N212FE

Part: HOSE — LEAKING (HYD SYSTEM) · airframe 31,847 hrs · 18,218 cycles

COMPLETE LOSS OF SYSTEM A HYDRAULICS ON DEPARTURE. LEAK COMING FROM RIGHT GEAR RETRACT ACTUATOR. APPEARED TO BE COMING FROM AFT LINE CLOSE TO ACTUATOR. QTY IS ZERO. REMOVED AND REPLACED RT MAIN GEAR RETRACT ACTUATOR HYDRAULIC HOSE. CLEANED AREA, SERVICED A SYSTEM HYD SYSTEM AND RAN ENGINES 1 AND 2. CHECKED FOR SYSTEM OPERATION AND LEAKS. JACKED AIRCRAFT, CYCLED GEAR SEVERAL TIMES AS PRECAUTION TO CHECK FOR LEAKS, ENSURE LINE IS PURGED AND PROPER OPERATION PER SMP AND 12-12-000.

Part: ENGINE — LEAKING (NR 2) · airframe 30,899 hrs · 17,605 cycles

NR 2 OIL QTY DECREASED TO ZERO AT FLT LEVEL, APPROX 3 MIN LATER OIL PRESS DROPPED INTO YELLOW BAND AND CONTINUED TO FALL. COMPLIED WITH ALL RED TABS AND SHUTDOWN ENGINE. ENGINE WAS NEVER OPERATED AT ZERO OIL PRESSURE. WINDMILLED FOR APPROXIMATELY 15 MINUTES BEFORE LANDING.

Part: SKIN — PUNCTURED (FUSELAGE) · airframe 29,594 hrs · 16,811 cycles

FUSELAGE SKIN AT STA 1110 BELOW STR 20R IS PUNTURED. REPAIRED AREA IAW SRM 53-30-3 FIG 5. THIS IS A CLASS B-REPAIR PER SRM 53-30-3 FIG 5 SHT 6.

Part: STRINGER — CORRODED (MAIN CARGO) · corrosion level 2 · airframe 29,594 hrs · 16,811 cycles

MAIN CARGO COMPT FS 344-360 STR 5L HAS CORROSION JUST AFT OF L-1 DOOR CUTOUT. REMOVED AND REPLACED STRINGER IAW SRM 51-30-2.

Part: FLOORBEAM — CORRODED (ZONE 100) · airframe 29,594 hrs · 16,811 cycles

REMOVED NUT PLATES IAW SRM 51-30-2, REMOVED CORROSION IAW SRM 51-10-6, FOUND TO BE OUT OF LIMIT IAW SRM 53-10-1 FIG 1. FABRICATED NEW SUPPORT ON TRAVELER T5/516572 IAW SRM 53-10-2 FIG 8, INSTALLED 2 ANGLE REPAIR IAW SRM 51-40-4 FIG 1, INSTALLED NUT PLATE IAW SRM 51-30-2.

Part: FLOOR SUPPORT — CRACKED (COCKPIT FLOOR) · airframe 29,594 hrs · 16,811 cycles

COCKPIT FLOOR DENTED AND 3 EACH SUPPORT ANGLES CRACKED AT APPROX FS 259 LBL 5 AND 9 AS SEEN THRU NWW UPPER CEILING PANEL. REWORKED DENT IAW SRM 51-40-1. REMOVED AND REPLACED IAW SRM 51-30-2.

Part: SUPPORT ANGLE — CRACKED (LT WING) · airframe 29,594 hrs · 16,811 cycles

LEFT WING LOWER T/E SUPPORT ANGLES CRACKED BELOW INBOARD END OF NR 4 SPOILER. REMOVED AND REPLACED INBOARD AND OUTBOARD SUPPORT ANGLES IAW SRM 51-30-2.

Part: FILLER — CORRODED (RT SPOILER) · corrosion level 2 · airframe 29,594 hrs · 16,811 cycles

RIGHT WING NR 6 TRACK AT SPOILER BEAM ATTACHMENT FITTING HOLES ARE CORRODED. REMOVED AND REPLACED SUPPORT FILLER IAW SRM 51-30-5 & 51-30-2.

Part: RETAINER — CRACKED (E/E BAY DOOR) · airframe 29,594 hrs · 16,811 cycles

E & E COMPARTMENT DOOR AFT SEAL RETAINER BENT AND CRACKED. REMOVED AND REPLACED SEAL RETAINER IAW SRM 51-30-2.

