N208FE

Part: CABIN PRESSURE — MALFUNCTIONED · airframe 29,959 hrs · 17,342 cycles

DEPARTING GTF A/C WOULDN'T PRESSURIZE. AUTO FAIL AND STBY. LIGHTS NOT ILLUMINATED. RAN FAILURE OF PRESS. CONTROL CHECKLIST, MANUALLY CLOSED OUTFLOW VALVE AND RECYCLED PACK SWITCHES TO EVENTUALLY RESTORE PRESSURIZATION. NO DOOR LIGHTS ILLUMINATED BUT LOUD WHISTLING THROUGH COCKPIT WINDOWS. CHECKED PER BMM 21-31-000-5, CHECKS NORMALLY, OK FOR CONTINUED SERVICE.

Part: SMOKE DETECTOR — FAILED (CARGO BAY) · airframe 29,844 hrs · 17,264 cycles

ON CLIMB OUT GOT NR 6 MAIN CARGO SMOKE LIGHT AND FIRE BELL. PERFORMED EMERGENCY PROCEDURES PER QRH. AT 500 AGL THE LIGHT WENT OUT AND THE SYSTEM TESTED OK. R & R NR 6 DETECTOR AND MAIN CARGO SMOKE DETECTOR MODULE PER 727-200 MM 26-16-011-4 AND 26-16-000-5.

Part: INDICATOR — MALFUNCTIONED (EPR) · airframe 29,679 hrs · 17,158 cycles

WHILE ADVANCING THROTTLES FOR T/O, NR 3 EPR INDICATOR JUMPED UP TO FROZE AT "2.07" AND REMAINED THERE FOR 5 MIN AFTER RTO WITH NR 3 THROTTLE AT IDLE. RELEASED FOR SERVICE PER MEL/CDL: 77-01-01. NR 3 ENGINE EPR INDICATOR INOP. REMOVED AND REPLACED NR 3 ENG "EPR" IND PER AMM 77-11-002-2. RAN ENGINE PER JRH CHAP 5 OPS CK'S GOOD.

Part: ENGINE — MALFUNCTIONED (NR 1) · airframe 29,623 hrs · 17,120 cycles

REPEAT GRIPE. ON T/O ADVANCED POWER TO STANDARD, NO RESPONSE ON NR 1 ENG. NR 1 ENG SHOWED EPR, N1, EGT, N2 FROZEN. FUEL FLOW MOVED 100PPH. AFTER QRH REJECTING T/O PROCEDURES AND THROTTLES AT IDLE N1=23 PERCENT, EGT 500 C, N2=47 PERCENT. AFTER RETURNING TO THE GATE FOR MAINTENANCE, THROTTLES AT IDLE SHOWED N1 ON NR 1 ENG WAS 10 PERCENT LOWER THAN N1 ON NR 3 ENG. AFTER SEVERAL THROTTLE ADVANCEMENTS NR 1 ENG RETURNED TO NORMAL OPERATION. (OPEN)

Part: BEAM — CRACKED (FUSELAGE) · airframe 28,649 hrs · 16,543 cycles

MAIN CARGO DOOR LWR LONGITUDINAL FRAME / CAP IS CRACKED OUTSIDE PREVIOUS REPAIRED AREA AT NR 4 LATCH CAM. COMPLIED WITH EA 7-5230-55418, REF: WRI 52-30/8452.

Part: SEAT TRACK — GOUGED (FUSELAGE) · airframe 28,649 hrs · 16,543 cycles

MAIN DECK - SEAT TRACK STA 1150 - 1170, BL 0 - LUGS GOUGED. BLENDED GOUGED AREA IAW SRM 53-10-1, FOUND TO BE OUT OF LIMITS. REMOVED SEAT TRACK IAW SRM 51-30-2, FABBED NEW SEAT TRACK FROM 60-5017/7178-T6511 BATCH 746883 AND INSTALLED IAW SRM 51-30-2.

Part: OVERHEAT LOOP — INTERMITTENT (AFT AIRSTAIRS) · airframe 26,606 hrs · 15,450 cycles

APPROX ONE HOUR INTO FLIGHT 28 DURING CRUISE NO TURBULENCE 29 EPR 27S 231 1.59 232 1.83 233 1.56_N2_231 86 25_232 86 25_ 233 85 25 LOWER AFT BODY OVERHEAT LIGHT FLICKERING. CHECKLIST ACCOMPLISHED-LT WENT OUT THEN BEGAN TO FLICKER AGAIN. LANDED GTF. REMOVED AND REPLACED R2 FH OVERHEAT DETECTOR LOOP IN AFT AIRSTAIR AREA. LOWER AFT BODY OVERHEAT SYS OPS CHECK NORMAL ON GROUND AT THIS STATION. REF B 727 MM 26-14--2.

