Aircraft Inspection

AIRCRAFT INSPECTION

737-33A

S/N 24096

REG#: 9M-AAF

REPORT NUMBER: 070501

REPORT DATE: 2012

TABLE OF CONTENTS

INTRODUCTION…………………………………………………..………………..…...…3

AIRCRAFT IDENTIFICATION………………………….…………………….…….……4

2.1AIRFRAME 4

2.2ENGINES 4

2.3AUXILLARY POWER UNIT 4

2.4LANDING GEAR 5

2.5AIRCRAFT WEIGHTS 5

2.6CONFIGURATION 5

OPERATING HOURS & CYCLES………………………………..……………….…...….6

3.1AIRFRAME 6

3.2ENGINES 6

3.3LANDING GEAR 6

PRINCIPAL AVIONICS………………………………...………………………….....….....7

AIRCRAFT INSPECTION SUMMARY………………………………….……….….……8

MAINTENANCE PROGRAM………………………………………..……………….…...12

6.1POWERPLANT PROGRAM 13

6.2 AUXILLARY POWER UNIT 13

AIRCRAFT CONFORMIRTY INSPECTION…………….……………………….……..14

INSPECTION RESULTS……………………………………………………….…………..20

EXTERNAL REPAIRS DOUBLERS…………………………………………………..….20

AIRCRAFT AVIONICS EQUIPMENT………………………………………………..….21

AIRWORTHINESS DIRECTIVES OUTSTANDING………………………………...... 24

APPENDIX……………………………………………………………………………...…...25

PHOTOGRAPHIC SURVEY………………………………………………………………26

INTRODUCTION

The company was allowed to conduct a physical inspection of one 1989 Boeing 737-300 aircraft equipped with CFM International CFM56-3B2 engines, identified as Serial Number 24096, Foreign registration mark 9M-AAF currently operated by Air Asia Airlines.

The physical inspection was carried out while the aircraft was parked at the Air Asia terminal facilities at Kuala Lumpur Malaysia Int’l Airport. It was given a close visual inspection using standard equipment and techniques. No engine run-up or confidence tests were performed, no engine borescope inspections, no detailed system operational tests were done and no aircraft taxi or flight tests were conducted. A thorough review of aircraft records was complete.

AIRCRAFT IDENTIFICATION

AIRFRAME

MANUFACTURER BOEING
CURRENT MODEL 737-33A
TYPE CERTIFICATE NUMBER PP920
SERIAL NUMBER 24096
CURRENT REGISTRATION 9M-AAF
ORIGINAL REGISTRATION PP-SNW
MANUFACTURER LINE NUMBER 1739
DATE OF MANUFACTURER 5/31/89

ENGINES

MANUFACTURER CFM INT’L
MODEL CFM56-3B2
SERIAL NUMBER 1 720722
2 721132

AUXILLARY POWER UNIT

MANUFACTURER HONEYWELL
MODEL GTCP85-129H
SERIAL NUMBER P-12132C
TIME SINCE SHOP VISIT 5,000 HRS

LANDING GEAR

MANUFACTURER BOEING
POSITION PART NUMBER SERIAL NUMBER
NOSE 65-73762-20 CPT2426ET
LEFT WING 65-73761-109 P01840
RIGHT WING 65-73761-110 P01733

AIRCRAFT WEIGHTS

MAXIMUM TAXI WEIGHT 139,000 lbs
MAXIMUM TAKEOFF WEIGHT 138,500 lbs
MAXIMUM LANDING WEIGHT 114,000 lbs
MAXIMUM ZERO FUEL WEIGHT 106,500 lbs
OPERATIONAL EMPTY WEIGHT 71,929 lbs
APPROXIMATE PAYLOAD CAPACITY 75,000 lbs
FUEL CAPACITY 5,311 US Gal

CONFIGURATION

CURRENT PASSENGER
COCKPIT 2 CREW, 1 obs
MAIN CABIN 134 Coach Cl
GALLEYS 1 Fwd, 2 Aft
LAVATORIES 1 Fwd, 1 Aft
CREW REST AREAS 1 Fwd, 1 Aft