Part: CONTROL UNIT — MALFUNCTIONED (FIRE DETECTION) · airframe 29,059 hrs · 16,483 cycles

IN DESCENT THROUGH FL200, THE NR 1 FIRE HANDLE LIGHT CAME ON INTERMITTENTLY. IN CONJUNCTION WITH THE FIRE HANDLE AND BELL, THE NR 1 ENGINE DETECTOR INOP LIGHT ILLUMINATED. RAN QRH FOR ENGINE FIRE AND SHUT THE NR 1 ENGINE DOWN. INSTALLED A NEW FIRE CONTROL UNIT PER AMM 26-11-000-4. TESTED PER AMM 26-11-000-1, OPS CHECK GOOD. INSTALLED A NEW MAIN OIL FILTER, NO METAL FOUND IN THE OLD FILTER. RAN THE ENGINE PER B-727-200 JRH, OPS AND LEAK CHECK GOOD.

Part: SMOKE DETECTOR — MALFUNCTIONED (CARGO BAY) · airframe 26,769 hrs · 15,221 cycles

ON T/O CPR PASSING 3000 AGL NR 4 UPPER DECK SMOKE DETECTOR LIGHT ILLUMINATED, MASTER FIRE LIGHT ON GLARESHIELD ILLUMINATED. FIRE WARNING BELL SOUNDED, DOWN LOADED CARGO. CHECKED CARGO FOR DEFECTS, FOUND NO DEFECTS. PRECAUTIONARY CHANGED NR 4 SMOKE DETECTOR P/N 77 40-1, S/N 211 INSTALLED IN NR 4 POSTION IAW 727 MM 26-16-011-4.

Part: WARNING LIGHT — FALSE ACTIVATION (NR 1 ENG FIRE) · airframe 26,522 hrs · 15,091 cycles

DURING DESCENT INTO MEM, FIRE WARNING BELL CAME ON 3 TIMES. DURATION WAS 2-3 SECONDS, DURING THIRD INCIDENT NR 1 FIRE LIGHT ILLUMINATED BRIEFLY. LIGHT TESTED GOOD DURING TEST. REMOVED AND REPLACED ENGINE FIRE DETECTION CONTROLLER, PER MM 26-11-000-4, OPS CHECK GOOD, OK FOR SERVICE.

Part: WARNING LIGHT — ILLUMINATED (NR 3 ENGINE) · airframe 26,217 hrs · 14,936 cycles

NR 3 ENGINE STRUT OVERHEAT LIGHT ILLUMINATED IN FLIGHT DURING CLIMBOUT. COMPLETED PROCEDURES IAW QRH. LIGHT EXTINGUISHED AFTER NR 3 BLEED CLOSED - R PACK OFF - NR 3 THRUST LEVER TO IDLE. NR 3 THRUST LEVER RESTORED WITH NO REOCCURANCE. ***S/D COMING ****

Part: FLOORBEAM — GOUGED (FUSELAGE) · airframe 26,115 hrs · 14,866 cycles

LONGITUDINAL FLOORBEAM OUTBOARD, LOWER FLANGE SIDE IS GOUGED JUST BELOW FASTENER HOLES BS 760-848, LBL 51, WL 208. LONGITUDINAL FLOORBEAM, BS 760-848, FOUND TO BE OUT OF LIMITS IAW SRM. REMOVED DAMAGED BEAM, FABRICATED, ALODINED, PRIMED AND INSTALLED REPLACEMENT BEAM IAW SRM.

Part: FLOORBEAM — GOUGED (FUSELAGE) · airframe 26,115 hrs · 14,866 cycles

LONGITUDINAL FLOORBEAM OUTBOARD, LOWER FLANGE, UPPER SIDE IS GOUGED, JUST BELOW FASTENER HOLES FROM BS 740-848, RBL 51, WL 208. FABRICATED AND REPLACED LONGITUDINAL BEAM UPPER CHORD IAW SRM.

Part: SUPPORT ANGLE — CORRODED (FUSELAGE) · airframe 26,115 hrs · 14,866 cycles

CORROSION FLOORBEAM SUPPORT ANGLE, UPPER FLANGE, LWR SURFACE BS 825, RBL 62, 207.5. REMOVED, FABRICATED AND REPLACED FLOORBEAM SUPPORT ANGLE IAW SRM AT BS 825, RBL 62.

Part: FRAME — CORRODED (FUSELAGE) · airframe 26,115 hrs · 14,866 cycles

CORROSION, BS 720A, FWD SIDE OF FRAME AT STR 8L.

