N217FE

Part: SMOKE DETECTOR — MALFUNCTIONED (CARGO BAY) · airframe 33,456 hrs · 20,011 cycles

ON FINAL, TWICE RECEIVED INTERMITTENT (1 SEC) MASTER FIRE WARNING LIGHTS (GLARESHIELD) AND BELL - NO FIRE INDICATIONS. AT ABOUT 600' AGL, FIRE LIGHTS ILLUMINATED, FIRE BELL SOUNDED AND THE NR 4 MAIN CARGO FIRE ILLUMINATED. LANDED AND EVACUATED THE COCKPIT THRU COCKPIT WINDOWS. REPLACED NR 4 MAIN CARGO SMOKE DETECTOR IAW AMM 26-16-001-4. SYS OPS CHECKED GOOD.

Part: HOOK AND LOOP — FAILED (PBE) · airframe 33,376 hrs · 19,951 cycles

PBE IN AFT CABIN CAME LOOSE ON INITIAL TAKEOFF. REATTACHED HOOK AND LOOP IN REF TO SMP, GOOD FOR SERVICE.

Part: LINE — DISCONNECTED (ENGINE INDICATOR) · airframe 33,187 hrs · 19,803 cycles

ON RUNUP FOR TAKEOFF SET EPR'S AT COMPUTED VALUE. NOMINAL N1'S FOR 2 & 3 ALONG WITH CORRESPONDING EGT & FUEL FLOWS NORMAL. NR 1 ENGINE, WHEN SET TO COMPUTED EPR SETTING FOR T/O HAD ABNORMALLY LOW N1 & FUEL FLOW COMPARED TO ENGINES 2 & 3. NR 1 ALSO VERY SLOW TO ADVANCE "COME UP" WHEN ADVANCING NR 1 THROTTLE FOR T/O. NR 1 EPR 2.02 N1 81 PERCENT FF 5800 IAW CREW DEBRIEF: NR1 ENG N1 80 PERCENT EGT 420 N2 89 PERCENT FF 5800 NR3 ENG N1 93 PERCENT EGT 540 N2 95 PERCENT FF 9000. (TARGET WAS EPR 2.02 AT 94.9 PERCENT FOR NR1 ENG) REMOVED NR 1 ENG INLET BULLET FOR T/S. FOUND FLEX LINE FOR PT2 PROBE DISCONNECTED. PRIOR TO RECONNECTING LINE, CLEARED PT2 LINE TO EPR TRANSMITTER WITH DRY NITROGEN AND RECONNECTED TO PT2 PROBE. INSTALLED INLET BULLET IAW 71-10-002-2. R & R NR 1 ENG EPR TRANSMITTER AS PRECAUTIONARY IAW AMM 77-11-011-4.

Part: A/C PACK — FAILED (LEFT) · airframe 32,681 hrs · 19,460 cycles

ON TAKEOFF FROM DSM ,THE LT PACK TRIPPED AND THE LT DUCT OVERHEAT LIGHT ILLUMINATED. THIS WAS ACCOMPAINED BY THE USUAL ODOR OF A PACK OVERHEATING AND SMOKE IN THE COCKPIT. QRH PROCEDURES ELIMINATED THE SMOKE & REESTABLISHED THE LT PACK. GIVEN THE OUTSIDE AIR TEMP AT DSM OF 21*C THERE IS NO EASY EXPLANATION OF WHY THE LT PACK WOULD PRODUCE THESE PROBLEMS; NOTE; THAT THIS IS THE 2ND INCIDENT IN THE PAST WEEK OF SMOKE IN THE COCKPIT. CLOSED J-4 BOX AND E&E COMPARTMENT. R & R LT PACK COOLING FAN REF AMM 21-56-091-4. CLOSED UP ALL ACFT BAY ACCESS PANELS. OPS CHECK OF LT PACK IS GOOD REF JRH CHAP 8. NO SMOKE SMELL OR HIGH PACK TEMP ON LT PACK. ACFT OK FOR SERVICE.

Part: FAN — FAILED (COOLING) · airframe 32,680 hrs · 19,459 cycles

ON TAKEOFF FROM DSM, THE LT PACK TRIPPED AND THE LT DUCT OVERHEAT LIGHT ILLUMINATED. THIS WAS ACCOMPAINED BY THE USUAL ODOR OF A PACK OVERHEATING AND SMOKE IN THE COCKPIT. QRH PROCEDURES ELIMINATED THE SMOKE & REESTABLISHED THE LT PACK. GIVEN THE OUTSIDE AIR TEMPERATURE AT DSM OF 21 DEGREES C, FOUND COOLING FAN GETTING POWER BUT FAN NOT OPERATING JUST HUMMING WITH A BURN SMELL COMING FROM FAN. R & R LT PACK COOLING FAN REF AMM 21-56-091-4.

