N207FE

Part: INDICATOR — FAILED (NR 1 EPR) · airframe 35,939 hrs · 20,999 cycles

REJECTED T/O AT 80 KNOTS. NR 1 EPR GUAGE INOP. RELEASED FOR SERVICE IAW MEL: 77-01-01, "MEL 77-01-01: NR 1 ENGINE EPR INDICATOR - INOP." ACFT OK FOR SERVICE. TO TROUBLSHOOT, FURTHER TROUBLESHOOTING REQUIRED. CODE 'A' ITEM DUE ON OR BEFORE 2-JAN-2011. ACFT OK FOR SERVICE. TROUBLESHOOT. PURGED SYS AND R & R EPR INDICATOR.

Part: INDICATOR — FAILED (EPR) · airframe 35,848 hrs · 20,945 cycles

THE NR1 EPR GUAGE WAS INOPERATIVE DURING TAKEOFF AND THE TAKEOFF WAS ABORTED, PRIOR TO SETTING TAKEOFF POWER AND REACHING 60 KNOTS. AFTER CLEARING THE RUNWAY AND WHILE TROUBLESHOOTING THE PROBLEM, DURING A JOINT DISCUSSION WITH MX THE NR1 EPR GUAGE STARTED WORKING PROPERLY. CREW DEBRIEF AND CONFIRMED WITH ENGINE RUN IAW JRH, NR1 EPR OPS NORMAL AT THIS TIME. ACFT OK FOR SERVICE. R&R NR 1 EPR GAGE OPS CHECK OK.

Part: HANDLE — UNSECURE (PAX DOOR) · airframe 35,740 hrs · 20,857 cycles

ON CLIMB OUT OF DAY FELT A SLIGHT ACFT VIBRATION (LIKE A SPOILER) RECYCLED NOT HELP- CONTINUUTE TO CLIMB AT ABOUT 12,500 HEARD AND FELT SEVERAL LOUD BANGS-LAST FOR SEVERAL SECONDS AFTER SLOWING BANGING STOPPED. RETURN TO BLOCKS, NOTICED L1 DOOR HANDLE NOT STOWED CREW DEBRIEF SAID VIBRATION FELT LIKE SPOILER FLOAT AND THAT BANGING JUST BEHIND COCKPIT. RERFORMED DETAILED VISUAL INSPECTION OF ALL FLT CONTROLS & FLAPS IAW SMP ALL CHECKED NORMAL. ACFT OK FOR SERVICE

Part: REGULATOR — INOPERATIVE (HYD SYSTEM) · airframe 35,646 hrs · 20,778 cycles

ON CLIMBOUT, SMOKE IN COCKPIT STARTED AND CONTINUED TO GET WORSE. "AIR RETURNED" AND SHUTDOWN ON TAXIWAY. SMOKE LESSENED WHEN THROTTLES WERE RETARTED TO ILDE AND COMPLETLY WENT AWAY AFTER SHUTDOWN. R & R HYD AIR PRESSURE REGULATOR IAW SMP. RAN ALL ENGINES IAW JRH TO 85 PERCENT N2, OPERATED PACKS, NO COCKPIT SMOKE NOTED. ALSO "A" SYS RESERVOIR HEAD PRESSURE NOW READS NORMAL. ACFT OK FOR SERVICE. PREMATURE REMOVAL/INSTALLATION.

Part: CLAMP — MISSING (BLEED DUCT) · airframe 35,399 hrs · 20,576 cycles

ON CLIMB-OUT NR 3 FIRE HANDLE AND WARN LIGHT, AND BELL CAME ON. ON LEVEL OFF THRUST LEVELS PULLED BACK LIGHTS (FIRE) WENT OUT. SHUT DOWN ENGINE, FIRE WARNING TEST WAS GOOD. REMOVED AND INSPECTED THE CHIP DETECTORS AND REPLACED THE OIL FILTER IAW P&W JT8D MM CH 72-00-00-810-004. DETERMINED THAT THE 6TH STAGE BLEED DUCT IS THE SOURCE OF THE LEAK. SEARCHED THE ENGINE BUT DID NOT FIND THE MISSING CLAMP. THE PART IS NIS REF IPC 32-10-00-02 ITEM 40. COMPLIED WITH MTSI 26-10/4398 AND REMOVED RELAYS R730 AND R731 AND CHECKED LOOPS AT D1480 OF M819 WITH NO DISCREPANCIES. REINSTALLED D1480 AND RELAYS R730 AND R731, ALL OPS CHECKS GOOD REF AMM 26-11-001-5. REPLACED CLAMP PER SMP, GOOD LEAK CHECK. AWAITING HIGH POWER AFTER PUSH. RAN ENGINE AT MAX POWER SETTING FOR 5 MINUTES, PER JRH, ALL NORMAL, GOOD FOR SERVICE.