OPERATING HOURS AND CYCLES

AIRFRAME

TOTAL HOURS 55,746
TOTAL CYCLES 42,523
TIME SINCE LAST “C” CHECK PHASE 15,294
TIME SINCE LAST “D” CHECK PHASE 15,294
TIME REMAINING TO NEXT “D” CHECK 8,706

ENGINES

SERIAL NO TT TC TSEHM CSEHM LIMITER TIME REM
720122 54,463 35,492 5,578 4,061
721132 56,047 37,345 2,579 1,680

LANDING GEAR

POSITION OH INTERVAL TSO TIME REMAIN
NOSE 20,000 Hr / 120 mo 15,294 4,706
LEFT MAIN 20,000 Hr / 120 mo 15,294 4,706
RIGHT MAIN 20,000 Hr / 120 mo 15,294 4,706

PRINCIPAL AVIONICS

ITEM QTY MFG P/N S/N MODEL
Air Data Computer (ADC) 2 Honeywell HG480B42 H0906
Auto Throttle Computer 1 Smith 735SUE10-12 5067
Weather Radar 1 Honeywell 2041217-0416 1877
VHF Comm. 2 Collins 822-1045-001 9982/873
HF Transceiver 1 Collins 622-5272-020 1869
VOR/ILS Rec. 2 Sherwood 2041234-3446 5498/5439
ADF Rec. 1 Collins 777-1492-005 16972
DME Indicator 2 Collins 622-2921-006 10921/11216
Marker Beacon 1 Collins 522-2996-011 2380
EGPWS 1 Honeywell 965-0976-020-213-213 14119
Voice Recorder 1 Fairchild 980-6005-076 9111
Flight Data Recorder 1 Boeing 980-4100-DXUN 4778
IRU 2 Honeywell HG1050AD05 7111/3025
Flight Management Comp. 1 Smith 176200-01-01 1283
TCAS 1 Honeywell 066-50000-2220 0276
Anti-Ski Unit 1 Patents 42-719-02 0421
ATC Transponder 2 Bendix 066-01127-1301 4022/3432
Stall Mgmt. Computer 2 Boeing 65-52822-7 D01211/D01925
Flight Control Computer 2 Honeywell 4051600-938 986030509
Window Heat Control 2 PED 231-2 7485/3169
Battery 1 SAFT 40176-7 105432

AIRCRAFT INSPECTION SUMMARY

The condition survey of the subject aircraft determined that it is in good physical condition for one of its type, age, and service. Its overall condition was considered good.

The physical inspection was carried out while the aircraft was parked at the Air Asia Airlines terminal facilities in Kuala Lumpur, Malaysia Int’l Airport. It was finished in the standard Air Asia scheme, a white fuselage with Air Asia painted in red letters on the left and right side along with the registration number just forward of the rear service doors. The tail is finished in White and Red. The fuselage crown is finished in white along with the belly of the aircraft. Paint and required markings and placards were in good condition, with only minor pealing noted in some areas.

Serial Number 24096 was delivered to Ansett Worldwide Aviation Services (AWAS) new in July of 1989 as a 737-300 model. The aircraft then was leased out to various airlines to include VASP, Jet Airways (India), AB Airlines, DebonAir, TAESA, Regional Air and Kenya Airways then to present Air Asia. The aircraft was leased to Air Asia on January 14, 2003 to present day operation. The data plate reflects Boeing model 737-33A bearing serial number 24096 and appears to be in good condition.

Review of all available databases uncovered no major incident or accident history.

9M-AAF is in the final phase of its maintenance cycle and will be due a “C” check very soon. Under the Air Asia maintenance program it will be due a Heavy Maintenance Visit (HMV) by August 2009. The HMV is the heaviest check under the program and is essentially an airframe restoration. The engines have been in service and have approximately three years of their life remaining. Landing gear are not expected to be removed for overhaul until Q1 2012 while the installed Auxiliary Power Unit will likely be removed for shop refurbishment in the next year or so.

Inspection revealed the fuselage to be in good structural condition overall. Five doubler repairs were found on the fuselage, each identified with a tag showing date of installation and referencing the work card that accomplished the job. This feature is unique to this operator and should prove helpful in locating referenced documents. All repairs appeared to comply with manufacturer Structural Repair Manual (SRM) guidelines. Fuselage lap Seams and belly skins were inspected and determined to be in good condition. Cabin windows were good with no excessive crazing noted. Composite fairings and Radome were inspected and found to be defect free.

