED NEW TIEDOWN TRACK, SRM 53-23 FIG 10 AND DWG NR 5922349, SRM 51-10-4. TREATED AND PRIMED PER SRM 51-10-3. INSTALLED TIEDOWN TRACK PER SRM 51-30-1 AND 51-30-5.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PNL NR 64 HAS FASTENER HOLE BROKEN OUT ON END. FABRICATED DOUBLER AND FILLER FOR MAIN CABIN FLOOR PANEL NR 64 IAW SRM DC-9 53-01 FIG 4. .025 7075-T6. LOCATED, DRILLED, DEBURRED IAW SRM DC-9 51-10-4. HFEC INSPECTED IAW NDT SPM 06-10-01.001 DAMAGE CONTAINED INSTALLED DOUBLER IAW SRM DC-9 51-30-2. ID TAG IAW PROCESS STANDARD 900-5-1 NO 4 P-226. REQUIRED INSPECTION COMP BY Q-948 490448 06 MAY 11.

Part: FLOOR PANEL — CORRODED (COCKPIT) · airframe 73,589 hrs · 69,813 cycles

COCKPIT FLOOR PANEL NR 15 HAS CORROSION SEVERAL PLACES. REMOVED CORROSION OUT OF LIMITS IAW DC9 SRM 53-01. OBTAINED MATERIAL TO FAB NEW PANEL USING 7075-T6 .026 IAW DOUGLAS AIRCRAFT DWG NR 9857825. FABRICATED PANEL LOCATED AND DRILLED HOLES IAW DC09 SRM 51-10-4. DEBURRED, TREATED PRIMED AND TOP COATED PANEL IAW DWG NR 9957825 AND ERA 491731-14MA. INST PANEL IAW DC9SRM 51-30-4.

Part: PAN — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FWD CARGO DOOR PAN HAS CORROSION AT RIV-NUTS IN 12 LOCATIONS AS MARKED. REMOVED WEB AND PAN AND 2 SPLICES. OBTAINED NEW PANEL. TRIMMED, FITTING, DEBURRED, DRILLED NEW PAN. ALODINED AND PRIMED AND INSTALLED NEW PAN AND WEB AND 2 FWD AND AFT SPLICES AND ID PLATES AND SEALED AREAS IAW DC9 SRM 53-13-2 FIGURE 2 SHEET 3, 53-05 FIGURE 44 SHEET 2.

Part: FLOOR PANEL — CRACKED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN PASSENGER CABIN FLOOR PANEL NR 35 TOP SKIN CRACKED FROM FASTENER HOLE TO EDGE OF PANEL. REMOVED DAMAGE IAW DC9 SRM 53-01 FIG 4. HFEC INSPECTION IAW DC9 SPM 06-10-01. DAMAGE FOUND TO BE REMOVED. REPAIRED PANEL IAW DC9 SRM 53-01 FIG 11 120294 016607. ADDED WEIGHT 34 GRAMS SCALE H9573 .025 7075T6 P-242.

Part: FLOOR PANEL — CORRODED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PNL NR 20 HAS CORROSION ON TOP AND BOTTOM OF CUT OUT. RECEIVED AND DRILL UP NEW PANEL IAW DC9 SRM 51-10-2 AND 51-10-4. PN 09-5300-0219 MATERIAL LOSS OUT OF LIMITS IAW 53-01 FIGURE 1.

Part: ATTACH FITTING — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN PASSENGER CABIN STA 1136 BULKHEAD AFT SIDE L17R ATTACH CLIP IS CRACKED. REMOVED CLIP. RECEIVED NEW CLIP PN 9912243-39. INSTALLED NEW CLIP IAW DC9 SRM 51-10-3, 51-80-5 DRAWING NO 9912243 ITEM 39.

Part: PANEL — CRACKED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN PANEL 73 HAS CRACKS ON EA END AS MARKED. REPAIRED 2EA CRACKS EACH END 7075-T6 .020 DOUBLER IAW DC-9 SRM 53-01 FIG 2 SHT 3 DOUBLER NR 1 CUT OUT OF DAMAGE 1.2 X 3.8 REPAIR DOUBLER 31 GRAMS TOOL 119573. DOUBLER 2 CUT OUT 1.2 X .7 WEIGHT 24 GRAMS FOR REPAIR DOUBLER AS MEASUREDTOOL H9573 WITH CUT OUTS. CRACK CONTAINED VERIFIED BY NDT TOOL A2700 AND INSTALLED REPAIR PLACARD IAW DC-9 PS 900-5-1 NO 4 PG 6.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PANEL 55 HAS HOLE IN FWD END. REMOVED FLOOR PANEL IAW DC-9 SRM 51-30-1. ROUTED OUT HOLE NDT VERIFY NO DAMAGE REMAINS FAB REPAIR DOUBLER MATERIAL .025 7075T6 AND INSTALLED IAW DC-9 SRM 53-01 FIGURE 4. REINSTALL FLOOR PANEL IAW SRM DC9-A-53-20-201-925A-A. TOTAL REPAIR WEIGHT .07 OZ. INSTALLED ID TAG IAW PROCESS STANDARD 900-5-1 NO 4 P-245.

Part: ATTACH ANGLE — CRACKED (LT PYLON) · airframe 73,589 hrs · 69,813 cycles

FUSELAGE EXTERIOR STA 1151 LT UPPER PYLON ATTACH ANGLE CRACKED AT 2 EA FASTENERS. REMOVED A SECTION OF UPPER PYLON ANGLE WHICH WAS CRACKED IN 2 PLACES. HAD AREA NDT NO CRACKS NOTED AROUND CUTOUT. RECEIVED PART NR 5913262043. LOCATED AND DRILLED, FABBED 2 REPAIR SPLICES FROM AMSSJ25 CRES .050 INCH. LOCATED AND DRILL, TREATED AND INSTALLED IAW DC-9 SRM 51-10-3, 51-30-02, 54-04 FIG 10, 51-30-05.

