N240FE

Part: NONE — NONE (NACELLE) · airframe 53,573 hrs · 41,430 cycles

NACELLES AND PYLONS MINOR DEVIATION TO SRM S DUCT HOUSING SKIN REPAIR. COMPLIED WITH EA 7-5410-102026 THIS ITEM CLEARED BY REPAIR PER SRM 54-10-3 FIG 4 WITH MINOR DEVIATION DOCUMENTED BY THIS EA.

Part: UNKNOWN — NONE (MCD) · airframe 53,573 hrs · 41,430 cycles

DOORS, MAIN CARGO LWR AFT CORNER EXTERNAL SKIN PERMANENT REPAIR P/N 52FX1435-2. COMPLIED WITH EA 7-5230-102022 DOORS MAIN CARGO, LWR AFT CORNER EXTERNAL SKIN PERMANENT REPAIR P/N 52FX14 35-2.

Part: ENGINE — FAILED (NR 2) · airframe 52,966 hrs · 40,913 cycles

ATTEMPTED TAKEOFF ON 18L HAD SLIGHT COMPRESSOR STALL ON POWER APPLICATION. ABORTED TAKEOFF AND CHECKED ENGINE CONDITIONS ELECTED SECOND ATTEMPT DUE TO CROSSWINDS. ON SECOND ATTEMPT HAD ANOTHER COMPRESSOR STALL. 1ST STALL OCCURRED AT 1.5 EPR AND SECOND STALL AT 1.8 EPR. C/W WITH THE ENGINE CHANGE W/C 70T0002. FAILED VIBRATION CHECK SEE WRI 72-00/8513 RII C/W ON WORK CARD. REMOVED AND REPLACED NR 2 ENG PER WORK CARD 70T0002.

Part: UNION — LEAKING (HYD SYSTEM) · airframe 52,553 hrs · 40,588 cycles

AFTER T/O WHEN GEAR LVR WAS RAISED TO THE UP POS THE HYD SYS (A) RESERVOIR WENT TO ZERO. THE GEAR REMAINED DOWN AND FLAPS STAYED AT 15 DEG. REMOVED AND REPLACED PACKING AND UNION FOR THE OB TE FLAP CONTROL VALVE IAW IPC REF 27-50-00-30AZZ ITEM 145. LEAK AND OP CK, GOOD ON ENG RUN. DEBRIEF INDICATED THAT (A) PUMPS OPERATED FOR 15 MIN AT ZERO QTY. REMOVED AND REPLACED NR 1 AND NR 2 ENG DRIVEN HYD PUMPS IAW MM 29-11-033-4. REMOVED AND REPLACED BOTH NR 1 AND NR 2 ENG HYD CASE DRAIN FILTERS. SERVICED AND CYCLED ALL FLT CONTROLS NUMEROUS TIMES AND RESERVICED HYD AFTER SHUTDOWN.

Part: OIL FILTER — BYPASSING (NR 1 ENGINE) · airframe 51,908 hrs · 40,071 cycles

DESCENDING THROUGH 20,000 FEET, THE NR 1 LOW OIL PRESSURE/FILTER BYPASS LIGHT ILLUMINATED; ENGINE OIL PRESSURE READ 45 PSI (MATCHED NR 2 AND NR 3). SHUT DOWN NR 1 ENGINE IAW QRH PROCEDURES. NO OTHER PROBLEMS NOTED.

Part: SHEAR TIE — DAMAGED (FUSELAGE) · airframe 51,710 hrs · 39,938 cycles

REPAIR SHEAR TIE AT BS 380 BETWEEN STR 15 & 16 LT TO ACCOMPLISH 9G BARRIER MOD.

Part: SHEAR TIE — DAMAGED (FUSELAGE) · airframe 51,710 hrs · 39,938 cycles

REPAIR SHEAR TIE AT BS 380 BETWEEN STR 14 & 15 LT TO ACCOMPLISH 9G MOD. REPAIRED PER SRM 53-10-4.