Originally equipped with forward airstairs and they have been since deactivated with all parts removed. The stairs will need to be reactivated prior to return from lease. The aircraft escape exits and slides appear to be in good condition and have full charge.

As viewed from the ground, the empennage appeared in good structural condition, as did elevators and rudder. The right and left horizontal stabilizers appear to be in good condition with no physical defects. The aft tail compartment is free of major defects or fluid leaks and paint is in good condition. The vertical stabilizer was in good state with no external repairs noted.

Landing gear and door assemblies were in good shape with protective coatings undamaged but in need of a little cleaning. Installed Bendix wheels and brakes exhibited normal wear and struts have been correctly serviced in accordance with the Maintenance Manual (MM). Wheel wells were free of paint erosion and have been thoroughly treated with corrosion inhibiting compounds. Data plates were found on all three gear displaying part number and serial numbers which were cross referenced to the component listing.

Inspection of equipment bays did not uncover significant problems. Accessible areas of internal structure were determined to be in good shape. Visible floor tracks, frames and longerons were good with corrosion inhibiting compounds applied. Lower cargo liners are of the fiberglass gilliner type and were found properly sealed and well maintained. As mandated by US Federal Air Regulations (FAR) 121.314 and 25.857, a Smoke Detection and Extinguishing System of Jetaire Aerospace & Technology manufacture was also found installed. The system has been FAA approved under Supplemental Type Certificate (STC) ST01901AT.

Inspection of the installed Auxiliary Power Unit (APU) revealed a Model GTCP85-129H unit. An APU condition check was performed with no findings noted. The area around the APU was free of evidence of any leakage. With over 5,000 hours accumulated since refurbishment, this APU can be expected to be removed for hot section repair and overhaul within the next two years or so of operation.

The installed CFM56-3B2 engines appeared in good shape externally. Inlets and exhausts were inspected with no evidence of excessive profiling or over temperature of blades noted. Nose and side cowls as well as pylons were in good condition and free of damage.

Both engines are serviceable and operating with this aircraft. Serial number (ESN) 720722 was returned to service after a heavy shop visit in December 2006. As of March 2007 it had accumulated 5,578 flight hours. The shop visit included refurbishment of all major modules with the exception of the Low Turbine. This engine is further limited by its C3 Low Compressor disk and can be expected to remain in service for approximately 7,000 flight hours or about 2 ½ years under current utilization.

With over 2,300 hours since restoration of Compressor sections, ESN 721132 is likely to remain in service for another 4-5,000 flight hours before being inducted for a Hot Section Inspection. This engine is further limited by the C6 disk, a Life Limited Part that must be permanently retired from service within 4,400 flight cycles.

The flight deck was in good shape overall. Flight crew seats are equipped with Pacific Scientific seat belts, as was the observer position. Instrument and side panel paint is good with no cracking or paint erosion noted. Windshields were in good shape, free of delamination or crazing. Equipment and instrumentation graduated in US measure, appeared operative, with markings and placards installed and clearly legible. This aircraft is not equipped with an Electronic Flight Instrumentation System (EFIS) and no Heads-Up Display (HUD) is installed. An Allied Signal Model TPA-81A TCAS, dual Bendix/King TRA-67A Mode “S” Transponders, and a Honeywell P/N 4059845-911 Windshear system have been provided as mandated by the US Federal Air Regulations (FAR) Parts 121.356 and 121.358.

Permanent cockpit door strengthening modifications required by FAR 121.313 have been accomplished and the system functioned normal.

The main passenger compartment was clean with carpets and sidewalls in fair condition. Standard issue overhead bins were clean with latches and doors properly maintained. Passenger accommodations include 134 Coach Seats of blank manufacture, fire blocked in accordance with FAR 25.853 and provisioned with American Safety Model 502731 seat belts. All seats have been kept in good shape and life vests were found under each passenger seat.

Three galley complexes are provided for passenger service, one forward and two aft. The forward cabin complex (G1) is equipped with one coffee maker and two large box type containers, while (G2) is fitted with three large boxes and one oven. Aft complexes are located on the left side of the cabin; (G3) is equipped with three trolleys and two coffee makers. The cabin has two lavatories, one forward and one in the aft cabin, each equipped with an operable smoke detector in compliance with US regulations. Galley and lavatory equipment functioned correctly, as did stowage compartment hinges and latches.