Part: SUPPORT BEAM — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT ACC COMPT STA 1314 RT SIDE AIRSTAIR STRUT SUPPORT BEAM CRACKED. MAT ID FOR REPAIR ANGLES, 2 EACH .050 7075-T6 A IAW DC-9 SRM 53-01 FIG 2 SHEET 4 AND SRM 53-13-04. LOCATED, FABED, DRILLED ANGLES IAW DC-9 SRM 51-10-4 AND SRM 53-01 FIG 2 SHEET 4. TREATED AND PRIMED REPAIR ANGLES IAW DC-9 SRM 51-10-03. INSTALLED REPAIR ANGLES IAW DC-9 SRM 51-30-01 AND SRM 53-02 FIG 2 SHEET 4. INSTALLED REPAIR TAG IAW DPS 900-5-1 NO 04.

Part: FLOOR PANEL — GOUGED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PNL 105 HAS GOUGE SPOT TOP SURFACE OF PNL AS MARKED. CLEANED UP GOUGED AREA 1.5 X 2 IN IAW DC9 SRM 51-10-3. ORIGINAL MAT .040 REMAINING .018 MAT LOSS .022 OUT OF LIMITS IAW DC9 SRM 53-01 FIG 1. CUT OUT DAMAGED SECTION OF SURFACE 1.5 X 2 IN. HFEC INSP IAW NDT SPM 06-10-06. FABBED, LOCATED, DRILLED AND INSTALLED REPAIR DOUBLER AND FILLER FROM .040 7075 T6 IAW DC9 SRM 53-01 FIG 4.

Part: GUSSET — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT CARGO COMPT FUSELAGE FRAME AFT SIDE GUSSET AT BS 1151 AND ABOVE LONG 261 HAS EXFOLIATED CORROSION. MATERIAL LOSS OUT OF LIMITS IAW DC9 SRM 53-01. REMOVED GUSSET IAW DC9 SRM 51-30-2. FABBED NEW GUSSET OUT OF 7075T6 .063 IAW DC9 SRM 53-13-3 FIG 3 & 51-10-2. TREATED & PRIMED GUSSET IAW DC9 SRM 51-10-3. INSTALLED GUSSET IAW DC9 SRM 51-30-2 P-174 03 MAY 11.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN PAX CABIN - UPON REMOVAL OF FLOOR SUPPORT FOUND INTERCOSTAL BETWEEN STA 256 & 275 CRACKED ON BOTH ENDS TOP SIDE. REMOVED AND REPLACED INTERCOSTAL IAW DC9 SRM 51-10-4, 51-30-05 AND 53-13-2.

Part: FLOOR PANEL — CRACKED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR PNL 74 BTM END OF PNL SUPPORT FASTENER HOLE CRACK OUT. CUT OUT DAMAGED HAT CHANNEL IAW DC9 SRM 53-05 FIG 1. FABBED NEW SECTION OF HAT CHANNELS & DOUBLER P/N 2912282 IAW DC-9 SRM 53-05 FIG 1. HFEC INSP IAW NDT SPM 09-10-01. DAMAGE REMOVED, LOCATED, DRILLED & INST IAW DC-9 SRM 53-05 FIG 1.

Part: GUSSET — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT CARGO GUSSET ON TOP OF INTERCOSTAL HAS CORROSION UNDERNEATH AT FRAME 1060 RIGHT O/B OF LONG 30. REMOVED AND RE-INSTALLED 1EA COVER PLATE FOR ACCESS TO GUSSET. REMOVED GUSSET, OBTAINED, FABBED AND INSTALLED NEW GUSSET. MAT ID .040 7075T6 DUE TO CORROSION. REMOVED CORROSION ORIG MAT .040 REMOVED .10 REMAINING .030. OUT OF LIMITS. TOOL K1-117260 DUE DATE 29 AUG 11 ALL IAW DC-9 SRM 51-10-3, 51-30-5, 51-30-01 DWG REV W 5936071 30 APR 11 P-138Q-919 483541.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR SUPPORT STA 200 LBL 44 TO LBL 57 HAS CORROSION. FLOOR SUPPORT FOUND TO BE OUT OF LIMITS. ORIG .060 REMOVED .025 REMAINING .045 IAW DC9 SRM 51-13-14, 53-01 FIG 1. REMOVED RECEIVED MAT 9. FABRICATED, LOCATED, DRILLED, DEBURRED, TREATED, PRIMED, INSTALLED IAW DC9 SRM 51-10-4, 51-10-3, 51-30-5 MAT S2652479 7075T6.

Part: PAN — CRACKED (STA 693-712) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN BETWEEN STA 693 AND 712 WINDOW PAN CRACKED ON TOP FWD CORNER. REMOVED 4EA FASTENERS ON WINDOW PAN IAW SRM 51-30-2. REMOVED DAMAGE ON WINDOW PAN IAW DC9-A-56-20-02-801-663A-A. HFEC INSP SPM 06-10-01. VERIFY DAMAGE REMOVED 1" X 1" CUT OUT. RECEIVED MAT FABBED REPAIR ANGLE IAW DC9-A-56-20-02-801-663A-A. TREATED AND PRIMED IAW SRM 51=10-3. INST REPAIR IAW SRM 51-30-5.

Part: FASTENER — LOOSE (NR 1 PYLON) · airframe 73,589 hrs · 69,813 cycles

PYLON NR 1 UPPER SURFACE SKIN HAS 8EA LOOSE FASTENERS AT I/B OF AFT ENG MOUNT. REMOVED 4EA FASTENERS LOOSE IAW DC9 SRM 51-30-2. FOUND CRACK AT 1EA FASTENER HOLE. REPAIR CRACK 54-01 FIG 2 SHEET 2. RESHOOT 4EA REMAINING LOOSE FASTENERS IAW DC9 SRM 51-30-2.