Part: CONTROLLER — FAILED (FIRE DETECTION) · airframe 35,371 hrs · 20,554 cycles

NR 3 ENG FIRE INDICATION CLIMBING THRU 10,000. PULLED FIRE HANDLE AND FIRE INDICATION CEASED. DID NOT DISCHARGE FIRE BOTTLE. NOTE: DELAYED STARTING NR 3 ENG ON TAXI OUT ENG OIL TEMP REQUIRED 5 MINUTES TO REACH GREEN BAND ALL OTHER ENG INDICATIONS NORMAL. UPON BLOCK IN INSPECTED NR 3 ENG INLET AND EXHUAST NO DEFECTS NOTED RE-SET NR 3 ENG FIRE HANDLE OPS CHECKED FIRE WARNING SYS NO FAULTS NOTED IAW AMM 26-11-001-5 RAN ENGINE IAW JRH FOR APPROX 15 MINUTES AT DIFFERENT POWER SETTING, NO FAULTS NOTED WILL REQUIRE FUTHER T/S. R & R FIRE PROTECTION CONTROLLER IAW AMM 26-11-000-4. OPS CK NORMAL IAW AMM 26-11-001-5. FURTHER T/S REQ. REMOVED AND INSPECTED MAIN OIL FILTER AND INSTALLED NEW FILTER REF MM 72-00-00 ADJ/TEST AND AMM 79-00-000-3 RAN ENG REFJRH LEAK CHK GOOD. CHECKED LOOPS, HARNESSES, CONNECTOR PLUGS NO FAULTS NOTED. PERFORMED SHAKE DOWN OF WIRE HARNESS AROUND CONNECTOR PLUGS IN STRUT DURING ENG RUN WITH NO FAULTS. PERFORMED HIGH POWER RUN WITH NO FAULTS REF JRH. (CLOSED)

Part: SEAT TRACK — GOUGED (ZONE 100) · airframe 35,103 hrs · 20,364 cycles

GOUGED FLOATING SEAT TRACK BS 740-BS 760 LBL 24.5. REMOVED DAMAGED SEATTRACK AT BS 740 TO BS 760 LBL 24.5 IAW SRM 51-30-2. FABRICATED NEW SEAT TRACK FROM BAC 15201431 PO NR 6360180 APPROX DIM: 18 INCH IN LENGTH IAW SRM 53-10-2 FIG 7 AND SRM 51-30-5, TREATED AND PRIMED IAW SRM 51-10-2 INSTALLED NEW SEAT-TRACK IAW SRM 51-30-2.

Part: SKIN — CRACKED (RT WING TE FLAP) · airframe 35,103 hrs · 20,364 cycles

RT INBD FOREFLAP WBL 22, CRACK ABOVE CARRIAGE ATTACH FITTING, L/E SKIN. CHEMICALLY REMOVED PAINT IAW MM 51-20-001-7 STOP DRILL CRACK 2 EA DIM: .250 IAW SRM 51-10-1 HFEC SHOW CRACK END ON STOP DRILLS IAW NDTM PT6 51-00-00, FIG 23 FABRICATED DOUBLER REPAIR FROM 2024 T3 .063 PO NR 9008560 DIM: 4.7500 INCHES X 4.2500 INCHES IAW SRM 57-50-2 FIG 3 AND 57-50-4 FIG 1 ALODINE AND PRIMED DOUBLER AND AREA IAW SRM 51-10-2 INSTALLED DOUBLER REPAIR IAW SRM 57-50-4 FIG 1.

Part: CRANK ASSY — WORN (CARGO DOOR) · airframe 35,103 hrs · 20,364 cycles

MCD LWR AFT LOCK ACT BS 615 ROD END BEARING HAS PLAY, CAM ACTUATOR FITTING CRACKED AND MISSING BOLTS. REMOVED AND REPLACED MCD LWR AFT HOOK AND CRANK ASSY IAW MM 52-34-031-4. OPS CHECK GOOD IAW MM 52-34-000-5.

Part: FITTING — CRACKED (CARGO DOOR) · airframe 35,103 hrs · 20,364 cycles

MCD LWR AFT LOCK ACT BS 615 ROD END BEARING HAS PLAY, CAM ACTUATOR FITTING CRACKED AND MISSING BOLTS. REMOVED AND REPLACED MCD LWR AFT HOOK AND CRANK ASSY IAW MM 52-34-031-4. OPS CHECK GOOD IAW MM 52-34-000-5.