Part: UNKNOWN — ODOR (CABIN) · airframe 32,670 hrs · 19,452 cycles

AIR TURNBACK, SMOKE IN COCKPIT, SMOKE APPEARED TO ORIGINATE FROM THE THROTTLE QUADRANT. VISIBLY CHECKED FWD NOSE COMPARTMENT WIRING, LIGHT BALLAST AND UNDER QUADRANT AREA, FOUND NO EVIDENCE OF FAULT. CHECKED AVIONICS BAY, WIRING, BOXES, FOUND LIGHTS ON EPGWS, DFDR & COMPASS COUPLER 2, THESE ARE NORMAL ON GROUND. RAN ALL 3 ENGINES, APU & BOTH PACKS FOR ABOUT 15 MIN, PER JRH. WITH ENGS RUNNING, TRIED ALL LIGHTING IN COCKPIT, STAB TRIM, FLAPS. ALL OPS NORMAL WITH JRH, NO C/B'S FOUND TO BE OPENED. DURING ENGINE RUN AT 40% OBSERVED NO SMOKE, NO ODORS AND NO BURNED ELECTRICAL SMELLS IN ANY COMPARTMENTS. TOOK A/C TO HIGH POWER AT J-PAD FOR 4 MIN, WITH BOTH PACKS, OPERATED STAB CONTROL, FLAPS, SPEED BRAKE, RADAR & FLIGHT CONTROLS AT YOKE. ALL OPS NORMAL PER JRH WITH NOW SMOKE OR ODORS AT THIS TIME. REMOVED AND REPLACED RT WATER SEPERATOR COALESCER & REINSTALLED WATER SEPARATOR. REMOVED LT WATER SEPARATOR AND INSPECTED. COALESCER BAG CLEAN, REINSTALLED LT WATER SEPARATOR & COALESCER BAG PER AMM 21-55-051-4 & 21-55-41, CHECKS OK FOR SERVICE.

Part: UNKNOWN — SMOKE (COCKPIT) · airframe 32,671 hrs · 19,453 cycles

AIR TURN BACK, SMOKE IN COCKPIT SMOKE APPEARED TO ORIGINATE FROM THE THROTTLE QUADRANT.

Part: ANGLE — CRACKED (NR 4 SLAT) · airframe 31,808 hrs · 18,871 cycles

NR 4 SLAT AFT LOWER ANGLE IS CRACKED BELOW T-DUCT. REMOVED NR 4 SLAT INNER PANELS IAW SRM 51-30-2. REMOVED LOWER ANGLE IAW SRM 51-30-2. FABRICATED NEW ANGLE IAW SRM 57-50- 2. TREATED AND PRIMED. REPAIR PARTS IAW SRM 51-10-2 INSTALLED ANGLE IAW SRM 51-30- 2 AND 57-50-2 INSTALLED INNER SLAT PANELS IAW SRM 51-30-2.

Part: SPAR — CRACKED (ZONE 500) · airframe 31,808 hrs · 18,871 cycles

LT WING T/E FALSE SPAR, INBD END REPAIR DOUBLER IS CRACKED. WBL 118 REMOVED NR 7 SPOILER FITTING AND SUPPORT IAW SRM 51-30-2. REMOVED PREVIOUS DOUBLER, TRIMMED OUT WEB AND REMOVED PREVIOUS CHORD REPAIR IAW DWG SR 27-57-038 REV C. FABRICATED NEW WEB FROM 7075 T6 .032, NEW CHORD SECTION FROM BAC 1514-1437, FABRICATED 2 EACH ANGLES FROM 7075 'O' .071, FABRICATED DOUBLER FROM 2024 'O' IAW DWG SR 27-57-038 REV C, HEAT TREATED PARTS IAW FASI ENGINEERING REPORT NR 2-37153-801 REV A, FABRICATED STRAP FROM 7075 T6 .090 PO NR 9006152 DIM 12.5 INCH X 2 INCH IAW DWG SR 27-57-038 REV C, ALODINED AND PRIMED REPAIR PARTS IAW SRM 51-10-2, INSTALLED REPAIR PARTS IAW SR 27-57-038 REV C, INSTALLED SPOILER SUPPORT FITTING IAW SRM 51-30-2.