Part: SUPPORT — CRACKED (BS 753 LBL 44) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 753, LBL 44 VERTICAL SUPPORT CRACKED UNDER FLOOR. REMOVED CRACKED FLOOR SUPPORT IAW SRM 51-30-2 AND 51-30-5. RECEIVED MAT 51642726-1200 IAW DWG PL5923417. FAB, LOCATED HOLES, DRILLED, DEBURRED IAW SRM 51-10-4. INSTALLED FLOOR SUPPORT IAW SRM 51-30-5.

Part: SKIN — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FUSELAGE EXTERIOR STA 1209 BETWEEN L12L AND L13L SKIN CRACKED AT FASTENER. REMOVED RIVETS IAW DC9 SRM 51-30-2. CUT OUT DAMAGED AREA 2EA 1 INCH ROUND AT STA 1209 L12L L13L IAW DC9 SRM 53-01 FIG 4. FABRICATED REPAIR DOUBLER AND FILLERS .040 7075T6 IAW DC9 SRM 51-10-2 AND INSTALLED DOUBLER AND FILLERS IAW DC9 SRM 53-01 FIG 4 SHT 4.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 775 BETWEEN BL-0 AND LBL-22 FLOOR SUPPORT CRACKED. REMOVED CRACKED FLOOR SUPPORT. RCVD MAT .0502024-T3 PO 1130701. FABRICATED, LOCATED, DRILLED, DEBURRED, TREATED, PRIMED, SEALED, INSTALLED NEW FLOOR SUPPORT. ALL WORK ACCOMPLISHED IAW DC9 SRM 51-10-2, 51-10-3, 51-10-4, 51-30-2, 53-13-3 FIG 11, 51-20-00.

Part: SHEAR TIE — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT CARGO COMPT FRAME 1151 AFT SIDE SHEAR TIE HAS CORROSION BETWEEN LONG 30 AND L29R. REMOVED CORR ORIG MAT .050 IAW DC-9 SRM 53-13-3, REMOVED .020, REMAINING .030. OUT OF LIMITS IAW DC9 SRM 53-01. MAT FOR REPAIR .063 7075-T6 AND .050 7075-T6. CUT OUT DAMAGED AREA 8". FABBED AND INSTALLED REPAIR IAW DC-9 SRM 53-03 FIG 3, 51-10-3. WEIGHED REPAIR PARTS 32G TOOL #H9573 20 SEP 11 RIZ 117260 29 APR 11 P-245.

Part: FLOOR PANEL — CORRODED (CABIN) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN-FLOOR PANEL 35 UPPER SURFACE HAS CORROSION ON EXISTING REPAIR DOUBLER. REMOVED CORROSION IAW SRM 51-10-3. FOUND OUT OF LIMITS. FABED NEW DOUBLER FR0M 0.025 7075T6 IAW SRM 53-01, FIG 2, SHEET 3 AND 53-23-0, FIG 4. TREATED AND PRIMED IAW SRM 51-10-3 AND INSTALLED IAW SRM 53-01, FIG 2, SHEET 3 INSTALLED ID TAG IAW DPS 900-5-1, NR 4 P-226C REQUIRED INSP COMPLETED BY Q-919 483541 29APR 11.

Part: STIFFENER — CRACKED (STA 37 BULKHEAD) · airframe 73,589 hrs · 69,813 cycles

FUSELAGE EXTERIOR STA 37 BULKHEAD STIFFNER CRACKED AT FASTENER LT SIDE. REMOVED DAMAGED STIFFNER IAW SRM'S 51-30-2, 51-30-5. INSTALLED NEW STIFFENER PN 9911500-241 IAW SRM'S 51-30-2, 51-30-5 & 51-30-8.

Part: FLOORBEAM — CRACKED (BS 636) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 636 BETWEEN BL-0 AND LBL-20 FLOOR SUPPORT CRACKED. REMOVED CRACKED FLOOR SUPPORT STA 636 BL-0 LBL-20 IAW SRM 51-30-2. REC MAT .050 2024T3. DEBURRED NEW FLOOR SUPPORT IAW SRM 51-10-4. TREATED & PRIMED IAW SRM 51-10-3. INSTALLED NEW FLOOR SUPPORT STA 636 BL-0 LBL 20 IAW SRM 51-30-2 P-245.

Part: FLOORBEAM — CORRODED (BS 655) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 655 BETWEEN BL 0 AND LBL 20 FLOOR SUPPORT HAS CORROSION. REMOVED CORR IAW 53-01, FIG 1. ORIG .050 IAW SRM 53-12-2, FIG 4, REMOVED .012, REMAINING .038 TOOL H1117585 23 SEP 11 OUT OF LIMITS IAW SRM 53-01. RECEIVED MATERIAL 50 X 48 X 144 2024T3 PO 1130711. LOCATED, DRILLED, DEBURRED IAW SRM 51-10-4. INSTALLED FLOOR SUPPORT IAW SRM 51-30-2.4.

Part: CUSP WEB — CRACKED (BS 712-753) · airframe 73,589 hrs · 69,813 cycles

MAIN PASSENGER CABIN-CUSP WEB AT STA 712-753, RBL 44, RBL 60 IS CRACKED SEVERAL PLACES. FABBED CUSP WEB & RING 1120200, .050 7075-T6,.080 7075-T6, .090 7075-T6. INSTALLED RINGS ON WEB. WEIGHT OF RING DOUBLERS & FASTENERS 1 LB 13.2 OZ SCALE H9573 CAL DUE 30 SEP 11 INSTALLED ID TAG IAW IAW DWG SG 09530019 SRM 51-30-02, PSM 900-5-1, NR 4 P-245. REQUIRED INSP COMPLETED Q-948, 490448.