Part: CONTROL PANEL — MALFUNCTIONED (COCKPIT) · airframe 26,606 hrs · 15,450 cycles

IN CRZ FLT LOWER AFT BODY OVERHEAT LIGHT CAME ON BLINKING AT VARIOUS RATES. ACCOMPLISHED QRH L.A.B. OVERHEAT CHECKLIST TO INCLUDE CLOSING NR 3 ENG. BLEED. BLINKING SLOWED THEN STOPPED. SYSTEM TESTED GOOD. CONTINUED IN CRUISE WITH NR 3 BLEED CLOSED. R7R OVERHEAT DETECTION PANEL 69-67178-1, WITH CANNED SERVICABLE UNIT FROM A/C 210FE. S/N'S OFF D00176 ON D00172. REMOVED AND REPLACED OVERHEAT DETECTION ACC. UNIT M113 WITH CANNED SERVICABLE UNIT FROM A/C 210FE. SUSPECT BAD LOWER AFT BODY HEAT LITE ASSY. STOPPED. REMOVED AND REPLACED UNITS ABOVE FOR PRECAUTION. SRL 670502 TAG 901161 ON MFG 65-24920-1 SRL 040 TAG 901151

Part: OVERHEAT LOOP — CHAFED (FUSELAGE) · airframe 26,606 hrs · 15,450 cycles

DURING CRUISE FLIGHT AT FL 330 MACH .82, THE LOWER AFT BODY OVERHEAT LIGHT STARTED TO LIGHTLY FLICKER INTERMITTENTLY. LIGHT RARELY FLICKERED ON AND WAS MOSTLY COMPLETLEY OUT. SUSPECTED A SHORT IN THE IND SYSTEM. FURTHER DOWN LINE THE WARNING LIGHT FLICKERED MORE OFTEN AND WAS CLOSE TO FULL BRIGHTNESS. FOLLOWED RED TAB PROCEDURES WITH ALL THREE THROTTLES AT IDLE AND ALL BLEEDS OFF. LIGHT WOULD NOT EXTINGUISH. ENGINE OR WING ANTI-ICE NEVER USED. STRUT AND AFT BODY OVERHEAT TESTS NORMAL. VISUALLY INSPECTED VENTRAL STAIR AREA FOR DUCT LEAKS, NONE NOTED. FOUND DETECTION LOOP CHAFING ALONG ROUTING BETWEEN FRAME STA'S 1240 TO 1303 LEFT HAND SIDE, MOVED ELEMENT AWAY FROM STRUCTURE.

Part: BRACKET — BROKEN (NR 1 ENG NACELLE) · airframe 26,000 hrs · 15,147 cycles

NR 1 FIRE WARNING LITE AND BELL COMES ON INTERMITTANTLY ABOUT 30 SEC INTERVALS, OCCURRED ON FINAL WITH THRUST LEVER AT IDLE. ENGINE SHUT DOWN ON LANDING. OPENED ENGINE NACELLE TO FACILITATE MAINTENANCE. DISCOVERED ENGINE FIRE DETECTION LOOP BRACKET ASSY TO BE BROKEN NEXT TO THE STARTER AT THE AFT INBOARD SIDE. REMOVED AND REPLACED NR 1 ENGINE SENSING ELEMENT PER MM 26-11-012-4 OK FOR SERVICE.