Part: ANGLE — CRACKED (ZONE 500) · airframe 31,808 hrs · 18,871 cycles

NR 2 SLAT LOWER AFT ANGLE IS CRACKED BELOW TEE DUCT REMOVED INNER PANELS IAW SRM 51-30-2. CUT OUT DAMAGED AREA OF ANGLE IAW SRM 51-40-4 FIG 1 FABRICATED ANGLE SECTION IAW SRM 57-50-2 AND 51-40-4, ALODINED AND PRIMED PARTS IAW SRM 51-10-2. INSTALLED REPAIR PARTS IAW SRM 51-40-4. CLOSED INNER PANELS IAW SRM 51-30-2.

Part: SKIN — CRACKED (NR 3 SLAT) · airframe 31,808 hrs · 18,871 cycles

NR 3 SLAT CRACKED T/E AT OTBD HOOK AFT ATTACH FASTENERS. HFEC VERIFIED THAT CRACK ENDS AT FASTENER HOLE IAW NDTM 51-00-00. FABRICATED DOUBLER AND INSTALLED IAW SRM 57-50-3 AND 51-30-8.

Part: FLOORBEAM — CORRODED (BS 344) · airframe 31,808 hrs · 18,871 cycles

FORWARD ENTRY WAY - FLOORBEAM CORRODED AT BS 344 RBL 10 TO LBL 45. REMOVED FLOORBEAM, FABRICATED NEW FLOORBEAM AND INSTALLED IAW DWG SR27-53-007 AND SRM 53-10-2, 51-30-5 AND 51-30-2.

Part: SKIN — DENTED (ZONE 100) · airframe 31,808 hrs · 18,871 cycles

OIL CANNING SKIN AT STA 180 STR 26L. CUT OUT DAMAGED AREAS, FABRICATED REPAIR DOUBLER AND INSTALLED IAW SRM 53-30-3, 53-30-2, 51-10-2 AND 51-30-2.

Part: UNKNOWN — MISREPAIRED (BS 380) · airframe 31,808 hrs · 18,871 cycles

PREVIOUS REPAIR STA 380 STR 29L HAS FASTENERS WITH IMPROPER EDGE MARGIN. REMOVED PREVIOUS REPAIR, HFEC INSPECTED HOLES WITH NO DEFECTS NOTED, FABRICATED NEW DOUBLER AND INSTALLED IAW EA 7-5330-126836.

Part: SKIN — CRACKED (LT MLG DOOR) · airframe 31,808 hrs · 18,871 cycles

LT MLG WING DOOR IS CRACKED AT AFT HINGE POINT. REMOVED DAMAGED AREA, FABRICATED REPAIR AND INSTALLED IAW DRAWING 65C27128 AND SRM 51-30-2.

Part: SKIN — BULGED (BS 219 S24L) · airframe 31,808 hrs · 18,871 cycles

SKIN BULGE FUSELAGE STATION 219 STRINGER 24L. CUT OUT DAMAGED AREA, FABRICATED REPAIR DOUBLER AND INSTALLED IAW SRM 53-30-3, 51-10-2 AND 51-30-2.

Part: RIB — CRACKED (NR 4 SLAT) · airframe 31,808 hrs · 18,871 cycles

NR 4 SLAT HAS 2 CRACKED RIBS ON EITHER SIDE OF THE ACTUATOR FWD MOUNT. REMOVED L/E SLAT ACCESS PANEL IAW SRM 51-30-2. REMOVED DAMAGED RIBS AT NR4 SLAT 2 EACH IAW SRM 51-30-2. LOCATED AND DRILLED NEW RIBS IAW SRM 51-30-5 RIB PN 65-17276-9 AND 65-17276-11. INSTALLED NEW RIBS IAW SRM 51-30-2 CLOSED L/E SLAT ACCESS PANELS IAW SRM 51-30-2.

Part: WINDOW FRAME — CORRODED (BS 680) · airframe 31,808 hrs · 18,871 cycles

CORROSION ON WINDOW FRAME RT FUSELAGE STA 650. REMOVED CORROSION FROM WINDOW FRAME AND FOUND MATERIAL LOSS TO BE OUT OF LIMITS, FABRICATED REPAIR DOUBLER AND INSTALLED IAW SRM 51-10-6, 56-20-1, 56-20-3 AND 51-30-2.