Part: CUSP WEB — CRACKED (BS 1116-1136) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN BETWEEN STA 1116 AND 1136 LT CUSP WEB CRACKED AT LIGHTING HOLE. STOP DRILL 2EA CRACKS. NDT VERIFY CRACKS. CONTAINED FAB 2EA DOUBLERS IAW SRM DC9-A-53-10-16-801-663A-A. MATERIAL .025 7075T6. INSTALL AT STA 1164 & 1136 IAW DC9-A-53-10-16-801-663A-A.

Part: FLOORBEAM — CORRODED (BS 200) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR SUPPORT, STA 200, RBL 24 TO RBL 43 HAS CORROSION. REMOVED CORROSION IAW SRM 53-01 OUT OF LIMITS IAW SRM 53-01, FIG 1. REMOVED FLOOR SUPPORT IAW SRM 51-30-5. RECEIVED MAT S2652479, 7075T6. LOCATED HOLE, DRILLED, DEBURRED, IAW SRM 51-10-4. INSTALLED IAW SRM 51-30-5.

Part: FLOORBEAM — CORRODED (BS 674) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 674 BETWEEN BL-0 AND LBL-20 FLOOR SUPPORT HAS CORROSION. REMOVED CORROSION, OUT OF LIMITS. FABED, LOCATED, DRILLED, DEBURRED, TREATED & PRIMED NEW SUPPORT. REMOVED OLD SUPPORT. SEALED & INST NEW SUPPORT. ALL WORK ACCOMPLISHED IAW SRM'S 53-13-2, FIG 4, SHEETS 1 & 2, 53-01, 51-10-2, 51-10-4, 51-10-3, 51-20-00, 51-30-2.

Part: FLOORBEAM — CORRODED (BS 374) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVER WING STA 674 BETWEEN BL-0 AND RBL-20 FLOOR SUPPORT HAS CORROSION. CORROSION, OUT OF LIMITS. REMOVED OLD SUPPORT. RECEIVED MAT .050 2024-T3. FABRICATED, LOCATED, DRILLED, DEBURRED, TREATED, PRIMED, SEALED AND INSTALLED NEW FLOOR SUPPORT. ALL WORK ACCOMPLISHED IAW SRM'S 53-13-2, FIG 4, SH 1 & 2, 53-01, 51-10-2, 51-10-3, 51-10-4, 51-20-00, 51-30-2.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 73,589 hrs · 47,785 cycles

MAIN CABIN STA 522 RIGHT LONG 17 CRACKED. REMOVED SECTION OF L17R FROM STA 473-564 IAW DC9 SRM 53-02 FIG 18. RECEIVED NEW LONG AND SPLICE IAW DC9 SRM 53-13-2. NDT VERIFIED NO CRACKS EXIST IAW DC9 NDT SPM 06-10-01.001. INSTALLED SPLICE AND NEW SECTION OF LONG 17 RT FROM STA 473-564 IAW DC9 SRM 53-02, 51-30-22 AND 51-30-5.

Part: FLOORBEAM — CORRODED (BS 734) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN OVERWING STA 734 BETWEEN RBL-20 AND RBL-44 FLOOR SUPPORT HAS CORROSION. REMOVED, FOUND TO BE CRACKED .3750 INCH LONG, OBTAINED MATERIAL, (.050-2024T3), FORMED, NEW SUPPORT,DRILLED, DEBURRED, TREATED, PRIMED, SEALED, INSTALLED IAW SRMS (51-30-2) (53-13-3,FIG.11) (51-10-2) (51-10-4) (51-10-3) (51-20-0).

Part: SEAT TRACK — DAMAGED (BS 218-237) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN-AFTER REMOVAL OF SEAT TRACK ON FOUND PREVIOUSLY DOUBLE DRILLED HOLES IN CUSP WEB AT RBL 44 BETWEEN STA 218 AND 237. GAINED ACCESS, REMOVED DAMAGE WEB, MATERIAL PER DWG SG09530019 LOCATED, DRILLED, DEBURRED, ALODINED AND PRIMED ALL REPAIR PARTS PER DWG SG09530019 AND INSTALLED WEB PER SRM 51-30-2 AND 51-30-5, 51-10-2, 51-10-4 AND 51-10-3 AND DWG SG09530019, RESTORED ALL ACCESS P238 REQUIRED INSPECTION COMPLETED.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN BETWEEN STA 1116 AND 1136 RT CUSP WEB CRACKED AT LIGHTING HOLE. REMOVED FLOOR SUPPORT, RCVD MAT.025 7075-T6, FABRICATED, LOCATED, DRILLED, DEBURRED, TREATED AND PRIMED AND INSTALLED NEW DOUBLER AND FLOOR SUPPORT IAW DC9 SRM 51-10-4, 51-10-3, 51-30-2 & A-53-10-16-801-663A.

Part: CUSP WEB — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN BETWEEN STA 870 AND 889 RT CUSP WEB CRACKED SEVERAL PLACES. REMOVED DAMAGE 1 INCH BY 1 INCH STA 893. RCVD MAT (.025) 7075-T6 LOT NR 1120665. REMOVED DAMAGE 10 INCH BY 5 INCH STA 875-883. FAB, LOC, DRILLED, DEBURRED, TREATED, PRIMED AND INSTALLED 1 FILLER, 2 REPAIR DOUBLERS, 1 RING DOUBLER, 2 SHIMS IAW BOEING DWG SG09530019.

Part: FLOORBEAM — CORRODED (BS 237 LBL1-20) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN, STA 237, LBL 1 TO LBL 20 FLOORBEAM HAS CORROSION. FLOORBEAM FOUND TO BE OUT OF LIMITS DUE TO EXFOLIATION IAW SRM 51-10-3. REMOVED SUPPORT IAW SRM 51-30-2. FABRICATED LOCATED,DRILLED DEBURRED IAW SRM 51-10-4. TREATED & PRIMED IAW SRM 51-10-3. INSTALLED IAW SRM 51-30-5.

