N151

Part: SHIELD — CORRODED (BS 412-460) · corrosion level 3 · airframe 53,141 hrs

REPLACEMENT OF SHIELDS IN FWD AILERON CROSS. TO REPLACE CORRODED AND CRACKED SHIELDS IN THE FORWARD AILERON CROSS COMPARTMENT. SIX STRINGER TO FUSELAGE SHIELDS WERE FOUND DAMAGED IN THE FWD AILERON CROSS COMPARTMENT. ONE WAS BADLY CORRODED, ONE WAS SEVERELY CRACKED AND 4 OF THEM HAD CRACKS. THE 4 CRACKED ONES WILL BE STOP DRILLED AND REINSPECTED EVERY C CHECKS. THE OTHER 2 ARE BEING REPLACED. THE STOP DRILLED SHIELDS WILL BE RE-INSPECTED EVER C CHECKS. SHIELDS ARE PRESSURIZATION SEALS. SEE ACCOMPLISHMENT INSTRUCTION SECTION FOR DETAILS.

Part: SKIN — DENTED (VERTICAL STAB) · airframe 53,141 hrs

DENT ON VERTICAL STABILIZER LEADING EDGE AT VSS 90.

Part: FRAME — CRACKED (FUSELAGE) · airframe 53,141 hrs

FUSELAGE FRAME FOUND CRACKED. REMOVED AND REPLACED THE FRAME.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 53,011 hrs

UNSAFE LEFT MAIN GEAR INDICATION AFTER CYCLING SEVERAL TIMES FINALLY GOT DOWN & LOCKED SAFE INDICATION.

Part: STRINGER — CRACKED (RT WING)

STRINGER 21 CAP CRACKED AT RT WING STATION 195. REPAIRED IAW EO 9915.

Part: SKIN — CRACKED (LT WING)

LOWER WING SKIN CRACK W/STA 335L. TO REPAIR A CRACK ON THE LOWER WING SKIN AT W/STA 335L. AN APPROXIMATELY 2.25" CRACK WAS FOUND ON THE LOWER WING SKIN AT THE AFT LEG OF STRINGER 18L AT W/STA 335L. PREFORM SKIN CUT-OUT PER DRAWING 1712-01, MANUFACTURE FILLER, EXTERNAL REPAIR DOUBLER AND INSTALL PER DRAWING 1712-01.

Part: TEST SWITCH — MALFUNCTIONED (FIRE WARNING) · airframe 52,638 hrs

AFT BAG FIRE HANDLE INTERMITTENT ILLUMINATION. (LT/RT CYL ALSO)

Part: BRACKET — CRACKED (TE FLAP)

CRACKED FLAP BRACKET AT LT WING STA 281. THE FLAP BRACKET ON THE LT WING IS CRACKED AT WING STA 281. THE OTBD SIDE OF THE FLAP HINGE BRACKET IS CRACKED AT WING STA 281. REPAIR IAW THE PROCEDURES IN THE STR 13-6 DATED FEB 21, 1955.

Part: SKIN — CRACKED (WING)

CRACKED WING SKIN AND FILLER WITH STA 235.5 AND WING STR 20 TO REPAIR A CRACK IN THE WING SKIN AND FILLER BETWEEN WING SKIN AND LANDING DOUBLER. PERFORM CUTOUT OF THE CRACKED SKIN AND FILLER. INSTALL EXTERNAL DOUBLER MADE FROM 7075-T6 0.125" IAW THE ACCOMPLISHMENT INSTRUCTIONS SECTION OF THIS EO. THIS REPAIR INCLUDES A PREVIOUSLY ACCOMPLISHED WING STRINGER REPAIR DONE IAW EAC EO 0216.

Part: FRAME — CRACKED (BS 661)

CRACK ON LEFT FUSELAGE FRAME AT BS 661. SEVEN INCHES ABOVE FUSELAGE FLOOR.

