N506MC

Part: PANEL — DELAMINATED (RWS 199-263) · airframe 90,403 hrs · 18,774 cycles

RT WING LEADING EDGE, INBOARD OF LANDING LIGHTS, INTERIOR AREA OF LEADING EDGE, COMPOSITE SKIN IS DELAMINATED. AREA IS 64.0 INCH BY 20.0 INCH. INTERIM REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 57-30-02, FIG 10 AND SRM 51-40-09, FIG 18, REFERENCE ATLAS AIR XEO NR 57-111607 AND FAA FORM 8110-3.

Part: SEAL — DAMAGED (NLG DOOR) · airframe 89,730 hrs · 18,631 cycles

AIR TURN BACK DUE TO NOSE GEAR DOOR OPEN INDICATION AFTER GEAR RETRACTION. FLIGHT CREW ADVISED, ACTUAL DOOR OPEN FAULT AND NOT INDICATION. AFTER ARRIVAL, MX INSPECTED AND FOUND FWD DOOR SEAL PARTIALLY OUT OF RETAINER. UPON MORE DETAILED INSPECTION AND MULTIPLE OPS CHKS. MX WAS ABLE TO REPRODUCE FAULT ON GROUND. FOUND PROX SWITCH TARGET BRACKET BENT AND SHIMS FROM RIGHT NOSE DOOR CATCHING THE SEAL. REPAIRED DAMAGE AS PER XEO 53-090507.

Part: PUMP — LEAKING (HYD SYSTEM) · airframe 89,504 hrs · 18,581 cycles

NR 2 HYD LEAK STOPPED WITH 1.8 GALLONS REMAINING. EDP TO SUPPLY OFF. REMOVED AND REPLACED HYD PUMP AND CASE DRAIN RETURN FILTER, OPS AND LEAK CHECKED OKAY.

Part: SKIN — DENTED (THRUST REVERSER) · airframe 89,299 hrs · 18,539 cycles

NR 3 ENGINE RT THRUST REVERSER EXTERIOR SKIN LOWER AREA AT 5 O'CLOCK POSITION HAS 3 EACH DENTS. PERMANENT REPAIR WAS ACCOMPLISHED AS PER GE CF6-50 ENGINE MANUAL 78-32-01 REPAIR 3, FIG 1. ALSO, REFERENCE ATLAS AIR EO NR 4778A098.

Part: ACTUATOR — BROKEN (NLG DOOR) · airframe 88,385 hrs · 18,339 cycles

LOSS OF HYD SYSTEM NR 1, PERFORMED EMERGENCY/ABNORMAL CHECKLIST 3.29 FHB EDP, PUMP PLACED TO SUPPLY OFF AT TIME 2133Z, FLUID QTY TO 0. REMOVED AND REPLACED NOSE DOOR ACTUATOR AS PER AMM 32-34-14.

Part: SUPPORT BEAM — DAMAGED (LT WING) · airframe 88,001 hrs · 18,254 cycles

LT WING LEADING EDGE PANEL BETWEEN ILES 173.6742 AND 330, INNER PANEL SUPPORT BEAM, UPPER CHORD HAS 8 EACH HOLES DRILLED INCORRECTLY. INTERIM REPAIR WAS ACCOMPLISHED PER REFERENCE ATLAS AIR XEO 57-122806 AND 747 SRM 51-40-04, 51-30-02 AND 51-10-02 FAA FORM 8110-3 ISSUED, PERMANENT REPAIR TO BE ACCOMPLISHED AT NEXT "C" CHECK.

Part: RELIEF VALVE — FAULTY (NR 2 ENGINE) · airframe 87,920 hrs · 18,230 cycles

DURING CLIMB-OUT, NR 2 ENGINE FIRE WARNING. BOTH ENGINE NACELLE TEMPS ON NR 2 ENGINE READ 8.5. ALL OTHER INDICATIONS NORMAL. ENGINE FIRE HANDLE PULLED. FIRE LIGHT EXTINGUISHED AND NACELLE TEMPS RETURNED TO NORMAL. REPLACED NR 2 PRV PER AMM 36-11-19. REPLACED NR 2 ENG PRESS RELIEF VALVE AS PER MM 36-11-03.

Part: SKIN — DAMAGED (HORIZ STAB) · airframe 86,672 hrs · 17,967 cycles

ON WALKAROUND, FOUND HOLE IN LEADING EDGE OF RIGHT HORIZONTAL STABILIZER. REPAIR CARRIED OUT AS PER SRM 55-10-03 FIG 1. XEO 55-072806 ALL ORIGINAL SIGNATURES HELD ON XEO 55-072806 ITEM 2. FURTHER INSPECTION REVEALED HOLE IN LEADING EDGE OF RIGHT INBOARD FORE FLAP. REPAIR CARRIED OUT AS PER XEO 57-072806-2. INTERIM REPAIR AND APPROVAL GRANTED FROM 8110-3. ALL SIGNATURE HELD ON XEO.