Part: FLOOR SUPPORT — CORRODED (BS 200-237 BL 0) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 200 TO 237 BL 0 FLOOR SUPPORT HAS CORROSION. MAIN CABIN FLOOR SUPPORT STA 200-237 BL 0.FOUND OUT OF LIMITS IAW SRM FIG ` SHEET 3.MORE THAN 50% MATERIAL LOSS NOTED. FABRICATED AND REPLACED FLOOR SUPPORT IAW SRM 53-13-3,51-10-1 FIG 22 AND SRM 51-30-1 & 51-30-5.

Part: INTERCOSTAL — DAMAGED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN PAX CABIN-UPON REMOVAL OF FLOOR SUPPORT FOUND INTERCOSTAL BETWEEN STA 237 & 256 HAS EXISTING DOUBLER DRILLED HOLES. REMOVED AND REPLACED INTERCOSTAL P/N 3913576U501 IAW DC9 SRM 51-10-4, 51-30-5 AND 53-13-2.

Part: SUPPORT FITTING — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FWD CARGO STA 465 LEFT LONGERON 29 ON AFT SIDE OF FRAME SUPPORT CLIP HAS CORROSION REMOVED CLIP IAW DC9 SRM 51-30-5 TO GAIN ACCESS REMOVED CORR L 3" X W 2" IAW DC9 SRM 51-10-3 ORG .063 IAW DAC DWG DL5911412 REV DV. REMOVED .013 REMAINING.050 OUT OF LIMITS IAW DC9 SRM 53-01 FIG 1. FABBED CLIP USING .063 X 48" X 144" 2024T3 IAW DWG DL5911412 REV DV INST CLIP IAW DC9 SRM 51-30-5 03.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

FUSELAGE EXTERIOR, UPPER ANTI COLLISION LIGHT, MOUNTING DOUBLER CRACKED AT FWD END AS MARKED. REMOVED CRACKED DOUBLER IAW DC9 SRM 51-30-2 FABRICATED AND INSTALLED REPLACEMENT DOUBLER IAW DC9 SRM 51-10-2, 51-30-2.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 256 TO 275 LBL 20 FLOOR SUPPORT HAS CORROSION SIZE 1" X 1" ORG MAT .094 REMOVED .010 REMANING.084 FLOOR SUPPORT OUT OF LIMITS REMOVED FLOOR SUPPORT IAW DC9 SRM 51-30-2 RECEIVED MAT. FABRICATED, LOCATED DRILLED, DEBURRED, TREATED & PRIMED, INSTALLED IAW DC9 SRM 51-10-4, 51-10-3, 51-30-2, 51-30-5.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOOR SUPPORT STA 200 RBL 1 TO RBL 20 HAS CORROSION. FLOOR SUPPORT FOUND TO BE OUT OF LIMITS ORIG MAT .060 REMOVED.030 REMOVED FLOOR SUPPORT IAW DC9 SRM 51-30-5. RECEIVED, FABRICATED, LOCATED, DRILLED, DEBURRED, TREATED & PRIMED AND INSTALLED IAW DC9 SRM 51-10-4, 51-10-3 & 51-30-5.

Part: FLOORBEAM — CORRODED (BS 200 LBL1-20) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN FLOORBEAM STA 200 LBL1 TO LBL20 HAS CORROSION. FLOORBEAM FOUND TO BE OUT OF LIMITS IAW SRM 53-01 FIG 1. REMOVED FLOORBEAM. FABRICATED LOCATED DRILLED DEBURRED IAW SRM 51-10-4. TREATED AND PRIMED AND INSTALLED NEW FLOORBEAM IAW SRM 51-10-3 AND 51-30-5.

Part: SEAT TRACK — CORRODED (BS 200-247) · airframe 73,589 hrs · 69,813 cycles

MAIN CABIN STA 200 TO 247 RBL 44 SEAT TRACK HAS CORROSION. REMOVED SEAT TRACK STA 200-266 AND SPLICE. BOTH OUT OF LIMITS. LOCATED, DRILLED, DEBURRED, TREATED, PRIMED AND INSTALLED NEW SEAT TRACK AND SPLICE. ACCOMPLISHED IAW SRM'S 51-30-1, 51-30-2, 51-30-5, 51-10-3, 51-10-4, 53-05 FIG.4

Part: FRAME — CRACKED (FUSELAGE) · airframe 73,589 hrs · 69,813 cycles

AFT ACC COMPT STA 1234 CANTED FR CRACKED. REMOVED TAIL ANTI-ICE DUCT REPAIRED FRAME STA 1234 LT IAW DC-9 SRM 51-30-1 AND REINSTALLED TAIL ANTI-ICE DUCT LEAK AND OPS CHECKED GOOD P134 27 MAY 11. REQUIRED INSPECTION COMPLETED.

Part: WINDOW FRAME — CRACKED (BS 734-753) · airframe 72,525 hrs · 68,206 cycles

DURING M-CHECK FOUND CRACK IN LOWER AFT CORNER OF RT CABIN WINDOW FRAME AT BS 734-BS 753. REPAIRED IAW SRM 51-10-4, SRM 53-01 & 51-30-5.

Part: WINDOW FRAME — CRACKED (BS 794-813) · airframe 72,525 hrs · 68,206 cycles

DURING M-CHECK FOUND CRACK IN UPPER FWD CORNER OF LT CABIN WINDOW FRAME AT BS 794-813. REPAIRED IAW SRM 51-10-4, SRM 53-01 & SRM 51-30-5.

Part: STRINGER — CRACKED (BS 294 S17L) · airframe 72,525 hrs · 68,206 cycles

DURING M-CHECK, FOUND CRACK IN STRINGER AT BS 294 S17L. REPAIRED IAW SRM 53-02-18.

Part: STRINGER — CRACKED (BS 313 S17L) · airframe 72,525 hrs · 68,206 cycles

DURING M-CHECK FOUND CRACK IN STRINGER AT BS 313 S17L. REPAIRED IAW SRM 53-02-18.