Part: CHANNEL — CORRODED (FUSELAGE) · airframe 51,454 hrs · 39,746 cycles

FWD LWR CARGO A/C COMPT STR 27L BETWEEN F/S 720F TO 740, PROTECTIVE FINISH PEELING AND MINOR SURFACE CORROSION IN HAT CHANNEL. REMOVED CORROSION IAW SRM 51-10-6 PG 6, PARG 4. ORIG MAT .095, AFTER REWORK .075 .020 MAT LOSS, FOUND TO BE OUT OF LIMITS IAW SRM 53-10-1 PG 1, DETAIL I. REPAIRED HAT CHANNEL IAW SRM 53-10-3 MAT ID HAT CHANNEL BATCH NR 0000032659/MST0000666. REMOVED DAMAGED SECTION IAW SRM 53-10-3. HAT SECTION FABRICATED FROM (BAC1498-147/16), SPLICES FABBED FROM (BAC1498-131/16).

Part: SUPPORT BEAM — CORRODED (MLG) · airframe 51,454 hrs · 39,746 cycles

CLOSER COMPLY WITH EA NR 7-5710-82041 WINGS, LEFT MLG SUPPORT BEAM CORROSION AT FLAP TRACK MOUNT. BFM U COMPLIED WITH EA7-5710-82041 REAMED HOLE, FLAP PEENED AREA , INSTALLED REPAIR BUSHING AND WASHER ENT BY: 497236 RPT BY: 497236.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 51,454 hrs · 39,746 cycles

BFM CLOSER C/W WITH EA7-5321-82044 FUSELAGE, FLOORBEAM UPPER CORD REPAIR STA 950 AT BL 21.0 ENT BY: 497236 RPT BY: 497236 FACT 28SEP04 23:10. BFM U COMPLIED WITH EA 7-5321-82044. REMOVED CORROSION, TREATED AREA AND INSTALLED REPAIR ANGLE ENT BY: 497236 RPT BY: 497236.

Part: SKIN — DAMAGED (NR 1 PYLON) · airframe 51,454 hrs · 39,746 cycles

COMPLY WITH EA 7-5450-80610 PYLON STRUCTURE NR 1 ENG PYLON UPPER SKIN REPAIR. COMPLIED WITH EA 7-5450-80610, REPLACED SKIN SECTION AND INSTALLED EXT SPLICE DOUBLER.

Part: BEAM — CORRODED (ZONE 700) · airframe 51,454 hrs · 39,746 cycles

COMPLY WITH EA 7-5710-82042 WINGS RIGHT MLG SUPPORT BEAM CORROSION AT FLAP TRACK MOUNT. COMPLIED WITH EA 7-5710-82042 REAMED HOLE, FLAP PEENED AND INSTALLED REPAIR BUSHING.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 51,454 hrs · 39,746 cycles

FWD CARGO, INTERCOSTAL IS CRACKED AT STRINGER 25L STA.624. REMOVED INTERCOSTAL IAW SRM 51-30-2. FABRICATED,TREATED AND PRIMED NEW INTERCOSTAL IAW SRM 51-20-1 FIG.6, 51-30-5 AND 51-10-2. INSTALLED IAW SRM 51-30-2. FABRICATED INTERCOSTAL USING 2024-T3 .050, BATCH NR 8692, P.O. NR MST0012781.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 51,454 hrs · 39,746 cycles

NUMEROUS AREAS OF CORROSION FOUND AT FWD PIT BILGE AREA FROM STA 560 TO STA 580 AT STR 28L. REMOVED DAMAGED AREA FROM STA 550 - 590 IAW SRM 51-10-3 FIG 1 PG 4. FABBED 2EA STRINGERS FROM BAC1498-142 7075-T62, BATCH 318127, FABBED 3EA SPLICES FROM BAC1498-132 PO MST0009960. INSTALLED NEW PARTS IAW SRM 51-30-2.