Part: WARNING SYSTEM — FALSE ACTIVATION (COCKPIT) · airframe 25,282 hrs · 14,427 cycles

AFT AIRSTAIR LIGHT ON S/O PANEL ON AFTER TAKEOFF. ACN RELEASED FOR SERVICE PER MEL/CDL: 52-06-B. AIRSTAIR UP UPON ARRIVAL. INSPECTED SYSTEM, HANDLE IN CORRECT LOCK POSITION. CYCLED AIRSTAIR ALL INDICATIONS NORMAL AT THIS TIME. MACH SHOWS NO HISTORY FOR LAST 60 DAYS. PER MEL - LOWER AFT AIRSTAIR CONTROL STATION RED NOT LOCKED WARNING LIGHT OPS NORMALLY. DURING AIRSTAIR OPERATION & EXTINGUISHES WHEN AIRSTAIR IS LOCKED UP. CYCLED AIRSTAIRS SEVERAL TIMES ALL FUNCTIONS OF AIRSTAIRS OP CHECKS GOOD AS PER AMM 52-62-001-0, DEBRIEFED INCOMING FLIGHT CREW INDICATIONS WERE NORMAL.

Part: SWITCH — OUT OF ADJ (AFT AIRSTAIRS)

ON CLIMBOUT AT 12,000 MSL AFT AIRSTAIRS LIGHT ILLUMINATED. ADJUSTED MICRO SWITCH PER MM 52-62-001-5.

Part: SENSOR — INOPERATIVE (LT MLG)

LANDING GEAR FAILED TO RETRACT ON T/O. FOLLOW PREC IN QUICK REF HANDBOOK. LANDING GEAR ALIGNMENT MARKS ALIGNED, HORN WOULD SOUND, BUT THE WING ANTI-ICE GROUND TEST WOULD NOT TEST. GEAR HANDLE WOULD NOT GO PASS THE OFF POS. *S/D* REMOVED AND REPLACED RELAY R-92 AND LEVER LATCH SOL AND LG ACC UNIT PER MM 32-30-01, 32-09-121 AND AIR SENSING SENSOR PER WDM 32-31-01.

Part: WIRE — FAILED (RUDDER PUMP)

RUDDER STBY PUMP C/B POPS WHEN S/W IS TURNED ON. FOUND WIRE BUNDLE GOING TO STBY RUDDER PUMP BURNED. DESINTEGRATED AT LT BULKHEAD BS 1223. *S/D* REMOVED AND REPLACED STBY PUMP PER MM 29-11-0, REMOVED AND REPLACED DAMAGED WIRES PER WDM 30-13-01 & 30-12-01.

Part: DETECTOR — MALFUNCTIONED (NR 3 ENGINE)

LWR AFT BODY AND ENGINE NR 3 STRUT OVERHEAT LIGHTS FLICKER INTERMITTENTLY. INSPECTION WHEEL WELL AND PERFORMED GROUND OPS CHECK. COULD NOT DUPLICATE PROBLEM AT THIS TIME, PER MM CHAPTER 26.

Part: SHUTOFF VALVE — MALFUNCTION (NR 3 RT ANTI-ICE)

AFTER TAKEOFF, DUCT OVERHEAT LIGHT ILLUM FOLLOW BY ZONE 4 MAIN CARGO SMOKE WARN LIGHT AND BELL. SMELL SMOKE IN COCKPIT LIGHTS AND BELL EXTINGUISH THEN CAME ON ANOTHER. THE NR 3 ENG DUCT TEMP WAS 220 DEG NR 1 ENG WAS APPROX 180. OPER CKD WING ANTI-ICE SYS, ALL SYS ALL INDICATION NORMAL. REMOVED AND REPLACED NR 3 RIGHT HAND WING ANTI ICE SHUTOFF VALVE PER M/M 30-11-31 (PRECAUTIONARY). LEAK CHECK GOOD. REMOVED AND REPLACED WING ANTI-ICE HIGH PRESS SHUTOFF VALVE PER M/M 30-11-11 OPER CK GOOD. RAN ENG 1 AND 3 TO PERFORM A FUNCTIONAL TEST OF WING THERMAL ANTI-ICE SYS PER M/M 30-13-0, ALL CHECKS GOOD.