Part: STRUCTURE — DAMAGED (RT WING TE FLAP) · airframe 35,103 hrs · 20,364 cycles

CRACK LWR CHORD RT WING INBD MIDFLAP INBD SIDE. REMOVED SEAL RETAINER FOR ACCESS IAW SRM 51-30-2, CUT-OUT DAMAGE ON RT WING INBD MID FLAP INBD SIDE IAW SRM 51-40-4 FIG 1, FABRICATED NEW PARTS IAW SRM 51-40-4. TREATED AND PRIMED NEW PARTS IAW SRM 51-10-2, INSTALLED NEW PARTS IAW SRM 51-30-2 AND RE-INSTALLED SEAL RETAINER IAW SRM 51-30-2.

Part: STRUCTURE — CRACKED (RT WING TE FLAP) · airframe 35,103 hrs · 20,364 cycles

CRACK LWR CHORD RT WING INBD MIDFLAP OTBD SIDE. REMOVED PANEL AND RETAINER IAW SRM 51-30-2, CUT-OUT DAMAGE SECTION DIM: 40 INCH IAW SRM 51-40-4 FIG 1, FABRICATED SECTION FROM BAC 1503-100046 IAW SRM 57- 50-2 AND 51-40-4 PO NR 2909673 DIM: 40 INCH AND SPLICE FROM BAC1503-100046 PO NR 2909673 DIM: 8 INCH IAW SRM 51-40-4. ALODINE AND PRIMED PARTS IAW SRM 51-10-2 INSTALLED REPAIR PARTS IAW SRM 51-40-4. INSTALLED RETAINER AND CLOSED PANEL IAW SRM 51-30-2.

Part: BRACKET — CRACKED (ZONE 500) · airframe 35,103 hrs · 20,364 cycles

LT WING NR 1 SLAT OB ACT ATTACH BRACKET INSIDE PLATE IS CRACKED. REMOVED OTBD AND INBD STEELS DOUBLERS AND WEBS AND FABRICATED WEB DOUBLERS IAW S/B 727-57-0130 AND EA NR 7-5750-126843 HEAT TREATED WEBS TO T6 CONDITION IAW FASI ENGINEERING REPORT NR 2-32153-801, REV A CADMIUM PLATE STEEL DOUBLERS IAW EA NR 7-5750-126843 ALODINE AND PRIMED PARTS IAW SRM 51-10-2, INSTALLED REPAIR PARTS IAW S/B 727 52-0130 AND EA NR 7-5750-126843.

Part: FRAME — GOUGED (BS 1130) · airframe 35,103 hrs · 20,364 cycles

AFT CARGO COMPT. BS 1130 FRAME, PREVIOUS REPAIR DOUBLER IS GOUGED ABOVE STR 27R. REMOVED PREVIOUS REPAIR IAW SRM 51-30-2, FABRICATED ANGLE REPAIR FROM 7075 "O" .063 PO NR 9008655 DIM 12 INCH X 6 INCH IAW SRM 53-10-2, 51-30-5, 51-20-5 HEAT TREATED ANGLE FROM "O" TO "T6" CONDITION IAW FASI ENGINEERING REPORTS NR 2-37153-801 REV A, LOCATED AND DRILLED REPAIR IAW SRM 51-30-5, ALODINE AND PRIMED ANGLE IAW SRM 51-10-2 INSTALLED ANGLE REPAIR IAW SRM 51-40-3, AND 51-30-2.

Part: SKIN — DAMAGED (LT WING TE FLAP) · airframe 35,103 hrs · 20,364 cycles

LT IB MIDFLAP LWR SURFACE WBL 85 HAS ELONGATED FASTENER HOLE. EVALUATED FASTENER HOLE FOUND TO BE OUT OF LIMITS IAW SRM 57-50-01. CUT-OUT DAMAGED AREA APPROX 1 INCH X .5 INCH IAW SRM 57-50-4 FIG 3 FAB REPAIR DOUBLER FROM 2024T3 .125 PO NR 290757Y DIM 13 INCH X 11.5 IAW SRM 57-50-04 FIG 3 TREATED AND PRIMED IAW SRM 51-10-2 AND INSTALLED REPAIR DOUBLER IAW SRM 51-30-2 AND 57-50-4.