Part: ACCESS PANEL — CRACKED (WING)

CRACKED ACCESS PANEL ATTACH FLANGES AT WING STA 49 AT PANEL 136 LT AND RT, AND 133 RT. TO REPAIR 5 CRACKS IN THE ATTACH FLANGES OF ACCESS PANELS. THE CRACKS IN THE ATTACH FLANGES ARE AT WING STA 41 LT AND RT AT PANELS 136 FORWARD AND AFT FLANGES AND PANEL 133 RT FORWARD FLANGE. CRACKS ARE AT THE LINE OF THE OLD REMOVED RETARDANT TANK FILET. STOP DRILL CRACKS AND INSTALL 7075-T6 0.124" DOUBLERS IAW DWG 1623-01 AT EACH CRACK.

Part: LAP JOINT — CORRODED (FUSELAGE)

CORRODED SKIN LAP JOINT AT FS 906, BETWEEN STRINGER 33L & 33R. TO REPAIR A CORRODED SKIN LAP JOINT, CUT OUT DAMAGED SKINS & PERFORM REPAIR IAW THE INSTRUCTION OF EAC EO 0502 GENERIC REPAIR TO CORRODED SKIN LAP.

Part: STRUCTURE — CORRODED (FUSELAGE) · corrosion level 3 · airframe 51,799 hrs

REPLACEMENT OF MAIN CABIN FLOOR & FLOOR STRINGERS, BETWEEN FS 300 & 317. TO REPLACE A SECTION OF CORRODED FLOOR SKIN & STRINGER, BETWEEN FS 300 & 317. REMOVE FLOOR SKIN & FLOOR STRINGERS. REPLACE & SPLICE CORRODED STRINGER IAW DC-6 A & B OVERHAUL MANUAL FIGURE 15 - 16. REPLACE FLOOR SKIN IAW DC-6 A & B OVERHAUL MANUAL FIGURE 12 - 15.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 51,799 hrs

CRACKED FLOORBEAM AT FS 302, RBL 32. TO REPAIR CRACK IN THE UPPER FLANGE OF THE RBL 32 FLOORBEAM. INSTALL WEB DOUBLER & UPPER REINFORCING DOUBLER IAW DWG 1546-01 & ENGINEERING REPORT 87TC-ERIMA DATED OCT 27 1987 FIG 4 1 4 2. NOTE THE CRACK ENDS AT A FLOORBEAM LIGHTING HOLE. FINAL SIZE & SHAPE OF REPAIR TO BE DETERMINED ON THE AIRPLANE.

Part: SKIN — CRACKED (LT WING) · airframe 51,799 hrs

UPPER WING SKIN CRACKED AT NR 2 AT FUEL TANK ACCESS DOOR NR 90. TO REPAIR A CRACK IN THE UPPER WING SKIN AT THE AFT OTBD CORNER OF NR 2 ALT FUEL TANK ACCESS DOOR NR 90 & REPLACING THE CRACKED ACCESS DOOR DOUBLER. THE WING SKIN CRACKED EXTENDS BEYOND THE LIMITS OF SB 842. THE REPAIR WILL BE EXTENDED AFT TO THE AFT SPAR & OTBD TO THE NACELLE ATTACH ANGLE IAW DWG 1547-01. THE DOOR ACCESS DOUBLER WILL BE REPLACED IAW SB 842.

Part: SKIN — CRACKED (FUSELAGE) · corrosion level 3 · airframe 51,799 hrs

CRACKED & CORRODED SKIN AROUND ANTENNA BASE AT FS 79, BETWEEN STRINGER 5R & 6R TO REPAIR A CRACKED FUSELAGE SKIN, DUE TO CORROSION. REMOVE ANTENNA. CUT OUT DAMAGE, INSTALL FILLER & DOUBLER IAW DC-6 A & B OVERHAUL MANUAL FIGURE 12 - 22. REINSTALL ANTENNA & PERFORM OPERATIONS CHECK.

Part: FLOOR PANEL — CORRODED (FUSELAGE) · corrosion level 3 · airframe 51,799 hrs

FLOOR PANEL CORRODED THROUGH AT FS 560, CTR LINE. REPAIR CORRODED SKIN IAW DC 6 A & B OVERHAUL MANUAL FIGURE 12-5.