Part: WINDOW FRAME — CRACKED (BS 775-794) · airframe 72,525 hrs · 68,206 cycles

DURING M-CHECK FOUND CRACK IN UPPER FWD CORNER OF RT CABIN WINDOW FRAME AT BS 775-794. REPAIRED IAW SRM 51-10-4, SRM 53-01 & SRM 51-30-5.

Part: WINDOW FRAME — CRACKED (BS 775-794) · airframe 72,525 hrs · 68,206 cycles

DURING M-CHECK, FOUND CRACK IN UPPER FWD CORNER OF LT CABIN WINDOW FRAME AT BS 775-BS 794. REPAIRED IAW SRM 51-10-4, SRM 53-01 & 51-30-5.

Part: BATTERY PACK — INOPERATIVE (EMERGENCY LIGHTS) · airframe 71,340 hrs · 67,849 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT BOTH THE RIGHT AND LEFT HAND AFT OVERWING EMERGENCY EXIT IDENTIFIER PATHWAY LIGHTS WERE INOPERATIVE. MAINTENANCE REPLACED THE BATTERIES. OPERATIONAL CHECK WAS GOOD.

Part: LONGERON — CRACKED (BS 1230-1247) · airframe 71,176 hrs · 67,715 cycles

DURING "L" CHECK FOUND CRACK IN LONGERON 12R BETWEEN BS 1230-1247. REPAIRED IAW SRM 51-30-5 AND 53-02.

Part: CARGO TRACK — CORRODED (BS 1050-1167) · corrosion level 2 · airframe 71,176 hrs · 67,715 cycles

DURING "L" CHECK FOUND CORROSION ON CARGO TIEDOWN TRACK BS 1050-1167. REPAIRED IAW SRM 51-10-4 AND 51-30-5.

Part: ANGLE — CORRODED (BS 1167) · corrosion level 2 · airframe 71,176 hrs · 67,715 cycles

DURING "L" CHECK FOUND CORROSION ON ANGLE ON AFT PRESSURE BULKHEAD AT BS 1167, RBL 6. REPAIRED IAW SRM 51-10-4, 51-30-2, 51-30-5.

Part: FRAME — CRACKED (BS 1303 L14-15R) · airframe 65,785 hrs · 61,240 cycles

DURING "L" CHECK FOUND CRACK IN FRAME AT BS 1303 BETWEEN L14R AND L15R. REPAIRED IAW SRM 51-30-2 AND 53-01.

Part: SHEAR TIE — CRACKED (BS 1230 L15-16R) · corrosion level 2 · airframe 71,167 hrs · 67,708 cycles

DURING "L" CHECK FOUND SHEAR TIE CRACKED AT STA 1230, BETWEEN L15R AND L16R. REPAIRED IAW SRM 51-10-2, SRM 51-10-3, SRM 51-10-4, AND SRM 51-10-5.

Part: BATTERY PACK — DISCHARGED (CABIN) · airframe 69,177 hrs · 65,962 cycles

DURING LINE CHECK MX FOUND THAT THE EMERGENCY PATHWAY LIGHTING IN THE CABIN HAD FAILED. MX REPLACED THE BATTERY PACK AND THE LIGHTS WERE RETURNED TO AN OP CONDITION.

Part: PIN — PULLED (CABIN) · airframe 68,681 hrs · 65,518 cycles

DURING LINE CHECK MX FOUND THAT THE EMERGENCY PATHWAY LIGHTING IN ROWS 9-13 OF THE CABIN WERE INOPERATIVE. INVESTIGATION REVEALED THAT A PIN HAD BEEN PULLED FROM THE WALL DISCONNECT PLUG. MX REPAIRED IT BY RE-INSERTING THE PIN. ALL CHECKS WERE GOOD.

Part: CONNECTOR — CORRODED (EMERGENCY LIGHTS) · airframe 67,514 hrs · 64,483 cycles

DURING LINE CHECK, MAINTENANCE FOUND THAT THE EMERGENCY PATHWAY LIGHTING IN THE TAILCONE CATWALK WAS INOPERATIVE. MAINTENANCE FOUND THE COMPARTMENT FLOODLIGHTS CONNECTORS WERE CORRODED AND REPLACED THEM. THE LIGHTS WERE OPERATIONALLY CHECKED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FUSE — FAILED (BRAKE ASSY) · airframe 64,045 hrs · 64,078 cycles

AS THE AIRCRAFT WAS TAXING OUT FOR DEPARTURE THE LEFT HYDRAULIC SYSTEM LOST ALL FLUID AND PRESSURE. THE AIRCRAFT RETURNED TO THE GATE WITHOUT ANY FURTHER PROBLEMS. MAINTENANCE FOUND THE LEFT MAIN LANDING GEAR BOTTOM BRAKE FUSE "CAME APART" AND THE LEFT HYDRAULIC SYSTEM RESERVOIR WAS EMPTY. THE NR 1 ENGINE DRIVEN HYDRAULIC PUMP AND FILTERS WERE REPLACED. LEAK CHECK AND OPERATIONAL CHECK WERE GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 62,251 hrs · 59,787 cycles

DURING "H" CHECK, FOUND CRACK IN BULKHEAD SKIN AT BS 37. REPAIRED PER EA 98-203212.

Part: STIFFENER — CRACKED (BULKHEAD) · airframe 62,251 hrs · 59,787 cycles

DURING "H" CHECK, FOUND CRACK IN BULKHEAD VERTICAL STIFFENER AT BS 855 LBL 15. REPAIRED PER EA 98-202966.