Part: STRUCTURE — CRACKED (LT WING TE FLAP) · airframe 35,103 hrs · 20,364 cycles

LT, IB. MIDFLAP T/E LWR CHORD, WBL 103 IS CRACKED ON IB CORNER. OPENED MID FLAP ACCESS PANEL IAW SRM 51-30-2, REMOVED LWR CHORD PREVIOUS REPAIR IAW SRM 51-30-2 FABRICATED NEW T/E LWR CHORD FROM BAC1503-100046 7075 PO NR 29057145 DIM: 49 INCHES IAW SRM 57-50-2 FIG 5 AND 51-40-4 FIG 1 ALODINE AND PRIMED CHORD IAW SRM 51-10-2 INSTALLED NEW CHORD REPAIR IAW SRM 51-40-4 AND 51-30-2 CLOSED ACCESS PANEL IAW SRM 51-30-2.

Part: ANGLE — CRACKED (NR 7 SPOILER) · airframe 35,103 hrs · 20,364 cycles

CRACKED ANGLE CHORD AT NR 7 SPOILER BRACKET FALSE SPAR. REMOVED NR 7 SPOILER FITTING & SUPPORT, REMOVED DOUBLER, REMOVED DOOR STOP FITTING ON NR 7 SPOILER, TRIMMED OUT WEB DIM: 9.5 INCH, CUT OUT DAMAGE CHORD ANGLE SECTION, FABRICATED INBD WEB, FRABRICATED CHORD SECTION FROM BAC 1514-1437 DIM 20.5 INCH. FABRICATED 2 EA ANGLES IAW DRAWING SR 27-57-038 REV C, FABRICATED STRAP, FABRICATED DOUBLER IAW DWG NR SR 27-57-038 REC C ALODINE AND PRIMED PARTS IAW SRM 51-10-2 INSTALLED PARTS IAW DWG SR 27-57-038 INSTALLED FITTINGS SUPPORT IAW SRM 51-30-2. HEAT TREATED 2 EA ANGLES 7075 O TO T6 IAW REPORT NR 2-37153-801 REV A.

Part: DOOR — CRACKED (MLG) · airframe 35,103 hrs · 20,364 cycles

RT MLG WING DOOR CRACKED FWD OF AFT HINGE POINT. REMOVED FASTENERS AND COVER PLATE AT RT MLG WING DOOR IAW SRM 51-30-2. FAB NEW COVER PLATED AND FILLER, MAT USED 2024 T3 .040 PO NR 9008655, DIMENSION 14.8750 INCH X 8.1250 INCH AND FILLER 10.3750 INCH X 5.7500 INCH IAW DWG NR 65C27128. TREATED AND PRIMED IAW SRM 51-30-2, INSTALLED NEW COVER PLATE AND FILLER IAW SRM 51-30-2.

Part: DOOR — CRACKED (MLG) · airframe 35,103 hrs · 20,364 cycles

LT MLG WING DOOR CRACKED FWD OF AFT HINGE POINT. FABRICATED NEW SKIN AND DOUBLER FROM 2024T3 .040 PO NR 9008655 APPROX DIM: SKIN 5.5 INCH X 10 INCH, DOUBLER 13.5 X 8 INCH AND INSTALLED NEW SKIN AND DOUBLER AT LT MLG WING DOOR IAW SRM 51-30-2 DWG NR 65C27128.

Part: WEB — DAMAGED (ZONE 100) · airframe 35,103 hrs · 20,364 cycles

AFT AIRSTAIR AREA- RT LWR TORQUE BOX LIGHTING HOLE IS ROUTED OUT BEYOND LIMITS. FABRICATED DOUBLER REPAIR IAW SRM 53-10-2 AND 51-40-2. ALODINE AND PRIMED DOUBLER IAW SRM 51-10-2. INSTALLED DOUBLER REPAIR IAW SRM 51-40-3.

Part: FIRE DETECTOR — FAILED (NR 1 NACELLE) · airframe 35,061 hrs · 20,317 cycles

DURING CLIMBOUT AT APX 19000 FT, 1 BELL TONE FOR APX 1 SECOND. CHECKED ALL FIRE DETECTION SYS AND LOOPS (A B) AND APPEARED TO OPERATE NORMALLY. APX 2 MINS LATER HAD INTERMITTENT FIRE WARNING FOR NR 1 ENG, THEN WARNING STOPPED. RUN CHECKLIST FOR ENG FIRE AND SHUTDOWN NR 1 ENG. OIL PRESSURE FOR WINDMILLING ENG REMAINED AT 20 PSI UNTIL LANDING. REMOVED AND REPLACED NR 1 ENG B LOOP IAW MM 26-11-012-4 AND OPS 18 CHECKS GOOD IAW MM 26-11-001-5. AWAITING HIGH PWR 19 RUN FOR FURTHER VERIFICATION. HIGH POWER ENGINE RUNS AT 1.96 EPR NO FAULTS, FOUND ALSO RAN AT 1.75 EPR AGAIN NO FAULTS FOUND. ALL REF JRH, ACFT OK FOR SERVICE.