Part: CIRCUIT BREAKER — FAILED · airframe 30,220 hrs · 17,865 cycles

IN CRUISE SMELL OF SMOKE AND THE SIGHT OF SMOKE COMING FROM BACK OF S/O PANEL. SMOKE MOVED TOWARD F/O SEAT. THE SMELL WAS LIKE CAR EXHAUST. RAN ALL FUMES AND ODORS CHECK LIST. ALSO SHUT OFF GASPER FAN. THE SMOKE ONLY LASTED FOR AROUND 15 SEC. NO OTHER INDICATIONS. REPLACED APU C/B REF MM 24-20-041-4. REINSTALLED ALL REMOVED ITEMS FROM F/E PANEL REF ESP MM 20-46-50 AFTER VACUUMING DEBRIS AND DUST. RAN ALL THREE ENG'S, OPS CK'D ALL REMOVED ITEMS. OPERATED PACKS AND GASPER, CK'D ALL PANEL LTS AND TRANSFORMERS. NO ABNORMALITIES NOTED. CLEANED WIRES AND TERMINALS TO C/B. REMOVED IDENT MASKING TAPE. INSPECTED AREA FOR OTHER ARCING OR WATER DAMAGE. ALL OK.

Part: SKIN — DAMAGED (LT WING FLAP) · airframe 29,554 hrs · 17,353 cycles

LT WING FOREFLAP IS DAMAGED APPROX 79" FROM IB END. DAMAGE IS ON NOSE LE APPROX 3" LONG (DENT) REMOVED DAMAGE FROM L/E OF FLAP, FABRICATED REPAIR DOUBLER AND INSTALLED IAW SRM 57-50-2, AND SRM 57-50-4 PG 2A & 2B.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK, AGING AIRCRAFT INSPECTION IDENTIFIED EXTERNAL FUSELAGE SKIN REPAIR INSTALLED WITHOUT FAA APPROVED DATA. REPAIR IS LOCATED AT STA 294 AT STR 21R. REMOVED AND REPLACED REPAIR REF: SRM 53-30-3.

Part: FEEDER CABLE — CHAFED (ZONE 200) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK, FOUND GENERATOR FEEDER CABLE CHAFED AND SHORTED TO LOOP SUPPORT CLAMP. LOCATED AT STA 720E WATERLINE, 153 INCH AND LBL 10 INCH IN THE AIR DISTRIBUTION BAY.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK, AGING AIRCRAFT INSPECTION IDENTIFIED EXTERNAL FUSELAGE SKIN REPAIR INSTALLED WITHOUT FAA APPROVED DATA. REPAIR IS LOCATED AT STA 294 AT STR 21R. REMOVED AND REPLACED REPAIR REF: SRM 53-30-3 WO NR 33554, SNRM NR N00420. REMOVED EXT REPAIR AT STA 294.5, STR 21R REF SRM 51-30-02. FOUND OLD REPAIR OUT OF LIMITS REF SRM 53-30-3 FIG 3. FABRICATED AND INSTALLED NEW REPAIR REF SRM 53-30-3, FIG 3 STA 294.5 STR 21R. THIS REPAIR IS CLASSIFIED AS A MAJOR REPAIR.

Part: FEEDER CABLE — CHAFED (ZONE 200) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK, FOUND GENERATOR FEEDER CABLE CHAFED AND SHORTED TO LOOP SUPPORT CLAMP, LOCATED AT STA 720E WATERLINE, 153" AND LBL 10" IN THE AIR DISTRIBUTION BAY. WO NR 33554, SNRM NR N00628. REPLACED APU FEEDER WIRE NR 300-011-2. REF SWPM 20-30-13 AND WDM 24-45-01. OPS CHECK WAS GOOD .

Part: SKIN — MISREPAIRED (ZONE 100) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK, AGING AIRCRAFT INSPECTION IDENTIFIED EXTERNAL FUSELAGE SKIN REPAIR INSTALLED WITHOUT FAA APPROVED DATA. REPAIR IS LOCATED AT STA 950 AT STR 28L. REMOVED AND REPLACED REPAIR REF: B727 SRM 53-30-3 FIG 1 PG 8 WO NR 33554, SNRM NR N00556. INSTALLED EXTERNAL REPAIR ON FUSELAGE SKIN REF SRM 53-30-3 FIG 1 PG 8. THIS IS CLASSIFIED AS A MAJOR REPAIR.