Part: SMOKE DETECTOR — MALFUNCTIONED (ZONE 200) · airframe 51,700 hrs

SMOKE ALARM WENT OFF AFTER TAKEOFF. CREW DECLARED EMER & RETURNED, LANDED DUE TO SMOKE ALARM SOUNDING. FOUND NR 2 SMOKE DETECTOR IN MAIN CABIN TO HAVE HAD THE BEACON BULB FAILED. INSTALLED SERVICEABLE BEACON BULB. OPERATIONAL CHECKED GOOD IAW CMM PAGE 6.

Part: SKIN — WORN (TE FLAP)

LOWER FLAP SKIN WORN AT WS 250R. TO REPAIR WORN SKIN AT 250R AT CTR SPAR ATTACH FASTENERS. REMOVE DAMAGE & REPAIR IAW OVERHAUL MANUAL FIG 1347.

Part: BULKHEAD WEB — CRACKED (BS 600)

BULKHEAD WEB CRACKEDAT BS 600, RBL 12. REPAIRED IAW A & B O/H MANUAL FIG 11-52 AND DWG 1443-01.

Part: BULKHEAD WEB — PUNCTURED (BS 341)

BULKHEAD PUNCTURED BS 341, RBL 8. REPAIRED THE BULKHEAD IAW A & B O/H MANUAL FIG 12-6.

Part: STRINGER — CORRODED · airframe 50,465 hrs

STRINGER 13 CORRODED AT FS 80. REPAIRED IAW EO 1318.

Part: SKIN — DAMAGED (FLAP) · airframe 50,465 hrs

LOWER FLAP SKIN DAMAGED. SKIN REPAIRED IAW EO 1316.

Part: FIRE WARNING — ILLUMINATED · airframe 50,228 hrs

ABORTED TAKEOFF DUE TO FIRE WARNING LIGHT CAME ON FOR EITHER NR 1 OR NR 2 ENGINE ZONE 2 & 3.

Part: FLOOR PANEL — DAMAGED (CABIN) · airframe 49,998 hrs

FLOOR PANEL DAMAGED, REPAIRED IAW EO 1252.

Part: STRUCTURE — CRACKED (BS 437) · airframe 49,998 hrs

REINFORCING RING CRACKED AT CENTER WING SECTION REPAIRED PER EO INSTRUCTIONS.

Part: DOUBLER — CRACKED (BS 572) · airframe 49,574 hrs

CABIN HEATER EXHAUST DOUBLER BS 572 HAS TWO CRACKS. FABRICATE TWO INSERTS & AN EXTERNAL DOUBLER.

Part: FABRIC — TORN (RUDDER) · airframe 49,574 hrs

LOWER RUDDER END RIB FABRIC TORN. R & R OF TORN & DAMAGED FABRIC.

Part: SKIN — DAMAGED (BS 794) · airframe 49,574 hrs

FUSELAGE SKIN & DOOR FRAME CLOSE OUT ANGLES AT AFT EDGE OF MAIN CARGO DOOR BS 794. REPAIRED.

Part: ATTACH ANGLE — CORRODED (LT WING) · airframe 49,574 hrs

REPLACEMENT OF A CORRODED LE RIB ATTACH ANGLE BETWEEN WS 184L & NR 2 NACELLE & REPAIR OF THE WEB & ATTACHING SKIN EO 1214.

Part: ATTACH ANGLE — CRACKED (NR 4 NACELLE) · airframe 49,574 hrs

NR 4 NACELLE INBD ATTACH ANGLE CRACKED. R & R CRACKED ANGLE.

Part: BRAKE ASSY — WEAK (MLG) · airframe 48,806 hrs

BRAKES REQUIRED LARGE AMOUNT OF PRESSURE AND GAVE VERY POOR BRAKING. BLED AND INSP BRAKES IAW DC6LMM 26-23 GROUND AND OPS CHECK GOOD.

Part: DOOR — CRACKED (MAIN CARGO) · airframe 48,632 hrs

CRACK DISCOVERED IN MAIN CARGO DOOR REPAIRED PER EAC EO 1109 AND 8110-3 DATED 3/29/2011

Part: PIPE — DISCONNECTED (NR 4 ENGINE) · airframe 48,197 hrs

SHUTDOWN NR4 ENGINE DUE TO LOSS OF BMEP AND FUEL FLOW, RECONNECTED INTAKE PIPE AND SAFTIED AT CYL NR9.