Part: WARNING BELL — FALSE ACTIVATION · airframe 35,060 hrs · 20,316 cycles

AT LEVEL OFF 330 CREW HEARD DING OF FIRE BELL. INSPECTED COCKPIT FOR LIGHTS, NONE ILLUMINATED. DID ENG FIRE TEST WITH NORMAL RESULTS. RIGHT AFTER FIRE TEST, NR 1 ENG FIRE LIGHT ILLUMINATED WITH CONSTANT BELL. RAN RED TAB PROCEDURE, FIRE LIGHT WENT OUT WITH ENG SHUTDOWN. NO BOTTLE BLOWN INTO ENG. ENG WINDMILLED WITH POSITIVE OIL PRESSURE OF OVER 10 PSI FOR 20 MINUTES.

Part: UNKNOWN — UNKNOWN · airframe 35,060 hrs · 20,316 cycles

AT LEVEL OFF 330 CREW HEARD DING OF FIRE BELL. INSPECTED COCKPIT FOR LIGHTS, NONE ILLUMINATED. DID ENG FIRE TEST WITH NORMAL RESULTS. RIGHT AFTER FIRE TEST NR 1 ENG FIRE LIGHT ILLUMINATED WITH CONSTANT BELL. RAN RED TAB PROCEDURE, FIRE LIGHT WENT OUT WITH ENG SHUTDOWN. NO BOTTLE BLOWN INTO ENG. SERVICEABLE ENGINE FIRE PROTECTION CONTROL UNIT INSTALLED INTO AIRCRAFT IAW MM 26-11-000-4. ENGINE FIRE PROTECTION SYSTEM GROUND CHECKS SERVICEABLE.

Part: HOSE — CHAFED (ENGINE OIL) · airframe 33,979 hrs · 19,685 cycles

CRUISING AT 380, OIL QUANITY DECREASED FROM 3 QUARTS TO JUST OVER 1 QUART. PRESSURE RANGED FROM 41-38 PSI. INSTALLED TEMP FLEX LINE IAW EA 7-7930-121858. LEAK CHECK GOOD. SERVICED OIL AS REQUIRED. REQUIRES TUBE MFG 259-1112-504 TO FINALIZE THE REPAIR BEFORE THE NEXT A CHECK.

Part: ACTUATOR — FAILED (FLAPS) · airframe 33,553 hrs · 19,426 cycles

AFTER T/O, NON FLYING PILOT SELECTED FLAPS FROM 5 DEG TO 2 DEG CREW NOTICED AN ILLUMINATED LE FLAPS AMBER LIGHT WITH ASSOCIATED LOSS OF SYS A HYDRAULIC FLUID. SO FLAP CONFIGURATION PANEL INDICATED AN AMBER NR 4 SLAT. CREW FOLLOWED ALL APPLICABLE QRH PROCEDURES THEN RETURNED TO LANDING. DID NOT SHUT OFF SYS A FLUID SWITCHES. VERIFIED NR 4 SLAT ACTUATOR FAILED. REMOVED AND REPLACED NR 4 LEADING EDGE SLAT ACTUATOR OPS AND LEAK CHECK GOOD PER M/M 27-81-032-4. R/I FROM FACT, PREMATURE REMOVED AND REPLACED OFF MFG 2-690029-13,

Part: CONTROL UNIT — MALFUNCTIONED (CARGO SMOKE) · airframe 31,503 hrs · 18,139 cycles

FWD CARGO SMOKE WARNING INFLIGHT, 15000 MSL. NO SMOKE IN COCKPIT. PHASE T'S ACCOMPLISHED. SYSTEM CHECKED GOOD AFTER LIGHT WENT OUT 30 SECONDS AFTER WARNING. RTB MEM. REMOVED AND REPLACED 4 EACH SMOKE DETECTOR UNITS FWD B/B IAW B727 AMM 26-17- 011-2. REMOVED AND REPLACED CONTROL ELECTRONIC UNIT FWD B/B IAW B727 AMM 26-17-012-2. REMOVED AND REPLACED FIRE BOTTLE 1 EACH IAW B727 AMM 26-17-014-2. FUNCTION CHECKED SYSTEM, REF:727-200/AMM20-10-017-2, 26-17-001-1, 26-17-011-2, 26-17-012-2, 26-17-012-2, AND 26-17-014-2.