Part: FLOOR SUPPORT — CORRODED (FUSELAGE) · airframe 51,454 hrs · 39,746 cycles

AFT CARGO COMPT FLOOR SUPPORT BEAM CORRODED UNDER NUTPLATE STA. 1110, RBL 6. REMOVED CORROSION, MATERIAL OUT OF LIMITS IAW SRM 53-10-5 FIG.6,PG.16 AND SRM 51-10-6. REMOVED DAMAGED AREA FROM STA 1105 TO 1115 RBL, FABRICATED 4 EA ANGLES (SPLICES). REPAIR AND 1EA U-CHANNEL IAW SR27-53-039 FIG.27, PG.52 AND 53-10-5 FIG.4, PG.9, MATERIAL USED 10133-0702/18, BAC 1509-100146/18,AND 60-27570/18 IAW SRM 53-10-5 FIG.4,PG.9. INSTALLED NEW REPAIR IAW SR27-53-039 FIG.27, PG.52.

Part: O-RING — FAILED (FLAP CONTROL VAL) · airframe 51,042 hrs · 39,430 cycles

A-SYSTEM HYDRAULICS FAILED IN FLIGHT. IN CRUISE FLT LVL 220, NOTICED A-SYSTEM QUANTITY DECREASING, LEAK CONTINUED TILL CHECKLIST DIRECTED A-PUMPS TO BE TURNED OFF. FOUND O-RING FAILURE AT UPPER PORT OF FLAP CONTROL VALVE. REPLACED O-RING PER 727-200 MM 20-10-011-4. CLEANED AREA, PRESSURIZED AND CHECKED FOR LEAKS, NONE NOTED. TWO GALLONS A-SYS HYDRAULIC FLUID REMAINING, SERVICED HYDRAULICS IAW MM 12-12-000. AIRCRAFT OK FOR CONTINUED SERVICE.

Part: DOOR — FALSE INDICATION (ZONE 700) · airframe 50,598 hrs · 39,059 cycles

RED GEAR DOOR LIGHT ILLUMINATED AFTER GEAR RETRACTION AND HANDLE PLACED IN OFF POSITION. LIGHT EXTINGUISHED WHEN GEAR HANDLE PLACED IN UP POSITION. COMPLIED WITH ALL APPLICABLE CHECK LIST. PUT IN GEAR PINS, CYCLED GEAR DOORS, ALL INDICATIONS NORMAL, REF PER MM 32-12-000- 0. REMOVED GEAR PINS.

Part: PACKING — LEAKING (NR 1 ENGINE) · airframe 50,551 hrs · 39,017 cycles

AFTER T/O NR 1 ENG EPR LOW WITH A HI FF AT FL200 NR 1 ENG THROTTLE LEVER 3 INCHES FWD OF NR 2 & 3 THROTTLE LEVERS W/ ALL EPR'S MATCHING & NR 1 FF GAUGE 3000 LBS/HR MORE THAN NR 2 & 3 FF GAUGES. ALL ENG INST IN GREEN. CL THRU FL230, NR 1 EPR INDIC 0 & NR 1 FF GAUGE IND 0 LBS/HR. ALSO NR 1 EGT GAUGE COOLING DOWN & N1 & N2 GAUGE LOW. PUSHED NR 1 THROTTLE LEVER FWD W/ NO ENG RESPONSE. FAILURE CHECKLIST COMPLETED. INSPECTED NR 1 ENG FOUND FUEL LINE FROM P&D VALVE TO FUEL OIL COOLER LEAKING. R & R PACKING AT P&D VALVE. RUN ENG IAW 727 JRH-OPS & LEAK CHKS GOOD. GND RUN ALL ENG'S ALL THROTTLE & ENG PARAMETERS MATCH. INSPECTED NR 1 ENG MAIN OIL FILTERS IAW 72-00-00 FOR ENG WINDMILLING, FOUND NO CONTAMINATION.

Part: FITTING — CRACKED (FUSELAGE)

BS 1185, LBL 24, WL 292 BULKHEAD TO SPAR FITTING CRACKED AT FWD HORZ FASTENER HOLE. REMOVED AND REPLACED FITTING PER SRM & MM.

Part: SKIN — WORN

N 279 FASTENERS AROUND DRAIN HOLE 11" ABOVE LH AFT NLG DOOR WORN. ** S/D ** COMING

Part: SKIN — CHAFED (E/E BAY DOOR)

MAIN E/E BAY DOOR SKIN IS CHAFED AT LEFT AFT EDGE. R&R SKIN PER SRM.