Part: DUCT — LACK OF LUBE (RT WING SLAT) · airframe 61,460 hrs · 59,083 cycles

WHEN SLATS WERE SELECTED TO EXTEND, THE AIRCRAFT ROLLED TO THE LEFT AND THE 'SLAT DISAGREE' LIGHT ILLUMINATED. COMPLIED WITH COM PROCEDURES AND THE SECOND ATTEMPT HAD THE SAME RESULTS. THE SLAT DISAGREE LIGHT DID NOT EXTINGUISH. FLIGHT LANDED UNEVENTFULLY AT GRR WITH THE SLATS RETRACTED. MAINTENANCE LUBRICATED THE RIGHT 'T' DUCT, EXERCISED THE SLAT EXTENSION SYSTEM, AND ALL CHECKED NORMAL. THE AIRCRAFT RETURNED TO SERVICE.

Part: SMOKE — DETECTED (CABIN) · airframe 57,932 hrs · 55,824 cycles

AFTER TAKEOFF FLIGHT ATTENDANT REPORTED ELECTRICAL SMELL IN REAR OF AIRCRAFT. NO REPORT OF SMOKE. FLIGHT RETURNED AND LANDED WITHOUT INCIDENT. TROUBLESHOOTING ACCORDING TO MM INDICATED NO ANOMALIES. AIRCRAFT RETURNED TO SERVICE.

Part: ROLLER — LACK OF LUBE (WING) · airframe 56,675 hrs · 54,718 cycles

DURING TAKEOFF, FLAPS REMAINED AT 5 DEGREES. VISUALLY CONFIRMED FLAPS WERE EXTENDED. FLIGHT RETURNED TO MSP AND LANDED UNEVENTFULLY. MAINTENANCE WAS UNABLE TO DUPLICATE THE PROBLEM ON THE GROUND. FLAP RETRACTION CHECKED GOOD. LUBRICATED THE DOOR ROLLERS ON BOTH SIDES. AIRCRAFT RETURNED TO SERVICE.

Part: DOUBLER — CRACKED · airframe 56,424 hrs · 54,518 cycles

During Mck in ATL, a crack was discovered in the APB doubler. This EA provides inspection criteria and limits for crack. EA 98-188427

Part: PRESSURE PANEL — CRACKED · airframe 56,424 hrs · 54,518 cycles

During Mck in ATL a 2.0" crack was found in the flight compartment pressure panelat station 105 x=35. Repaired per EA 98-188410.

Part: LONGERON — CORRODED · corrosion level 2 · airframe 56,424 hrs · 54,518 cycles

During MCK in ATL longeron 29L and #) were found with corrosion between stations 466 and 484. Repaired per EA 98-188429.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 55,489 hrs · 53,642 cycles

DURING LINE CHECK IN CMH, A CRACK WAS NOTED IN THE APB VENTRAL DOOR JAMB PAN. THE CRACK WAS LOCATED 24 INCHES UP FROM THE FLOOR LINE ON THE LHS SIDE BY THE ROLLER ASSEMBLY. THE .375 INCH CRACK IS IN THE RADIUS OF THE DOOR JAMB. REPAIRED PER EA 98-164476.

Part: BATTERY — INOPERATIVE (FUSELAGE) · airframe 53,380 hrs · 51,792 cycles

DURING LINE CHECK, FOUND AFT FUSELAGE EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REPLACED EMERGENCY LIGHT BATTERY.

Part: WARNING LIGHT — ILLUMINATED (APU OIL SYSTEM) · airframe 53,006 hrs · 51,462 cycles

DURING TAKEOFF AT 110 KNOTS, MASTER CAUTION LIGHT AND APU LOW OIL PRESSURE WARNING ANNUNCIATED, ABORTED TAKEOFF. MAINTENANCE PERFORMED REJECTED TAKEOFF INSPECTIONS AND REPLACED THE APU.

Part: BATTERIES — DISCHARGED (TAIL COMP)

DURING LINE MAINTENANCE INSPECTION, FOUND TAIL COMPARTMENT EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERIES, OPERATIONAL CHECK NORMAL.

Part: BATTERY — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND LEFT WING EXTERIOR EMERGENCY EXIT LIGHT INOPERATIVE. MAINTENANCE REPLACED THE BATTERY PACK, OPERATIONAL CHECK NORMAL.

Part: WIRE — BROKEN (CABIN)

DURING LINE CHECK, FOUND EMERGENCY LIGHT AT SEAT 3C INOPERATIVE. MAINTENANCE INSTALLED WIRING SPLICE AND REPOSITIONED WIRING, OPERATIONAL CHECK NORMAL.

Part: PROX CONTROL — INOPERATIVE (E/E COMPARTMENT)

DURING CLIMB-OUT, THE LEFT MAIN LANDING GEAR UNLOCK INDICATION LIGHT REMAINED ILLUMINATED WITH ALL OTHER INDICATIONS NORMAL. THE FLIGHT CREW RECYCLED THE LANDING GEAR HANDLE AND FOUND NORMAL OPERATION AND INDICATION OF THE LANDING GEAR SYSTEM. AIRCRAFT LANDED AT DESTINATION WITHOUT INCIDENT. MAINTENANCE REPLACED THE LANDING GEAR PROXIMITY CONTROL UNIT. OPERATIONAL CHECK OK.

Part: CHARGER — INOPERATIVE (CABIN)

DURING LINE CHECK, FOUND TAIL COMPARTMENT EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE REPLACED CHARGER AND BATTERIES, OPERATIONAL CHECK OK.

Part: BATTERY — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND TAIL COMPARTMENT EMERGENCY EXIT LIGHTS INOPERATIVE. MAINTENANCE REPLACED BATTERIES FOR POWER SUPPLY. OPERATIONAL CHECK OK.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND OVERWING EMERGENCY LIGHTS DIM. MAINTENANCE REPLACED BATTERIES, OPERATIONAL CHECK OK.