Part: PANEL — CORRODED (LT WING) · corrosion level 2 · airframe 86,660 hrs · 17,965 cycles

L/W-L/E WING PANEL CORRODED TWO SPOTS AREA IS I/B ON MOST I/B L/E NEAR FUSELAGE.

Part: PANEL — CRACKED (T/E FLAP) · airframe 86,660 hrs · 17,965 cycles

R/W-O/B MID FLAP COVE PANEL CRACKED AT SUPPORT ARM APPROX 4" CRACK AT 3RD SUPPORT ARM I/B OF NR 8 CANOE.

Part: STRUCTURE — CHAFED (T/E FLAP)

R/W-I/B AFT FLAP-UPPER SURFACE HAS TWO CHAFE MARKS FROM LONG SCREWS IN COVE PANEL ARM. CHAFE AREA ON I/B END-MARKED.

Part: PANEL — CRACKED (T/E FLAP) · airframe 86,660 hrs · 17,965 cycles

R/W-O/B MID FLAP COVE PANEL CRACKED AT SUPPORT ARM APPROX 14". AREA IS BETWEEN NR 7/8 CANOE-MARKED.

Part: STRUCTURE — CRACKED (L4 DOOR) · airframe 86,538 hrs · 17,938 cycles

MAIN CARGO DECK DOOR L-4, AT THE ML POSITION HAS A VERY HIGH VOLUME AIR LEAK LIKE A BIG VAC. FOUND 8" CRACK IN FWD LWR CORNER OF 4L MED OUT OF LIMITS PER SRM 52-08-02. REMOVED 4L MED INSP OK TO INSTALL. INSTALLED 4L SERVICEABLE DOOR PER 52-11-01. NEEDS TO BE RIGG AND OPS CHECKED. RIGGED AND OPS CK PER 52-11-01.

Part: VALVE — MALFUNCTIONED (NR 1 ENGINE) · airframe 86,258 hrs · 17,887 cycles

AFTER T/O, FIRE INDICATION POINTERS BELL NR 1 ENGINE. COMPLETED ENGINE FIRE, SEVERE DAMAGE OR SEPARATION CHECKLIST. JETTISON APPROX 70,000 KGS, OF FUEL. LANDED UNDER MAX LANDING WEIGHT. PERFORMED PNEUMATIC LEAK CHECK PER MM 71-00-00 PG 510, CHECK OK. PERFORMED MPA CHECK PER MM 71-00-00 PG 524 OPS OK. INSPECTED ENGINE DUCTING, NO DEFECTS FOUND. LOCKED OUT HIGH STAGE VALVE AND ITEM DEFERRED.

Part: ENGINE — DAMAGED (NR 4) · airframe 85,996 hrs · 17,831 cycles

NR 4 ENGINE COMPRESSOR STALL 33,000. TAT-7, MACH .84, ENGINE SHUT DOWN. HIGH VIBRATION, EGT RISE. NO EXCEEDANCES. AIR TUR BACK. NR 4 ENGINE CHANGED IAW ATLAS AIR ENGINE CHANGES SHEET REV 15 JAN 02.

Part: SWITCH — DEFECTIVE (AFT CARGO DOOR)

AT APPROX FL 280, AFT CARGO LIGHT ON FE`S PANEL AND CARGO DOOR LIGHT ON PILOTS PANEL BEGAN FLICKERING, SHORTLY IT CAME ON STEADY. DESCENDED AC TO FL250 AND ACCOMPLISHED FHB PROCEDURES FOR DOOR OPEN LIGHT. AT NO TIME EXPERIENCED PRESSURIZATION PROBLEMS PRIOR TO DEPRESSURIZING AIRCRAFT. FOUND AFT CARGO WARNING SWITCH INOPERATIVE. REMOVED AND REPLACED AFT CARGO WARNING SWITCH IAW MM. OPS CHECK NORMAL. (K)

Part: DRAIN MAST — DAMAGED (NR 3 ENGINE)

A FIRM LANDING ON TOUCH DOWN, ON WALK AROUND, AFTER PARKING, NOTICED NR 3 ENGINE IAW MM. NO FURTHER DAMAGE NOTED. ALSO ALIGNMENT MARKS ON STRUT DOORS ARE ALIGNED AND NO DAMAGE TO CANOES OR TAIL SECTION OF AIRCRAFT FOUND. REPLACEMENT COWLS OR SLEEVES IS NOT NECESSARY. DAMAGED NR 3 DRAIN MAST TRANSFERRED TO DMI.