Part: SMOKE DETECTOR — FAILED (CARGO BAY) · airframe 29,384 hrs · 16,868 cycles

INFLIGHT AT FL330, THE MAIN CARGO SMOKE NR 1 (FORWARD) LT ILLUMINATED, FOLLOWED RED TABS AND PHASE ONES DIVERTED. WARNING LT WENT OUT ON FINAL APPROACH THREE CREW DETECTED A FAINT ABNORMAL ODOR AFTER LANDING AND CARGO DOOR OPEN. REMOVED AND REPLACED NR 1 SMOKE DETECTOR. PREMATURE REMOVAL, INSTALLATION OFF MFG 7740-01, ON MFG 7740-01.

Part: STRIP — DAMAGED (NR 3 NACELLE) · airframe 29,211 hrs · 16,749 cycles

COMPY WITH EA 7-7110-80586 POWERPLANT - COWL NR 3 ENG COWL RUB STRIP REPAIR P/N 259-0175-135. COMPLIED WITH EA 7-7110-80586.

Part: PRECOOLER — CRACKED (ZONE 400) · airframe 27,969 hrs · 16,074 cycles

ENG NR 1 STRUT OVERHEAT LIGHT CAME ON AFTER TAKEOFF FROM PHX. ENG ANTI ICE WAS NOT ON. WITH REDUCTION OF POWER TO QUIET EPR LIGHT WENT OUT. LIGHT WAS ON FOR A TOTAL OF 15 SECONDS. SYSTEM TESTED GOOD. CONSULTED QRH. NO FURTHER ACTION TAKEN. FOUND LEAK AT IB CLAMP ON PRECOOLER . FLANGE CRACK REMOVED PRECOOLER IAW MM 36-11-051-4, DUCTS IN AFT STAIR GOING TO PRECOOLER REMOVED . INSTALLED NEW PRECOOLER AND SECURED ALL DUCTING AND ALL ASSOCIATED HARDWARE. RAN ENGINE AT IDLE, IDLE LEAK CHECK IS GOOD IAW MM 36-11-051-4.

Part: CLAMP — LOOSE (ZONE 400) · airframe 27,919 hrs · 16,045 cycles

WHILE DEPARTING LAS, ENG NR 1 STRUT OVERHEAT LIGHT ILLUMINATED FOR (TEMP 37C) APPROX 15 SECONDS DURING INTIAL TAKE-OFF/ CLIMBOUT AT 180 KTS PRIOR TO FLAP RETRACTION, THEN EXTINGUISHED. SYSTEM TESTED OK REFERRED TO QRH AND CONTINUED. FOUND CLAMPS ON ENGINE BLEED VALVE LEAKING. REMOVED AND REPLACED CLAMPS IN REFERENCE TO B727-200 AMM 36-10-001-4. LEAK CHECK GOOD.

Part: CLAMP — LEAKING (ZONE 400) · airframe 27,929 hrs · 16,049 cycles

ON CLIMBOUT, FROM MEM NR 1 ENGINE STRUT OVERHEAT LIGHT ILLUMINATED. COMPLIED WITH QRH. LIGHT EXTINGUISHED. FOUND CLAMP BETWEEN SHUTOFF VALVE AND PRECOOLER LEAKING. REMOVED AND REPOSITIONED CLAMP IAW SMP PERFORMED ENGINE IAW JRH. LEAK CK. GOOD. RE-INSTALL LOWER STUB PANEL. IAW SMP.

Part: FAN — SHORTED (ZONE 100) · airframe 27,814 hrs · 16,000 cycles

GASPER FAN C/B POPPED IN FLT IMMEDIATELY FOLLOWING MILD SMOKEY ODOR IN COCKPIT. DID NOT RESET C/B ODOR WENT AWAY. REMOVED AND REPLACED GASPER FAN PER 727-200 M 2FM 21-23-011-4 2C, OPS CHECK OK.