Part: UPLATCH HOOK — OUT OF ADJUST (LT MLG)

AFTER TAKEOFF, THE LEFT GEAR RED LIGHT REMAINED ON AND DOOR GREEN LIGHT WOULD NOT ILLUMINATE. FLIGHT RETURNED TO BFM AND LANDED WITHOUT INCIDENT. ADJUSTED UPLATCH HOOK AND TESTED GEAR OPERATION SEVERAL TIMES, OPERATIONAL CHECK OK.

Part: CONTROLLER — MALFUNCTIONED (CABIN)

DURING CLIMBOUT, AIRCRAFT WOULD NOT PRESSURIZE. CABIN CLIMBED AT SAME RATE OF CLIMB AS AIRCRAFT. FOLLOWED COCKPIT OPERATING MANUAL PROCEDURE. AFTER RESETTING CIRCUIT BREAKERS, SYSTEM BEGAN TO OPERATE INTERMITTENTLY. FLIGHT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. REPLACED PRESSURE CONTROLLER AND AMPLIFIER, OPERATIONAL CHECK OK.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE CHECK, FOUND OVERHEAD EMERGENCY LIGHTS AT ROWS 18-23 INOPERATIVE. REPLACED BATTERIES IN POWER SUPPLY B5-58. OPERATIONAL CHECK OK.

Part: POWER PACK — INOPERATIVE (LT NACELLE)

DURING LINE CHECK, FOUND LEFT NACELLE EMERGENCY LIGHTS INOPERATIVE. REPLACED EMERGENCY LIGHT POWER PACK, OPERATIONAL CHECK OK.

Part: ADI — MALFUNCTIONED (NR 2)

FIRST OFFICER'S ADI INDICATED TURN 30 DEGREE ANGLE WHEN LEVEL. FLIGHT RETURNED TO MEM AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED NR 2 ADI, OPERATION CHECKS GOOD.

Part: DOOR LINK — FAILED (NLG DOOR)

AFTER TAKEOFF DURING GEAR RETRACTION, A LOUD NOISE CAME FROM THE NOSE WHEEL AREA. UPLATCH CHECK WAS NORMAL, HOWEVER, AFTER 5 MINUTES, NOSE GEAR UNSAFE LIGHT ILLUMINATED. FOLLOWED COM PROCEDURE AND RETURNED TO MSP. AIRCRAFT LANDED WITHOUT INCIDENT. FOUND THE RIGHT NOSE GEAR DOOR OPEN AND RIGHT GEAR DOOR LINK INOPERATIVE. REPLACED THE RIGHT GEAR DOOR LINK AND OPERATIONAL CHECK GOOD.

Part: BATTERY PACK — DISCHARGED (COCKPIT)

DURING LINE CHECK, FOUND EMERGENCY LIGHTS IN COCKPIT AFT OVERHEAD SWITCH PANEL, FORWARD ENTRY LIGHT ASSEMBLY, GALLEY AREA LIGHT ASSEMBLY AND FORWARD COMPANION WAY INOPERATIVE. REPLACED BATTERIES IN POWER SUPPLY AND OPERATIONAL CHECK GOOD.

Part: STOP FITTING — CRACKED (ENTRY DOOR)

DURING H-CHECK, FOUND A CRACK IN THE AFT ENTRY DOOR STOP FITTING APPROXIMATELY 18 INCHES ABOVE THE FLOOR. REPLACED FITTING PER SRM 51-30-2.

Part: PROX SWITCH — MALFUNCTIONED (NLG)

DURING CLIMB, THE NOSE LANDING GEAR UNSAFE LIGHT ILLUMINATED. PERFORMED COCKPIT OPERATING MANUAL PROCEDURE AND THE LIGHT REMAINED ILLUMINATED. AIRCRAFT CONTINUED TO DESTINATION AND ACCOMPLISHED TOWER FLYBY AND LANDED WITHOUT INCIDENT. REPLACED THE NOSE LANDING GEAR DOWNLOCK PROXIMITY SWITCH. OPERATIONAL CHECK GOOD.

Part: PROX CONTROL BOX — MALFUNCTIONED (LANDING GEAR)

DURING CLIMBOUT FROM BUF, NOSE LANDING GEAR UNSAFE AND GEAR DOOR OPEN LIGHTS REMAINED ON AFTER GEAR WAS RETRACTED. RECYCLED GEAR AND NORMAL INDICATIONS WERE ARCHIEVED. FLIGHT CONTINUED TO DESTINATION (DTW) AND LANDED WITHOUT INCIDENT. REPLACED LANDING GEAR PROXIMITY CONTROL BOX. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE.

Part: MECHANISM — LACK OF LUBE (SPOILER)

DURING DESCENT WITH SPEED BRAKE FULLY EXTENDED, THE AIRCRAFT EXPERIENCED A SLIGHT ROLL. CREW DISCONNECTED AUTOPILOT AND RETRACTED SPEED BRAKES. AIRCRAFT LANDED WITHOUT INCIDENT. FOUND ACCUMULATION OF ICE IN THE RIGHT SPOILER CONTROL. REMOVED THE ICE AND LUBRICATED THE SYSTEM, OPERATIONAL CHECK GOOD.

Part: SWITCH — MALFUNCTIONED (PARKING BRAKE)

TAKEOFF WARNING HORN SOUNDED AS THROTTLES WERE PUSHED FORWARD FOR TAKEOFF. ABORTED TAKEOFF AND RETURNED TO GATE. FOUND PARKING BRAKE SWITCH HAD FAILED, FERRIED AIRCRAFT TO MSP. REPLACED PARKING BRAKE SWITCH. OPERATIONAL CHECK OK, AIRCRAFT RETURNED TO SERVICE.

Part: ACTUATOR — MALFUNCTIONED (RT SPOILER)

AIRCRAFT ROLLED LEFT AFTER SPEED BRAKES WERE DEPLOYED DURING DESCENT. REPLACED THE RIGHT SPOILER ACTUATOR. OPERATIONAL CHECK OK. AIRCRAFT RETURNED TO SERVICE.