Part: A/C PACK — CONTAMINATED (CABIN) · airframe 25,921 hrs · 15,114 cycles

5 MIN. AFTER T/O R/PACK OVERHEAT LIGHT ILLUM'D. PACK COOLING FLAP SELECTOR IN AUTO. PACK TEMP APPROX. 180 DEG. ,SHUT DOWN PACK, TEMP DECREASED. FOLLOWED BY NR 6 MAIN SMOKE CARGO LIGHT AND FIRE WARN GLARESHIELD LIGHTS. HORN ILLUMINATED, FOLLOWED BY NR4 THEN NR5 CARGO SMOKE LIGHTS. DONED O2 MASK, CONTINUED. DEPRESSURIZED A/C, MAIN CARGO DOOR LIGHT ILLUM. BETWEEN 2000 AND 3000 FT. MSL. CLOSED WING AI AND LIGHT EXTINGUISHED SHORTLY THERE AFTER. REMOVED AND REPLACED WATER SEPARATOR (BAG) NO SMOKE OR ODOR. INSPECT MAIN CARGO SMOKE DET SYS. COULD NOT DUPLICATE. FOUND PROBLEM TO BE DEICE FLUID FILLING COMPARTMENT THRU PACKS. AFTER BAG REMOVED AND REPLACED COULD NOT DUP PROBLEM. CHECK MAIN CARGO DOOR AS REQUIRED .

Part: ACTUATOR — LEAKING (L/E SLAT) · airframe 25,437 hrs · 14,862 cycles

AFTER T/O, LOST A SYSTEM HYDRAULICS. PERFORMED CHECKLISTS AND RED TAB PROCEDURES. DECLARED EMERGENCY, CALLED MOCC. AFTER SLAT ACTUATOR CHANGE PER 27-80-6282 SERVICED HYD SYS PER MM 12-12-000-3. OPS CHECK GOOD.

Part: INDICATOR — STICKING (COCKPIT) · airframe 25,330 hrs · 14,801 cycles

ON INITIAL FLAP RETRACTION, THE OUTBOARD TRAILING EDGE FLAP STOPPED MOVING AT ABOUT 1 DEG AND THE LEFT AND RIGHT NEEDLES ON THE GAUGE SHOWED ONE NEEDLE WIDTH SPLIT. RED TAG PROCEDURES ACCOMPLISHED AND AIR ABORT ACCOMPLISHED. UPON INSP FOUND O/B FLAP IND STICKING. R&R O/B FLAP IND IAW MM CH 27-52-021-2. CYCLED FLAPS SEVERAL TIMES. NO FLAP SPLIT NOTED AND ALL INDICATIONS AND LIGHTS, OPS NORMAL.

Part: FRAME — GOUGED (FUSELAGE) · airframe 25,247 hrs · 14,748 cycles

GOUGE IN FRAME BS 348, LBL 44, WL 281.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 25,247 hrs · 14,748 cycles

COMPLY WITH EA 7-5330-65843 FUSELAGE SKIN REPAIR BS 304 & STR 22R/23R. COMPLIED WITH EA 7-5330-65843.

Part: SKIN — GOUGED (FUSELAGE) · airframe 25,247 hrs · 14,748 cycles

SKIN GOUGED AT BS 720D+13, STR 10L.

Part: SKIN — DENTED (FUSELAGE) · airframe 25,247 hrs · 14,748 cycles

DENT IN SKIN AT BS 1072, RBL 60, WL 200. REMOVED AND REPLACED SKIN PER SRM 53-30-1.

Part: KEELBEAM — CORRODED (FUSELAGE) · airframe 25,247 hrs · 14,748 cycles

CORROSION (C53-113-01) ON KEELBEAM FLANGE AT BS 950B - 950B+11, LBL 7, WL 149. REMOVED AND REPLACED KEELBEAM FLANGE PER DWG 27-53-023.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 25,247 hrs · 14,748 cycles

BULGE IN SKIN AT STR 28L, BS 1030. REMOVED AND REPLACED SKIN PER SRM 53-10-3 & 53-30-3, 53-30-1 FIG 2.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 25,247 hrs · 14,748 cycles

CORROSION ON BS 344 FLOORBEAM TOP CHORD AT NUT PLATE LOCATIONS UPPER AND LWR FLANGES LBL 57 TO RBL 12, WL 208. R&R UPPER CHORD ON FLOORBEAM PER SRM 53-10-8.

Part: CLAMP — LOOSE (PNEUMATIC SYS) · airframe 24,941 hrs · 14,577 cycles

LOWER AFT BODY OVERHEAT LIGHT FLICKERED SEVERAL TIMES THEN REMAINED ON STEADY FOR APPROX 20 SEC IN FLT WHILE EXECUTING PROC IN ORH LIGHT WENT OUT. PERFORMED RESISTANCE CHECKS OF OVERHEAT ELEMENTS. ALL RESISTANCE CHECKS ARE GOOD PER MM 26-14-001-2. GAIN ACCESS TO KEEL BEAM AND AFT CARGO DUCTING AND ELEMENTS TO BE PHYSICALLY CHECKED ON ENGINE RUN. NR 1 ENGINE PURGE VALVE PNEUMATIC DUCT CLAMP LEAKING AIR ON OVERHEAT LOOP AFT OF STA 1243 IN AFT AIRSTAIR AREA. TIGHTEN CLAMP AND LEAKED CHECK OK.