Part: SKIN — MISREPAIRED (ZONE 100) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK, AGING AIRCRAFT INSPECTION IDENTIFIED EXTERNAL FUSELAGE SKIN REPAIR INSTALLED WITHOUT FAA APPROVED DATA. REPAIR IS LOCATED AT STA 950 AT STR 28L. REMOVED AND REPLACED REPAIR REF: B727 SRM 53-30-3 FIG 1 PG 8.

Part: SKIN — MISREPAIRED (FUSELAGE) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK AGING AIRCRAFT INSPECTION, IDENTIFIED EXTERNAL FUSELAGE SKIN REPAIR INSTALLED WITHOUT FAA APPROVED DATA. REPAIR IS LOCATED AT STA.640 BETWEEN STRINGERS 24L AND STR 28L. REMOVED AND REPLACED REPAIR PER B727 SRM 53-30-3 FIG 5 PG 22. INSTALLED EXTERNAL REPAIR TO FUSELAGE AT STA 640 REF SRM 53-30-3 FIG 5. ALSO, INSTALLED STR REPAIRS ON STR 25, 26 AND 27. REF SRM 53-10-3 FIG 1 AND FED EX EA 7-5310-99288.

Part: SKIN — MISREPAIRED (BS 640) · airframe 29,153 hrs · 17,079 cycles

DURING C-1 CHECK AGING AIRCRAFT INSPECTION, IDENTIFIED EXTERNAL FUSELAGE SKIN REPAIR INSTALLED WITH OUT FAA APPROVED DATA. REPAIR IS LOCATED AT STA 640 BETWEEN STRINGERS 24L AND STR 28L REMOVED AND REPLACED REPAIR PER B727 SRM 53-30-3 FIG 5 PG 22.

Part: DUCT — LEAKING (13TH STAGE) · airframe 28,986 hrs · 16,972 cycles

ON TAKEOFF LEG AT APPROX 500' AGL, NR 2 FIRE LIGHT ILLUMINATED AND FIRE WARNING BELL SOUNDED. ACCOMPLISHED RED TAB PROCEDURES. FIRELIGHT WENT OUT AFTER DISCHARGING ONE FIRE BOTTLE. INSPECTED NR 2 ENG IAW PW MM 72-00-00 FOR WINDMILLING. INSPECTED OIL FILTER AND CHIP DETECTORS PER W/C 79X0404-2. NO DEFECTS NOTED. RAN NR 2 ENG WITH FIRE GUARD IAW JRH. FOUND HIGH PRESSURE SUPPLY MANIFOLD BLOWN AT TOP T FITTING. NEED NEW MANIFOLD, CRUSH GASKETS, AND BLOWOUT DISK. REMOVED AND REPLACED THE FIRE BOTTLE AND SQUIB ASSY IN REFERENCE TO B727 MM 26-21-001-4. REMOVED AND REPLACED 13TH STAGE SADDLE DUCT, AS PER PW JT8D-MM-72-70-00.

Part: O-RING — DAMAGED (ENGINE) · airframe 28,437 hrs · 16,618 cycles

REJECTED FIRST T/O DUE TO ENG FAIL LIGHT ON, NR 3 ENG ADV UP TO RED LINE N1 BUT EPR WAS STILL VERY LOW TO CONTINUE T/O, PILOT SAID ENG RED LINE NI WAS NOT EXCEEDED, REMOVED NR 3 ENG BULLET, PRESS TESTED THAT SECTION OF PT2 LINE, CHKS GOOD. FOUND THE TWO O-RINGS ON THE PT2 COUPLER IN THE BULLET DRYROTTED, CRACKING, AND OF THE WRONG TYPE. REMOVED AND REPLACED TWO "HIGH TEMP" O-RINGS, AND INSTALLED BULLET, PRESS TESTED PT7, AND THE REM. PT2 LINES FROM THE TRANS TO THE ENG, FOUND PT2 LINE LEAKING AT THE FLYING WING TO FUSE CONN, DISCONN, AND INST THAT CONN, LK CHECKS GOOD. RAN NR 1 AND NR 3 ENG AT HIGH PWR PER 727-200JRH, NR 3 EPR OPS CHKS GOOD, ALL NR 1 AND NR 3 NORM.