Part: DOOR FRAME — DENTED (CARGO DOOR)

MAIN CARGO DOOR AFT SIDE FRAME DENTED ABOVE CENTERING GUIDE RAMP. REMOVED AND REPLACED FRAME PER EA 7-5230-64028.

Part: FRAME — DENTED

N 697 MAIN CARGO DOOR AFT SIDE FRAME DENTED ABOVE CENTERING GUIDE RAMP. ** S/D ** COMING

Part: SKIN — DENTED (CARGO DOOR)

NR 2 CARGO DOOR OUTER SKIN HAS THREE LARGE DENTS FWD OF AFT EDGE 6 INCHES FROM BOTTOM. REMOVED AND REPLACED SKIN PER EA 75230-64035.

Part: WEB — CORRODED (GALLEY DOOR)

FWD GALLEY DOOR INTERNAL WEB ABOVE CENTER PRESSURE PANEL UPPER SURFACE OF WEB HAS CORROSION. REMOVED AND REPLACED WEB PER SRM 51-20-1, 51-10-1.

Part: CONTROLLER — FAULTY (CABIN PRESSURE)

00-365 FLT 1239/19 AIR TURN-BACK SEA. AC WILL NOT PRESSURIZE. WITH REF TO B727-200 MM 21-31-00-0 INSP AIRFRAME. RESET & PRESSURE TEST C/W CHECKS OK.

Part: SWITCH — MALFUNCTIONED (RT MLG DOOR)

WHEN PUTTING GEAR HANDLE FROM UP TO OFF, DOOR LIGHT ILLUMINATED WITH RIGHT MAIN DOOR LIGHT ILLUMINATED ON S/O PANEL. COMPLETED RED TABS HANDLE TO OFF, LIGHT OUT. *S/D* REMOVED AND REPLACED DOOR WARN SWITCH PER MM 32-62-011-4 & OPS CK NORMAL PER MM 32-62-011-5.

Part: FIRE WARN LIGHT — MALFUNCTION (APU)

BOTH MASTER FIRE WARNING LIGHTS ILLUMINATE INTERMITTENTLY. ALL FIRE WARNING LIGHTS OFF PRIOR TO TAKEOFF. ONCE AIRBORNE APU FIRE LIGHT CAME ON STEADY. MASTER FIRE WARNING LIGHTS STARTED FLICKERING. REPLACED APU FIRE BOTTLE. FOUND CORROSION ON PLUG D-4858P FOR R421 BLOCKING RECTIFIER. CLEANED SAME, ALSO REPLACED AURAL WARNING BOX. FIRE SYSTEM TESTS OK. RAN APU, NORMAL OPERATION.

Part: FIRE LIGHT — MALFUNCTIONED (APU)

RED LIGHT ON IN AUXILIARY POWER UNIT FIRE HANDLE IN FLIGHT. TOOK OFF AT 0334Z AND NOTICED THE AUXILIARY POWER UNIT RED LIGHT ON AT 0400Z, FLIGHT LEVEL 310. PULLED THE HANDLE AND DISCHARGED THE AGENT. RED LIGHT REMAINED ON BUT WITH VARIATION OF INTENSITY. LATER RED FIRE WARNING LIGHTS UNDER GLARESHIELD CAME ON WITH VARYING INTENSITY. THIS HAPPENED AFTER RESETTING THE AUXILIARY POWER UNIT CIRCUIT BREAKER. ENGINE AND WHEEL WELL FIRE TEST OK. REMOVED AND REPLACED APU FIRE EXTINGUISH BOTTLE IAW MM 26-11-1. BOTTLE CIRCUIT CONTINUITY CKS NORM. ITEM REMAIN DEFER DUE TO APU WARN CIRCUIT INTEGRITY. REMOVED AND REPLACED R421 BLOCKING RECTIFIER. REPLACED ALL PINS IN CONNECTOR D4858P. APU FIRE TEST OK.