Part: REGULATOR — MALFUNCTIONED · airframe 27,712 hrs · 15,946 cycles

SMOKE OR FUMES IN COCKPIT CLIMBING THRU FL 180 NO INDICATION ON S/O PANEL EXCEPT VERY HIGH DUCT PRESSURE L AND R ABOVE 65 PSI. BLEED SWAPPED TO 2 AND 3 LOWERED PRESSURE TO NORMAL RANGE (BETWEEN 30 40 PSI). REMOVED AND REPLACED HIGH PRESSURE SHUT OFF VALVE USING MM-36-12-042, LEAK CHECK NORMAL. ENTERED COCKPIT TO DEBRIEF CREW, NOTICE NO SMOKE OR ODOR AT THAT TIME. RAN ALL THREE ENGINES, AND WAS UNABLE TO DUPICATE WRITEUP. PER T/S TREE FLOW CHART SUGGEST FOR PRECAUTIONARY MEASURES TO CHANGE HIGH PRESSURE REGULATOR AND HIGH PRESSURE MODULATING SHUT OFF VALVE. REMOVED AND REPLACED LT HIGH PRESSURE REGULATOR REF MM CHP 36-12-051. PERFORMED HIGH PRESSURE BLEED CONTROL SYSTEM TEST, OPS NORMAL REF B727JRH.

Part: WARNING LIGHT — ILLUMINATED (WINDSHEAR) · airframe 27,211 hrs · 15,693 cycles

DURING INITIAL CLIMB PASSING 800-1000 FT WE EXPERIENCED A RED WINDSHEAR WARNING AND AURAL WARNING. WE PERF THE EMERGENGY ESCAPE MANUVER AND IMMEDIATELY FIREWALL ALL THRUST LEVERS. WARNING LASTED 5 SECONDS. THRUST LEVERS WERE THEN RETARDED TO MAX POWER. #1 EPR READ 2.15 WITH MAX ON T.O.L.D CARD 1.94. WE DID HAVE DECREASING A/S INITIALLY. DIVERSION FLIGHT TIME WAS 31 MINUTES AT 14000 FEET PERF INLET AND EXHAUST INSPECTION. PERF ANALYTICAL ANALYSIS WORKSHEET ON ALL THREE ENGINES PER JRH FIREWALL AND OR EMERGENCY ESCAPE CHECK ON PAGE 6-38 AND 6-38A PREF BITE TEST OF GPWS PER 32- 52-000-1. NO FAULTS ANNUNCIATED C/W INSPECTION PROCEDURES PER E.A. 78-7100-69076.

Part: ACTUATOR — MALFUNCTIONED (ZONE 600) · airframe 27,088 hrs · 15,622 cycles

AMBER LEADING EDGE FLAPS LIGHT REMAINED ILLUMINATED ON CLIMBOUT AFTER SELECTED FLAPS 2. SECOND OFFICER AUX PANEL SHOWED SLAT 7 AMBER LIGHT ILLUMINATED. QRH PROCEDURES CONDUCTED UNSUCCESSFULLY. FLAPS EXTENDED NORMALLY IN ALL OTHER POSITIONS. REMOVED AND REPLACED NR 7 SLAT ACTUATOR. IAW M/M 27-81-032-4. OPS. AND LEAK CHECKS NORMAL.

Part: STRUCTURE — DAMAGED (CARGO DOOR) · airframe 25,988 hrs · 15,040 cycles

AFT LWR CARGO DOOR HAS DAMAGE AT FWD UPPER CORNER. REMOVED AND REPLACED DOOR PER SRM 52-00-3 FIG 4, 52-00-2.

Part: FRAME — WORN (COWLING)

RIB STRIP AT BS 1352 IS WORN THROUGH IN SEVERAL PLACES, OVER ENTIRE LT & RT SIDES. REMOVED AND REPLACED CHORD PER SRM 51-30-2, 53-10-1, 51-30-5.

Part: SKIN — CHAFED (FUSELAGE)

AFT CARGO DOOR CUTOUT SKIN AT UPPER FWD CORNER IS CHAFED. REMOVED AND REPLACED SKIN PER EA 7-5310-63844.

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION ON LWR LONG FLOORBEAM UNDER NUT PLATES FROM BS 1030 TO 1060, WL 200, LBL 2 TO RBL 2. *S/D* REMOVED AND REPLACED FLOORBEAM PER SRM 51-30-5, 51-20-1 & 51-30-2.

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION ON LWR LONG FLOORBEAM UNDER NUT PLATES FROM BS 1030 TO 1160, WL 200, LBL 2-RBL 2. REMOVED AND REPLACED FLOORBEAM PER SRM 51-30-5, 51-20-1, 51-30-2 & BAC 1506-1706.