Part: SMOKE DETECTOR — MALFUNCTIONED (CARGO BAY) · airframe 26,155 hrs · 15,176 cycles

ON CLIMBOUT, MAIN CARGO SMOKE WARNING ACTIVATED. SHORTLY THERE AFTER LIGHT EXTINGUISHED. APPROXIMATELY 1.5 TO 2 MINS LATER MAIN CARGO SMOKE WARNING RE-ACTIVATED. ALSO MIGRATED FROM ONE ZONE ILLUMINATED TO 2 ZONES (BULBS) ILLUMINATED. REPLACED ZONE 1 AND 2 DETECTION UNITS. ALL TESTS OK MM 26-16-001-0.

Part: MOTOR — FAILED (L/E FLAP) · airframe 25,935 hrs · 15,046 cycles

ALT FLAPS EXT SYSTEM DOES NOT EXTEND LED'S. FLAPS APPEAR TO WORK OK BUT DIDN'T GO BEYOND 2. TROUBLESHOT ALT FLAP SYS. REPLACED L/E MOTOR PUMP ASSY. REPLACED L/E FLAP AND SLAT SELECTOR VALVE. REPAIRED L/E STANDBY DRIVE SHUT OFF VALVE GROUND WIRES AT GD846. ALL WORK DONE IAW FEDEX WDM 27-51-01 FEDEX MM 27-81-091-4, FEDEX MM 27-81- 041-4 SWPM 20-30-11, 20-10-12. FUNCTIONAL TESTED GOOD. RII INSP COMPLIED WITH ENT BY: 59992V RPT BY: 59992V.

Part: CLAMP — OUT OF POSITION (COCKPIT) · airframe 25,934 hrs · 15,045 cycles

FLIGHT TEST: NOSE GEAR INDICATOR LIGHT FLICKERS & IS INTERMITTENTLY OFF WITH GEAR DOWN & LOCKED. FOUND IF PRESSURE IS APPLIED TO INBOARD EDGE OF MASTER DIM AND TEST SWITCH, LIGHTS (NOSE GEAR AND NR 3 OIL PRESSURE LIGHT) WOULD FLICKER, LOOSENED PANEL, AND FOUND HOSE CLAMP IN CLOSE PROXIMITY TO MASTER DIM AND TEST SWITCH. RELOCATED CLAMP, RESECURED INSTRUMENT PANEL AND TRIED TO DUPLICATE DISCREPANCY AGAIN, NOTED TO REPEAT OF DISCREPANCY, ALSO NOTED NO ARCING ON CLAMP OR CONTACTS ON MASTER DIM AND TEST SWITCH.

Part: FLOORBEAM — DAMAGED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

STA 950F, WL 208, LBL 30 & 36 FLOORBEAM HAS TOOL MARKS. BLENDED TOOL MARKS FROM 950F FLOORBEAM WL 208, LBL 30-36, REMOVED 1 X1 X.150 & 1 X2 X.045 FROM ORIGINAL OF .225 . OUT OF LIMIT PER SRM 51-10-1. CUT OFF DAMAGE SECTION OF FLOOR BEAM, AFT UPPER FLANGE LBL 17.4-37.8 BS 950F, WL. 208. REPAIRED FLOORBEAM IAW FED EX EA. REPAIRED ACCESS SEAT TRACK FROM BS 950F 10 TO B/S 950E 10 PER SRM 53-10-5.

Part: LAP JOINT — CHAFED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

CHAFING ON LAP JOINT SKIN STR19R, BS720D PLUS 10 INCHES. BLENDED OUT LAP JOINT SKIN STR 19R, BS 720D 10, 2 X 2 X .022 FROM ORIGINAL OF .060. FOUND TO BE OUT OF LIMITS PER SRM 53-30-1 CUT OUT DAMAGE FROM LAP AND REPAIRED PER SRM 53-30-3,

Part: SKIN — CHAFED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

CHAFING ON LAP JOINT SKIN STR 19L B/S 720D PLUS 10 INCHS. BLENDED CHAFFE FOUND TO BE OUT OF LIMITS, CUT OUT DAMAGED AREA AND REPAIRED. PER SRM 53-30-3 FIG 14.

Part: FLOORBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 25,932 hrs · 15,041 cycles

CORROSION BS 320-340, RBL 40, WL 208 ON TOP OF FLOORBEAM AND INTERCOSTAL REMOVED AND REPLACED FLOORBEAM.