Part: SENSE LINE — OUT OF POSITION (OVERHEAT SYS) · airframe 24,908 hrs · 14,560 cycles

DURING DESCENT THE LOWER AFT BODY OVERHEAT LIGHT CAME ON FOR APPROX 2 SECONDS THEN WENT OUT. THIS OCCURRED ONLY 1 TIME AND THE SYSTEM TESTED NORMALLY. ALL OTHER AIRCRAFT SYSTEMS/INDICATIONS NORMAL. INSPECTED AND FOUND SENSE LINE AT STATION 1243 LT SIDE OF AFT STAIR WELL TOUCHING BLEED AIR SUPPLY LINE. REPOSITIONED LINE WITH NEW CLAMPS OPERATIONALLY CHECK GOOD. ALL WORK DONE IAW B727MM 26-14-00, OK FOR SERVICE.

Part: DETECTOR — MALFUNCTIONED (OVERHEAT SYS)

LWR AFT BODY OVERHEAT LIGHT ILLUMINATED IN FLT. REMOVED AND REPLACED FIRE DETECTION PER MM 20-10-017-2.

Part: ACM — FAILED (A/C BAY)

BLUE/BLACK OILY SMOKE IN COCKPIT 3 MIN AFT T/O SEEM TO BE RIGHT AFT NR 3 BLD AND RT PACK TURN ON. *S/D* REMOVED AND REPLACED RT AIR CYCLE MACHINE AND PERFORMED FUNCTIONAL CK PER MM 21-55-011-4. A/C OK TO CONTINUE.

Part: FIRE DETECT SYS — MALFUNCTIONED (NR 3 ENGINE)

FIRE LIGHT ON THE NR 3 ENG WITH THE FIRE BELL. RED TABS LED US TO DISCHARGE BOTH FIRE BOTTLES AND LIGHT REMAINED ON. REMOVED AND REPLACED NR 3 ENG ELEMENT PER FEDEX 727-200 MM 26-11-012-4. PRECAUTIONARY REMOVED AND REPLACED ENG FIRE PROTECT CTR & FIRE BOTTLES PER 26-11-002, 26-21-001-4.

Part: STRUT — DISCHARGED (NLG)

00-18 - NOSE WHEEL LIGHT DID NOT EXTINGUISH UPON GEAR RETRACTION ON T/O. LIGHT BEGAN TO FLICKER AND EVENTUALLY WENT OUT. RECYCLED GEAR WITH SAME RESULTS. TROUBLE SHOT AND FOUND NOSE GEAR STRUT REQ SERVICE. NOSE WHEEL HITTING GEAR DOORS. SERV AS PER FEDEX MM 12-15-025-2. OPS CK GOOD AS PER FEDEX MM 32-33-0005.

Part: BOOST PUMP — FAILED (NR 2)

LEFT AFT TANK NR 2 BOOST PUMP FAILED. POPPED CIRCUT BREAKER WHILE IN FLT. RESET ONCE, FAILED AGAIN. *S/D* DRAINED FUEL BOOST PUMP AND CLEANED CANNON PLUG. OPER NR 2 FUEL TANK LEFT AFT BOOST PUMP PER MM 28-22-21.

Part: ANNUNCIATOR PANL — MALFUNCTIONED (RT COCKPIT)

CREW SAW BRIGHT FLASH AND A LITTLE SMOKE BEHIND 2ND OFFICER'S PANEL WHEN NR 3 FUEL BOOSTS WERE TURN OFF. BOOST TURNED BACK ON, NO SMOKE EVIDENT. COULD NOT DUP. REMOVED 2ND OFFICER'S FUEL SYS ANNUNCIATOR PANELS AND INSPECTED BEHIND HIS STATION. FOUND NO EVIDENCE OF BURN OR FIRE. NO POPPED CIRCUIT BREAKERS, NO MAINTENANCE PERFORMED.