The aircraft has two Flight Attendant positions, one large seat which fits two in the fwd cabin and one if the aft cabin which also holds two people. Each position is positioned with a life vests and emergency flashlights.

Review of records suggest that the airplane is current within its program with most high cost Airworthiness Directives (AD) either complied with or falling due concurrently with the next HMV check. Time controlled components also have sufficient time remaining to reach the next HMV.

Overall, our inspection did not reveal any significant problems and the aircraft appeared in good condition structurally, mechanically and aesthetically.

6MAINTENANCE PROGRAM

Air Asia Airlines 737-300 aircraft are maintained under the MSG III approved maintenance program which is detailed in their 737 Maintenance Specifications Manual. The airframe systems and component maintenance program generally parallels the recommendations of the FAA 737 Maintenance Review Board document (MRB) using the MSG III maintenance concept. Some maintenance significant components recommended by the MRB to be maintained by the process of “Condition Monitored” have been transferred to the process of “On Condition” and vice versa, based on operating experience. The 737 Structural Inspection Program has been incorporated within the 737 HMV Check inspection program. Air Asia’s landing gear overhaul interval is 20,000 hours for all three Landing Gears. Weighing interval for aircraft Weight and Balance calculations is 36 months. Based on the above, the current maintenance intervals are as follows:

Layover CheckAccomplished each day at stations where maintenance is available and aircraft is held for more than four hours.

Service CheckAccomplished as no more than 500 Hours from the last Service Check or higher.

Letter CheckThe Letter Check is an opportunity inspection scheduled by the Aircraft Planning Department from time to time consisting of 2,000 hours or 9 calendar month tasks as detailed within the maintenance program. The Letter is similar to an industry standard “Phased C” type check.

HMV CheckThe heaviest check under the Air Asia program and is accomplished every 15,000 hours in service.

6.1POWERPLANT PROGRAM

The General Electric engines installed on this aircraft are repaired through GE Engine Services Malaysia. Engine performance is continually monitored and periodic tests, checks and inspections are accomplished “on wing”. The engines remain installed until internal Life Limited components or modules are due for replacement or condition determines the need for a shop visit.

6.2AUXILIARY POWER UNIT PROGRAM

The APU is maintained during normal airframe maintenance visits and is scheduled for a shop visit when condition determines the need for repairs or overhaul.