Part: BOLT — JAMMED (ELEV PWR CONTL)

BEFORE TAKEOFF CHECK, ELEVATOR JAMMED PULLING AFT ON YOKE. OPENED ACCESS PANELS 9115, 9118, BOUND BOLT AT FORWARD END OF FORWARD TAB ROD ON LEFT HAND ELEVATOR POWER CONTROL UNIT WORKED LOOSE. INSTALLED BOLT, WASHERS, NUT AND SAFETY PER MAINTENANCE MANUAL 27-30-81, OPERATIONAL CHECKED OK. CLOSED ACCESS PANELS 9115, 9118.

Part: CHORD — CORRODED (BS 344-350)

NR 0302 005. CORROSION (C53-100-01(1)) ON MID LT NOSE CHORD BS 344-350, LBL 16, WL 170. REMOVED AND REPLACED MID LT NOSE CHORD PER BAC DWG 65-18415 AND FED-EX SRM 51-30-2.

Part: KEEL BEAM — CORRODED (BS 720)

NR 0250 004, CORROSION (C53-113-01-1) ON KEEL BEAM AT BS 720F, RBL 7, WL 149. *S/D* REMOVED CORROSION, SPOT FACED, FLAP PEENED AND INSTALLED STRAP AT BS 720F, RBL 7, WL 149 IAW FED-EX EA 7-5310-32976.

Part: FOREFLAP — DELAMINATED (LT TE FLAP)

NR 0349 003, LEFT WING I/B UPPER SURFACE STAINLESS STEEL RUB STRIP DISBONDED. *S/D* REMOVED, REPAIRED AND INSTALLED ON LEFT WING I/B FOREFLAP, I/B UPPER SURFACE STAINLESS STEEL RUB STRIP IAW FED-EX SRM 51-40-6. FUNCTIONAL TEST LEFT WING I/B FOREFLAP OK IAW FED-EX M/M 27-51-1.

Part: WEDGE — PUNCTURED (TE MID FLAP)

NR 0106 001, RIGHT WING I/B MIDFLAP TRAILING EDGE WEDGE PUNCTURED ON LOWER SURFACE 25 FROM INBOARD END. *S/D* REMOVED RIGHT WING I/B AFT FLAP, REPAIRED PUNCTURE ON RIGHT WING I/B MID FLAP T/E WEDGE, INSTALLED RIGHT WING I/B AFT FLAP, REPAIR PERFORMED IAW FED-EX SRM 51-40-6.

Part: FRAME — DAMAGE (BS 720)

NR 0244 002, DENT IN FRAME AT BS 720A, RBL 15, WL 155. BLENDED OUT DENT AND REPAIRED FRAME BS 720A, RBL 15, WL 155. ALL WORK ACCOMPLISHED PER FED-EX 727 SRM 51-10-2, 51-10-6, 53-10-4. FABRICATED REPAIR PART PER FED-EX SRM 53-10-4.

Part: ACCESSORY UNIT — FAILED (LANDING GEAR)

LANDING GEAR WOULD NOT RETRACT UNLESS WE USED LATCH LEVER RELEASE. REMOVED AND REPLACED GEAR ACCESSORY UNIT IAW 32-09-121 PG 401, FUNCTIONAL TEST GOOD IAW 32-09-122 PG 501 TO 505.

Part: SENSOR — DIRTY (LANDING GEAR)

GEAR WOULD NOT RETRACT NORMALLY AFTER TAKEOFF. RETRACTED GEAR USING LEVER LOCK OVERRIDE. GEAR EXTENDED NORMALLY FOR LANDING. FOUND ICE ON AIR GROUND SAFETY SENSOR. CLEANED AND LUBED AS REQUIRED.

Part: ACCESSORY UNIT — FALSE WARNING (LT MLG)

AFTER T/O FROM MEM AT GEAR RETRACTION, THE L/MAIN GEAR RED LIGHT WOULD NOT EXTINGUISH. CHECKLIST PROCEDURE ACCOMPLISHED. ALL GREEN ALL GEAR DOOR LIGHTS AND THE NOSE AND R/MAIN RED LIGHT EXTINGUISHED. THE L/MAIN RED LIGHT STILL WOULD NOT EXTINGUISH. FLT CONTINUED PER CHECKLIST PAGE 2-6-20. REPLACED LANDING GEAR ACCESSORY UNIT AND TESTED GOOD PER MM 32-09-121 PG 501.