Part: SMOKE DETECTOR — INOP (CARGO COMPT)

98-307 - MAIN CARGO SMOKE DET POS NR 4 CAME ON IN FLT. REMOVED AND REPLACED DET PRECAUTIONARY FOR RETURN BK DUE TO NR 4 SMOKE DET LIGHT ON DURING CLIMB-OUT. RAMP INSP ALL CARGO FOR EVIDENCE OF SMOKE, NONE FOUND. CARGO SMOKE DETECTION SYS TEST NORM ON GRND. ALL WORK DONE IAW MM CHAPTER 26-16-1,PG 401

Part: SMOKE DETECTOR — FAILED (E/E COMPARTMENT)

APPROX 4 TO 5 MIN AFTER T/O, NR 4 MAIN CARGO SMOKE ALARM SOUNDED AND ILLUMINATED. LIGHT REMAINED ILLUMINATED FOR A FEW MIN AND THEN WENT OUT. NO SECONDARY IND OF FIRE OR SMOKE. REMOVED AND REPLACED NR 4 SMOKE DETECTOR, OPERATIONAL CHECKS NORMAL PER B727 MAINTENANCE MANUAL CHAPTER 26.

Part: CONNECTOR — DIRTY (LT MLG DOOR)

AFTER LOWERING LANDING GEAR, LEFT MAIN GEAR DOOR LIGHT ILLUMINATED ON SECOND OFFICER'S PANEL. RECYCLED GEAR AND LIGHT EXTINGUISHED. CHECKED DOOR SWITCH FOR SECURITY, NORMAL. CYCLED DOOR, INDICATION NORMAL. FOR PRECAUTION DEFERRED LEFT GEAR DOOR WARNING SYSTEM. CLEANED CANNON PLUG ON LEFT MAIN DOOR SWITCH, SYSTEM OPERATES NORMAL, AND PER FLIGHT CREW DOOR LIGHT OPERATED NORMAL ON LEG OF FLIGHT.

Part: CONNECTOR — DIRTY (LT MLG)

DURING TAKEOFF WITH LANDING GEAR IN UP AND OFF LEFT MAIN GEAR LIGHT ON SECOND OFFICER'S ANNUNCIATOR PANEL WITH CORRESPONDING RED DOORS LIGHT ILLUMINATED. FOLLOWING RED TABS, CYCLED LANDING GEAR WHICH CORRECTED PROBLEM. CHECKED AND CLEANED LEFT GEAR UP SWITCH CANNON PLUG CYCLED DOOR SEVERAL TIMES AND CHECKS OK.

Part: FLOORBEAM — CORRODED (BS 344)

NR 0358, MAIN CARGO CORROSION TOP AND BOTTOM OF FLOORBEAM AT 2 FAST HOLES RBL 5 TO RBL 15, FS 344. REMOVED CORROSION ON BEAM BY CUTTING OUT AFFECTED AREAS AND INSTALLING ANGLE REPAIR PER SRM 53-10-08 FIG 7.

Part: SKIN — CRACKED (BS 1098)

NR 0715, FUSELAGE SKIN CRACKED AT RIVET RBL 1, STA 1098 ONE INCH TO RIGHT OF STRINGER 1. GAINED ACCESS TO AREA. HFEC CHECK TO FIND AND MARK END OF CRACK. CUT OUT DAMAGED AREA. HFEC TO CONFIRM DAMAGE REMOVED. INSTALLED REPAIR PER SB 727-53A0204 REVISION 3; SRM 53-30-03 PAGE 12 FIGURE 3; AND SUBSTITUTED FASTENERS AS REQUIRED FOR SKIN THICKNESS PER SRM 51-30-0 PAGES 5, 6 AND EO 7-5330-7-2342 F1.

Part: RETRACT MECH — MALFUNCTIONED (LT MLG DOOR)

ON TAKEOFF AT IND LEFT MAIN GEAR DOOR HAD TO BE RECYCLED BEFORE IT WOULD RETRACT. WORKED FINE AT JFK. INSPECTED LEFT DOOR ASSEMBLY AND OPERATED GEAR DOOR SEVERAL TIMES, GEAR LIGHT CHECKED NORMAL.

Part: FUEL TANK — LEAKING (NR 2)

NR 2 FUEL TANK LEAKING ONTO AIR CYCLE MACHINE, LEFT SIDE INSIDE PANEL 3351L. INSPECTED AREA AROUND LT AIR CYCLE MACHINE, FOUND NO EVIDENCE OF FUEL LEAKING. CLEANED AREA AND CHECKED FOR LEAKS, NONE FOUND.