7. AIRCRAFT CONFORMITY INSPECTION CHECKLIST

I. FUSELAGE EXTERIOR REMARKS

1. Corrosion – (Belly Skin and all lap joints) Blind Fasteners installed? ______

2. Dents – (Out of limits – See SRM) ______

3. Damage – (Out of limits/not repaired) ______

4. Working Rivets ______

5. Indication of Hard Landings ______

6. Presence of Scab Patches – (No, location, Size, map all repairs) ______

7. Filler Repairs – (Non SRM) ______

8. Doors – (Properly close, Seal, Fair Condition) ______

9. Forward Airstairs installed? ______Deactivated? ______Parts Removed? ______

10. Fiberglass Fairings – (Delamination) ______

11. Windshields – (Crazing, Delamination) ______

12. Antennas – (Condition) ______

13. Cargo Compartments – (Condition of floor, walls, nets, limits) ______

14. Radome – (Condition) ______

15. Paint – (Condition) ______

16. Required Placards – (Presence, Condition, See Operator Manual) ______

17. Cabin Windows – (General Condition) ______

EMPENNAGE

1. Corrosion______

2. Working Rivets______

3. Presence of Scab Patches – (Number, Location, Size)______

4. Outflow Valve – (Condition)______

5. Airstairs if Installed______

6. Vertical Stabilizer – (Condition)______

7. Horizontal Stablizer – (Condition)______

8. Rudder & Elevators – (Condition delamination, missing wicks)______

9. Paint Condition______

10. Aft Tail Compartment – (Leaks, General Condition)______

11. Dorsal Fin Type tail cone installed?______

12. Pylons – (Condition, Loose Panels)______

III. WINGS AND CONTROL SURFACES

1. Corrosion______

2. Damage – (Cracks, Dents)______

3. Working Rivets – (Wing Tips)______

4. Fuel Leaks – (Evidence)______

5. Fairings – (Condition, Ailerons, Tabs)______

6. Flaps, Trailing Edge – (Condition, Looseness, Delamination, Leaks)______

7. Leading Edge Slats – (Condition, Leaks, Seals)______

8. Spoilers – (Condition, Leaks, Delamination, Links)______

9. Flap Wells – (Rear spar corrosion, cable damage, seal damage)______

IV. LANDING GEAR, GEAR DOORS, WHEEL WELLS

1. Main Gear – (Strut Leakage, damage, general condition)______

2. Brakes – (Leakage, evidence of overheat, wear)

Manufacturer______

Part Number______

3. Tires – (Condition) Size______Ply ______

Speed Rating______TSO ______

4. Wheel Wells – (Hydraulic leaks, cable condition, and cleanliness)

5. Landing Gear Data from data plates

Manufacturer______

NLG P/N ______S/N ______

L/H MLG ______S/N ______

R/H MLG ______S/N ______

AIRFRAME INTERNAL INSPECTION

1. Cockpit______

2. Seats – (Condition, Seat Belt TSO’s)______

3. Presence of Safety Equipment – (Fire Extinguisher, Smoke Goggles) ______

4. Interior Condition – (Markings)______

5. Instruments & Equipment – (Markings)______

6. Pitot Heat Indication System – (Lights or Ammeter?)______

7. EFIS Installed – (Yes or No)______

8. HUD Installed – (Yes or No)______

9. Placards Present? Certificate of Airworthiness and Registration______

V. AIRFRAME INTERNAL INSPECTION (CONT’D)

1. Main Deck Interior – PAX configuration or Freighter Configuration______

2. Seats – (Condition, mounting, missing parts, breakover, include F/A Seats ______

PAX Seats must have wrap around restraints TSO’d ______Fireblocked ______

3. Seat Belts – (Condition, missing parts)

Seat Belt Mfg and P/N ______

4. Life Vests – OH Date - ______

Mfg and Model ______Exp. Date ______

5. Overhead Compartments – (Condition, Latches, etc.) ______

6. Side Walls & Ceilings – (Condition, Window Shades) ______

7. Floor & Carpet – (Condition)______

8. Galley – (Cleanliness, Security of Pantry, Missing Parts______

9. Galley Carts – (Missing & Loose Parts) Condition______

AIRFRAME INTERNAL INSPECTION (CONT’D)

Emergency Equipment

NUMBERCONDITION

2. Mikes______

3. Headsets______

4. Quick Don Mask______

TSO 99 Incorp?______

5. O2 Bottles______

6. Megaphones______

7. Halon Ext.______

8. H2O Ext.______

9. Smoke Masks______

10. Crash Axes______

11. Emer. Flashlights______

12. First Aid Kit______

13. MED______

14. Rafts______

15. PBE______

MFG______

V1. AFT TAIL COMPARTMENT/AVIONICS

1. Avionics Equipment – (Condition, Missing Equipment, Corrosion)______

2. Air Conditioning Bays – (Condition, Leaks, Corrosion)______

3. Structure – (General Condition) Is slide installed in tailcone?______

4. Airstair installed in rear pressure bulkhead?______

V11. ENGINES

Serial Number Check – (Check engine data plate on gearbox and insure it matches data plate on right hand exhaust case rail)

Engine #1 S/N ______Stage III? ______

Engine #2 S/N ______Stage III? ______

2. Leaks______

3. Inlet Blade Damage______

4. Turbine Blade Damage______

5. Cowling – (Condition)______

6. Thrust Reverser - (Condition)______

VIII. APU

1. Model – (Verify type from data plate) ______

2. Leaks______

3. Exhaust Pipe – (Condition)______

GENERAL

Verify current compass calibration card installed in Cockpit.
Verify Aircraft Data Plate installed on the L1 Door and note details.

A/C Model ______S/N ______

TC No. ______Mfg. Date: ______

TCAS Installed? Mfg and Model ______
Wind Shear System Installed? Mfg and Model ______
DFDR Installed? 6, 11, or 17 parameter? ______
Inventory Avionics Equipment per attached checklist.