Part: SKIN — CORRODED (WING) · airframe 48,186 hrs

FOUND CORROSION ON BOTTOM WING SKIN STA 347R IN EXHAUST PATH AREA. REPAIRED IAW EAC EO 1056.

Part: BULKHEAD — DAMAGED (CARGO BAY) · airframe 48,486 hrs

FOUND 6 DAMAGED AREAS ON AFT CARGO COMPARTMENT BULKHEAD STA X -18/Y 29.5, STA X -9/Y 22.5. REPAIRED MINOR DAMAGE TO THE REAR CARGO COMPARTMENT BULKHEAD IAW EAC EO 1058 AND 8110-3 NR1029, DATED 11/10/10.

Part: SKIN — CRACKED (BS 919-930) · airframe 48,186 hrs

FOUND 3 SMALL CRACKS IN CARGO FLOOR SKIN FUS, STA 919 TO 930, 2 SMALL CRACKS IN CARGO FLOOR SKIN AT FUS, STA 869.5 TO 859.5, FOUND 5 SMALL CRACKS IN CARGO FLOOR SKIN FROM FUS, STA 914 TO 874.5. ALL DAMAGE REPAIRED IAW EAC EO 1057 AND 8110-3 NR1028 DATED 11-10-10.

Part: STRUCTURE — CORRODED (BS 964.75-1010) · airframe 48,032 hrs

FOUND CORROSION BETWEEN FUSELAGE STA 964.75 AND 1010.25 NEAR TAIL HEATER EXHAUST DOUBLER. REPAIRED IAW 8110-3 DATED 9/13/10, 1026.

Part: AMPLIFIER — OVERHEATED (COCKPIT) · airframe 47,597 hrs

AUDIBLE POP SOUND FOLLOWED BY A BURNING/SMOLDERING SMELL IN COCKPIT. NO VISUAL SMOKE REPORTED BY THE FLIGHT CREW. FOUND THAT THE NR 2 COMPASS AMPLIFIER HAD BLOWN A TRANSFORMER.

Part: BRACKET — BROKEN (T/E FLAP)

AFTER FLIGHT MAINTENANCE FOUND THE OB ATTACH BRACKET AT THE OB END OF FLAP ASSY 5363998-501 BROKEN. THIS ALLOWED THE VANE ASSY 5371802-1 TO COME LOOSE AND DAMAGE THE FLAP. REPLACE THE FLAP AND VANE ASSY. RETURNED AC TO SERVICE. (K)

Part: BALLAST — SMOKE (CABIN LIGHTS) · airframe 2,243 hrs · 1,585 cycles

ORD - DURING BOARDING, EXPERIENCED SMOKE IN THE CABIN AT ROW 8. REMOVED AND REPLACED THE LIGHT BALLAST AT ROW 8.

Part: SWITCH — SHORTED (COCKPIT)

NR 4 FUEL BOOST PUMP SWITCH SHORTED OUT WHEN PLACED IN THE LOW BOOST POSITION DURING ENGINE START. SWITCH INTERNALLY SHORTED DIRECT TO GROUND. SWITCH REPLACED. SYSTEM THOROUGHLY INSPECTED. OPS CHECKED NORMAL. (X)

Part: SWITCH — FAILED (BOOST PUMP)

NR 4 FUEL BOOST PUMP SWITCH SHORTED OUT WHEN PLACED IN THE LOW BOOST POSITION DURING ENGINE START. SWITCH INTERNALLY SHORTED DIRECT TO GROUND. SWITCH REPLACED. SYSTEM THOROUGHLY INSPECTED. OPS CHECKED NORMAL. (X)

Part: SWITCH — SHORTED (BOOST PUMP)

NR 4 FUEL BOOST PUMP SWITCH SHORTED OUT WHEN PLACED IN THE LOW BOOST POSITION DURING ENGINE START. SWITCH INTERNALLY SHORTED DIRECT TO GROUND. SWITCH REPLACED. SYSTEM THOROUGHLY INSPECTED. OPS CHECKED NORMAL. (X)