Part: KEELBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 25,932 hrs · 15,041 cycles

CORROSION ON RT KEEL BEAM BS 950F 8 O/B FLANGE. *S/D* BLENDED CORROSION ON RT KEEL BEAM BS 950F 8 O/B FLANGE AND FOUND OUT OF LIMITS. FABRICATED REPAIR STRAP AND INSTALLED REPAIR STRAP. ALL WORK DONE IAW SR 27-53- 023A.

Part: FRAME — DENTED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

FWD CARGO SIDE FRAME DENTED STA 680, LBL 33, WL 160 . OUT OF LIMITS. CUT OUT DAMAGE & REPAIRED FRAME BS 680, LBL 33, WL 160 PER SRM 53-10- 1, 51-40-3 FIG 1 AND FED EX EA 7-5310-55028.

Part: FRAME — DENTED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

FWD CARGO SIDE FRAME DENTED STA 660 RBL 35 WL 160 ** SD ** COMING

Part: FRAME — DENTED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

FWD CARGO SIDE FRAME DENTED STA 720 LBL 34 WL 160. DENT OUT OF LIMITS. CUT OUT DAMAGE AND REPAIRED FRAME BS 720, LBL 34, WL 160 IAW SRM 53-10-1, 51-40-3 FIG 1 AND FED EX EA 7-5310-55029.

Part: FRAME — DENTED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

FWD CARGO SIDE FRAME DENTED STA 680 RBL 30 WL 157. FWD CARGO SIDE FRAME DENTED STA 680, RBL 30, WL 157 FOUND TO BE OUT OF LIMITS PER SRM 53-10-1. REPAIR FRAME PER SRM 51-40-3.

Part: FRAME — DENTED (FUSELAGE) · airframe 25,932 hrs · 15,041 cycles

FWD CARGO SIDE FRAME DENTED STA 700 LBL 50 WL 166 FWD CARGO FRAME DENTED AT STA 700, LBL 50, WL 166 FOUND TO BE OUT OF LIMITS PER SRM 53-10-1. REPAIRED DAMAGE FRAME PER SRM 51-40-3. ALSO REPAIRED PER FED EX EA 7-5310-55031.

Part: ACCESSORY UNIT — FAULTY (E/E BAY) · airframe 24,537 hrs · 14,322 cycles

UPON GEAR RETRACTION, LEFT GEAR UNSAFE LIGHT REMAINED ILLUMINATED WITH LG LEVER IN THE UP POSITION. COMPLIED WITH RED TAB PROCEDURE. LEFT GEAR UNSAFE LIGHT REMAINED ILLUMINATED. REMOVED AND REPLACED LANDING GEAR ELECTRONIC MODULE B727 M/M 32-09-121-4. REMOVED AND REPLACED LT MLG UPLOCK SENSOR B727-200 M/M 32-61-081-4. OPS CKS GOOD PER 727-200 M/M 32-61-081-4. OPS CK'D LANDING GEAR ELECTRONICS MODULE PER 727-200 M/M 32-09-122-5, OPS CKS GOOD.

Part: SWITCH — FAILED (L/E FLAP)

LEAD EDGE DEVICE NR 4 FAILED TO INDICATE UP ON FLAP RETRACTION AFTER T/O. REMOVED AND REPLACED NR 4 LEAD EDGE FLAP JUMPER CABLE. REMOVED AND REPLACED L/E FLAP NR 4 SWITCH PER MM 27-82-001-4.

Part: TIRE — FAILED (NR 3)

WHEEL WELL FIRE LIGHT CAME ON WITH GLARESHIELD. REMOVED AND REPLACED NR 3 & 4 TIRE ASSY AND NR 3 WHEEL TRANSDUCER PER MM 32-45-001-4, 32-2-001-4.

Part: COALESCER BAG — DIRTY (A/C BAY)

ELECTRICAL SMELL IN COCKPIT FROM AIR COND VENTS. REMOVED AND REPLACED BOTH COALESCER BAGS PRECAUTIONARY PER MM 21-55-051-4. CND ODORS AT THIS TIME.

Part: COALESCER BAG — DIRTY (A/C BAY)

TWO HR INTO FLT, CREW NOTICED ELECTRICAL SMELL IN COCKPIT. REMOVED AND REPLACED BOTH COALESCER BAGS PRECAUTIONARY PER MM 21-55-051-4. CND.