8INSPECTION RESULTS

Aircraft fuselage paint is in good condition
Aircraft needs an exterior wash
Both wing tips are a little cloudy
Right Hand Stabilizer has a bondo repair on the leading edge
All three data plates on the landing gear are clear and visible
Cabin carpet shows wear and tear and could use a cleaning
No. 2 ADF Missing
No. 2 FMC Missing

9EXTERNAL REPAIR DOUBLERS

External Doubler Repair
Large External Doubler Repair
Large External Doubler Repair

10AIRCRAFT AVIONICS EQUIPMENT

Avionic Equipment Fit List
Aircraft Registration: 9M-AAF Aircraft Type: 737-300 Aircraft S/N: 24096
Installed equipment / Part Number / Manufacturer / Serial No.
HF TRANSCEIVER / 622-3371-001 / ROCKWELL COLLINS / 1125
HF TRANSCEIVER / 622-1181-001 / ROCKWELL COLLINS / 8261
VHF TRANSCEIVER / 622-1181-001 / ROCKWELL COLLINS / 7F4519
DECODER SELCAL / NA135 / N/A / J21L2H
VOICE RECORDER / 93A100-80 / FAIRCHILD / DU51207
UNDER WATER BEACON / DK120 / DUKRANE / DU8112
FDAU / ED742951-9 / N/A / 88050265
ADC / HG280D80 / HONEYWELL / 205
ADC / HG280D80 / HONEYWELL / 88081808
AIRSPEED INDICATOR / WL101AMS1 / HONEYWELL / 3783
VERTICAL GYRO / 2587335-113 / N/A / 86085731
VERTICAL GYRO / 2587335-113 / N/A / 86055618
VERTICAL GYRO / 2587335-113 / N/A / 85065296
DIRECTIONAL GYRO / 2588302-4 / N/A / 77031604
DIRECTIONAL GYRO / 2588302-4 / N/A / 78062503
CDU / 1117-21 / N/A / 2510
MARKER BEACON / 2087821-2811 / N/A / 5089
GPW COMPUTER / 3010-00-00 / N/A / 790
TCAS COMPUTER / 622-8971-022 / ROCKWELL COLLINS / 1013
ADF RECEIVER / 777-1492-004 / ROCKWELL COLLINS / 6308
ADF RECEIVER / 777-1492-004 / ROCKWELL COLLINS / 8671
DME / 622-2921-001 / ROCKWELL COLLINS / 13952
DME / 622-2921-002 / ROCKWELL COLLINS / A236
MODE S TRANSPONDER / 622-7878-201 / ROCKWELL COLLINS / 8307
MODE S TRANSPONDER / 622-7878-201 / ROCKWELL COLLINS / 5696
DATA TRANSFER UNIT / 1066-10-010 / N/A / 686
VOR/ILS RECEIVER / 2041234-3445 / N/A / 1034
VOR/ILS RECEIVER / 2041234-3445 / N/A / 5413
FLIGHT MANAGEMENT UNIT / 1116-40-1116 / N/A / 2004
DFGC / 4034241-930 / HONEYWELL / 80090193
DFGC / 4034241-930 / HONEYWELL / 88061601
STALL WARNING COMP. / 965-0449-002 / N/A / 2854
STALL WARNING COMP. / 965-0449-002 / N/A / 1867
AURAL WARNING / H05A0035-3 / N/A / N/A
PASSENGER ADDRESS / 622-4096-003 / ROCKWELL COLLINS / N/A
VHF TRANSCEIVER / 622-1396-002 / ROCKWELL COLLINS / N/A
VHF TRANSCEIVER / 622-1396-002 / ROCKWELL COLLINS / N/A
CABIN PRESSURE CONT / 2117180-2 / N/A / 40-1919
CABIN PRESSURE CONT / 2117180-2 / N/A / 81-350
GCU / 947F945-3 / WESTINGHOUSE / N/A
GCU / 947F945-3 / WESTINGHOUSE / N/A
GCU / 947F945-3 / WESTINGHOUSE / N/A
BUS PANEL / 947F946-3 / WESTINGHOUSE / N/A
PROXIMITY SWITCH / 8-336-05 / ELDEC CORP / N/A

11AIRWORTHINESS DIRECTIVES