Part: STARTER — FAILED (NR 3 ENGINE)

WHEN TURNING ON NR 3 BLEED ON CLIMB-OUT, NR 3 FIRE LIGHT AND FIRE WARNING CAME ON. TURNING OFF THE BLEED, THE FIRE LIGHT AND HORN WENT OFF. FOUND STARTER CONTROL VALVE STUCK 25 PERCENT OPEN AND STARTER IN TOO MANY PIECES. REPLACED STARTER AND CONTROL VALVE PER MAINTENANCE MANUAL 80-10-02. STARTER AND VALVE OPERATIONALLY CHECKED NORMAL.

Part: THERMO VALVE — MALFUNCTIONED (NR 2 ENGINE)

ON CLIMBOUT, GOT ANTI-ICE DUCT OVERHEAT LIGHT NR 1 AND NR 3 ENGINES WERE BOTH OFF THE TEMPERATURE SCALE. FOLLOWED RED TABS, LIGHT WENT OUT AFTER 1 TO 2 MINUTES ON LANDING. LIGHT CAME ON AGAIN WITH WINGS OFF AND ENGINE ANTI-ICE OPEN. REMOVED AND REPLACED NR 2 ENGINE COWL ANTI-ICE THERMOSTATIC VALVE PER MAINTENANCE MANUAL 30-21-21. NR 2 ENGINE COWL ANTI-ICE THERMAL SWITCH, AND WING ANTI-ICE THERMAL SWITCH. OPERATIONAL CHECK GOOD ON GROUND.

Part: FLOORBEAM — GOUGED (BS 880)

FLOORBEAM UPPER CHORD FWD SIDE LWR SURFACE GOUGED BS 880 RBL 55 WL 208. BLENDED OUT GOUGE, FABRICATED REPAIR STRAP FROM .071 7075-T6. INSTALLED STRAP PER AMERICAN AIRLINES REPAIR 53-10-07-2 FIG 1 3/20/96.

Part: VALVE — LEAKING (AFT AIRSTAIRS)

LOWER AFT BODY LIGHT ILLUMINATED IN FLIGHT. REMOVED AND REPLACED NR 1 CABIN AIR MODULATING VALVE PER MAINTENANCE MANUAL 36-00. RAN ALL THREE ENGINES PER B-727 JET RUN HANDBOOK. THE OVERHEAT LIGHT DID NOT ILLUMINATE. NO LEAKS FOUND.

Part: STARTER — FAILED (NR 3 ENGINE)

NR 3 ENGINE FIRE WARNING CAME ON AT 2,500 MSL, LIGHT WENT OUT WHEN NR 3 POWER RETARDED. FOUND STARTER TURBINE SHEARED FROM SHAFT, STARTER DESTROYED. REPLACED NR 3 ENGINE STARTER PER MAINTENANCE MANUAL 80-10-01. REPLACED NR 3 ENGINE START VALVE PER MAINTENANCE MANUAL 80-10-02. RAN ENGINE OPERATIONAL AND LEAK CHECK GOOD. NO DEFECTS NOTED WITH NR 3 ENGINE BLEED AIR DUCTS.

Part: GASPER FAN — FAILED (AIR COND BAY)

FLIGHT CREW SMELLED ELECTRICAL INSULATION BURNING IN THE COCKPIT. WE NOTICED THE GASPER FAN CIRCUIT BREAKER OPENED. A FEW MINUTES LATER THE SMELL SUBSIDED. GASPER FAN CIRCUIT BREAKER WAS LEFT OPEN AND GASPER FAN SWITCH TURNED OFF. A/C RELEASED FOR SERVICE PER MEL 21-24 CAT D EXP 10-16-96. REMOVED AND REPLACED GASPER FAN AS PER MM 21-33-11, ALL CKS GOOD.

Part: FIRE WARNING — ACTIVATED (NR 1 ENGINE)

NR 1 ENG FIRE IND INTERMITTENT BELL AND LIGHT ON CLIMBOUT. RETARDING THROTTLE HAD NO EFFECT ON THE INDICATIONS.

Part: FIRE CONNECTOR — LOOSE (NR 1 ENGINE)

NR 1 ENG FIRE LIGHT INTERMITTENT IND DURING CLIMBOUT. FIRE TEST CHECKED GOOD, NO SECONDARY INDICATIONS. INSPECTED FIRE LOOP AND FOUND LOOSE CONNECTOR, RESEATED SAME AND CHECKED AS PER MM 26-11-01, NO FAULTS NOTED. RAN NR 1 ENG PER JET HANDBOOK, NO FAULTS NOTED OK FOR SERVICE.