Part: PIN — CORRODED (RT WING)

RT WING REAR TERMINAL PIN AT BS 870 HAS RUST AROUND BASE OF PIN. REMOVED AND REPLACED PIN.

Part: SKIN — CHAFED (FUSELAGE)

SKIN LAP AT STR 19R, BS 720E IS CHAFED. REMOVED AND REPLACED SKIN PER SRM 53-30-3 FIG 14.

Part: FLANGE — CORRODED (VERTICAL STAB) · corrosion level 2

VERTICAL FIN MATING SURFACE FOR PANEL 9602 CORRODED (C55-391-30). REMOVED AND REPLACED FLANGE PER EA 7-5510-64063.

Part: FRAME — CRACKED (FUSELAGE)

FRAME CRACKED AT BS 1130, STR 26R. REMOVED AND REPLACED FRAME PER SRM 51-40-3 FIG 1 & EA 7-5310-63837.

Part: FRAME — CRACKED (FUSELAGE)

FRAME CRACKED AT BS 1050, STR 26L. REMOVED AND REPLACED FRAME PER EA. 7-5310-63836.

Part: SKIN — CHAFED (FUSELAGE)

SKIN LAP AT STR 19L, BS 720E IS CHAFED. REMOVED AND REPLACED SKIN PER SRM 53-30-3.

Part: SEAL — DIRTY (CARGO DOOR)

A/C WILL NOT PRESSURIZE OR HOLD PRESSURE. NOTED MCD VENT FLAP/DOORS NOT FLUSH AND SEALS LEAKED. CLEANED SEALS.

Part: WARNING LIGHT — ILLUMINATED (COCKPIT)

A-SYS HYD QUANTITY DROP TO ZERO FOLLOWED BY NR 1 LOW PRESSURE LIGHT ILLUM. REMOVED AND REPLACED O-RING PER MM 29-11-000-1.

Part: INDICATOR — MALFUNCTIONED (TE FLAPS)

99-94 - ASSYMMETRIC INBD FLAP FROM 5 DEG TO 2 DEG RAN RED TABS FLAPS DID NOT LOCK OUT WHEN FLAPS EXTEND PER CKLIST. REMOVED INBD FLAP POS IND PER MM 27-52-021. OPER CK NORM.

Part: RT UNIT — INOP (E & E COMPT)

RADAR NOT PAINTING WEATHER ACCURATELY ALL MODES AND RANGES. REMOVED AND REPLACED RADAR RECEIVER TRANSMITTER. OPER CKS GOOD PER MM 34-0. WEATHER RADAR OK FOR SERVICE.

Part: DUCT — RUPTURED (NR 3 ENGINE)

98-262 #3 ENG FIRE LIGHT CAME ON, #3 THROTTLE WAS RETARDED TO IDLE LIGHT WENT OUT. FOUND #3 COWL ANTIICE DUCT BROKEN. R&R DUCT RAN ENGINE FOR LEAK CHECK. NO LEAKS NOTED A/C IS OK FOR SERVICE.

Part: RETRACT MECH — OUT OF ADJUST (LT MLG)

L/MAIN GEAR LIGHT ILLUM'D ON BOTH FWD PANEL AND S/O PANEL DURING EACH GEAR HANDLE PLACED IN THE UP POS ON FOR 30 SECS. FOUND GEAR RLS MECHANISM OUT OF ADJ, ADJUSTED AND TESTED PER 32-34-21. NO GEAR SWING REQ BY MM.

Part: FIRE LIGHT — ILLUMINATED (CARGO)

AFTER TAKEOFF, NR 4 FIRE LIGHT CAME ON. SILENCED BELL AND NR 5 CARGO FIRE LIGHT CAME ON SILENCED THAT LIGHTS STAYED ON. DID 180 AND LANDED. SMOKE CONTROL WAS ON AND AFTER ROLLOUT LIGHTS EXTINGUISHED. NEVER DETERMINED OR SMELLED SMOKE. REMOVED FREIGHT FROM UPPER DECK, NO PROBLEMS FOUND. PER DANGEROUS GOODS SPECIALIST POSITION 7 HAD 25 KILOS OF DRY ICE. BUMPED POSITION, RELOADED FREIGHT. OPERATIONALLY TESTED SMOKE DETECTORS, ALL CHECKED GOOD ON GROUND.

Part: PITOT TUBE — BLOCKED (LEFT)

FIRST OFFICER'S AIR SPEED FAILED. FOUND PILOT TUBE BLOCKED. REMOVED BLOCKAGE, CHECKED INDICATION WITH BARFIELD TESTER AND OK FOR SERVICE.