Part: UNKNOWN — ODOR (COCKPIT)

CREW SMELLED FUMES IN COCKPIT. DEBRIEF FUMES W/N SKYDROL, NOR FUEL, NOR ELECTRICAL. AS PRECAUTION RAN ENG AND PRESSURIZED A/C PER 727 JRH. NO IRREGULAR ODORS, OPS CK NORMAL.

Part: SENSING ELEMENT — CHAFED (NR 2 ENGINE)

LWR AFT BODY OVERHEAT LIGHT CAME ON, BOTH PACKS ON WITH ENG 2 L + 3 BLEEDS, OPEN, LIGHT WENT OUT WHEN BLEEDS SWITCHED FROM ENG 2 TO ENG 1. INSTALLED SENSING ELEMENT CORRECTLY. CLEANED CONNECTORS. NO DUCT LEAKS. SYSTEM OK FOR SERVICE.

Part: DETECTOR — FAULTY (AIRSTAIR)

ON CLIMBOUT, LOWER AFT BODY OVERHEAT LIGHT CAME ON. FOLLOW CKLIST WHEN ENG NR 2 BLD SHUT OFF LIGHT WENT OUT. FOUND CLAMP COMING ADRIFT ON LEFT OVERHEAT LOOP IN AIRSTAIR AREA. ENG RUN CARRIED OUT PER JET RUN HDBK & CK FOR AIR LEAKS. OVERHEAT LIGHTS TEST PER 26-11-000-5, AIRCRAFT OK FOR SERVICE.

Part: WARNING LIGHT — FALSE INDICATION (COCKPIT)

LWR AFT BODY OVERHEAT LIGHT ILLUM. PERFORMED RED TAB PROC. INSP LEFT AFT SECTION DUCTS AND HEAT SENSING ELEMENT FOR SIGNS OF LEAK OR DAMAGE, NONE FOUND. CLEANED HEAT SENSING ELEMENT CONNECTORS. RAN APU AND ENG WITH BOTH PACKS ON LIGHT STAYS OFF. TEST PER MM 26-14-0. OK FOR SERVICE.

Part: DUCT — CRACKED (SEPARATOR)

THROTTLES RETARD CR FLT. PRESURIZATION START RUMBLING AND CABIN ALT INCREASE. RAN RED TABS. FOUND CLAMP BLOWN OFF WATER SEPARATOR DUCT CRACKED. INSTALLED SERVICEABLE WATER SEP ASSY PER MM 21-55-041. LEAK CHECK GOOD, SYS OK FOR SERVICE.

Part: STRINGER — CORRODED (BS 720)

NR 206 CORROSION (C53-224-01) ON STR CLIP AND STR, BS 720D, STR 5 RT. *S/D* REMOVED CORRODED SECTION OF STR NR 5 RT FROM BS 720C+10 TO 720D+8 IAW FEDEX SRM 53-10-3. REPLACED STR 5 R, BS 720C+10 TO 220D+8 PER FEDEX SRM 53-10-3.

Part: CONTROL MODULE — INOPERATIVE (E/E COMPT)

DURING LANDING GEAR RETRACTION, GEAR HANDLE WOULD NOT RAISE PAST OFF. COMPLIED WITH RED TABS. LANDED WITH DOWN IN GREEN. *S/D* DUPLICATED PROBLEM. REMOVED AND REPLACED LAND GEAR CONTROL MODULE PER M/M 32-09-121, TESTS NORMAL. REMOVED AND REPLACED LANDING GEAR LOCK SOLENOID PER M/M 32-31-16, TESTS NORMAL. CLEANED AIR/GROUND SENSORS. SYSTEM CHECKS NORMAL. PER M/M OPERATON CHECKS.

Part: RIB — CRACKED (LT WING)

HFEC INSP EXHIBITS CRACKS EMANATING AT 12 AND 6 O'CLOCK FROM THE FWD MOST UPPER HOLE AT THE LT WING RIB CHORD BL 70.5 BS 760. REMOVED CRACK BY STOP DRILLING AND INSTALLED SMALL REPAIR AT STA 760 LBL 70.5 WL 209 TO 208 IAW FEDEX EA 7-5710-28232.

Part: RIB — CRACKED (BS 760)

NR 0137, -001, HFEC INSP EXHIBITS A CRACK IN THE FWD MOST UPPER HOLE AT APPROX 12 O'CLOCK AT RT WING RIB CHORD BL 70.5 BS 760. CUT OUT DAMAGE AT 630 JUST BELOW STR 22R AND REPAIRED PER FEDEX SRM 53-30-3 AND EA 7-5710-28223.