Part: SEQUENCE VALVE — FAILED (MLG)

NOSE GEAR CYCLED X3 DURING CLIMB-OUT, TO DOORS OPEN AND NOSE GEAR INTRANSIT. ALSO AT THE SAME TIME RT WING DOOR ANNUNCIATOR ON AND GEAR INTRANSIT. ALL CONDITIONS ASSOCIATED WITH AIRCRAFT VIBRATION NOISE VIA AIR STREAM. ALL THREE CYCLES WERE PRECEDED BY RED GEAR WARNING LIGHT AT LANDING GEAR LEVER. FOUND RT WING GEAR DOOR SYSTEM CABLE SLIGHTLY SLACK FROM GROUND DOOR RELEASE HANDLE TO DIFFERENTIAL. ADJUSTED TENSION PER MM 32-35-00. REMOVED AND REPLACED NOSE GEAR OPERATED DOOR SEQ VALVE AND NOSE GEAR DOOR OPERATED SEQUENCE VALVE AS A PRECAUTION PER MCC REQUEST. PERFORMED GEAR RETRACTION AND EXTENSION CHECK. OPS CHECKED OK AIRCRAFT RETURNED TO SERVICE. (M)

Part: RELAY — INOPERATIVE (P14 PANEL)

REJECTED TAKEOFF DUE TO TAKEOFF WARNING HORN AT 135KTS. STAB TRIM INDICATION SYSTEM TEST CUT OUT IAW MM 27-48-00. OPS NORMAL. STAB TRIM INDICATION AND CONTROL SYSTEM WITH MULTI GREEN BAND CUT OUT OPS NORMAL PER MM 27-48-00. REPLACED RELAY R-586 STAB TRIM GREEN BAND TIME DELAY RELAY PER MM 27-48-00. DURING GREEN BAND FUNCTION TEST NOSE STRUT FOUND TO BE OVER INFLATED. STRUT SERVICED, PRESSURE AND EXTENSION WITH GRAPH TOLERANCE PER MM 12-15-05. (M)

Part: BULB — FAILED (SMOKE DETECTOR)

PO380/10 DXB/CGK LOWER CARGO AFT FIRE LIGHT CAME ON DURING TAKEOFF: LOWER CARGO AFT FIRE LIGHT CAME (ON) AT ROTATION. APPROPRIATE DRILLS CARRIED OUT. AIRCRAFT RETURNED TO DEPARTURE. CHECKED LOWER AFT CARGO FOR FIRE OR DAMAGE, NO EVIDENCE. BULK CARGO IS EMPTY. CHECKED DETECTORS, ALL LAMPS ARE WORING. RELAMPED AS A PRECAUTION IAW MM 26-16-00, TEST OK. NO FUEL DUMPED.

Part: WARNING LIGHT — FALSE ACTIVATION (CARGO FIRE)

AFT CARGO FIRE WARNING LIGHT ILLUMINATED, CAUSING FIRE WARNING. CARRIED OUT PROCEDURE IAW QRH. RETURNED FOR LANDING. CARRIED OUT INSPECTION OF AFT CARGO IAW MM 26-16-00. NO EVIDENCE OF SMOKE OR FIRE DAMAGE. OFF LOADED CARGO FOR INSPECTION. ALL SYSTEM NORMAL, FIRE TEST CARRIED OUT. OPS CHECKED SATISFACTORY. CARRIED OUT CONDITIONL IAW MM 5-51-39, SEE LOG PAGE 82077 ITEM NR 1/2. (M)

Part: PDU — SMOKE

ANC/DFW - PDU MAIN DECK POSITION 18R INOPERATIVE STARTED SMOKING. REMOVED PDU FOUND MOTOR INOPERATIVE. REMOVED CONNECTOR AND DEACTIVATED PDU. TRANSFERRED TO DI PAGE 55833 DMI C-4-003. (M)

Part: CONNECTOR — DIRTY (NR 1 ENGINE)

GT8971/5 DNA/BKK ATB AND IFSD DUE TO NR 1 ENGINE FALSE FIRE WARNING: NR 1 ENGINE FIRE INDICATION DURING CLIMB, ALL OTHER SYSTEMS NORMAL EXCEPT (B) LOOP WAS DEFERRED. (A) LOOP WAS INDICATION FAULT AND FIRE. ENGINE SHUTDOWN ACCOMPLISHED AND FUEL JETTISON 28.3K. PERFORMED THROUGH INSPECTION OF ENGINE FIRE LOOPS. FOUND TWO CONNECTORS AT CORE SECTION LOOSE. CLEANED AND SECURED THEM. CLEANED AND REINSTALLED AFT FIREWALL CONNECTORS. PERFORMED ENGINE RUN, ALL CHECKED NORMAL IAW MM 26-11-00.

Part: ENGINE — MAKING METAL (NR 3)

IN CRUISE, ENGINE NR 3 COMPRESSOR STALLS WITH N1, N2 AND EGT FLUCTUATION. PERFORMED ENGINE FIRE, SEVERE DAMAGE OR SEPARATION CHECK IAW FLIGHT HANDBOOK 3.70.1. SHUTDOWN ENGINE AND RETURNED. FUEL DUMPED 6,000 KGS. VISUAL INSPECTION OF NR 3 ENGINE, FOUND METAL IN TAILPIPE. REMOVED AND REPLACED NR 3 ENGINE IAW FORM 01-AA-44B AND IAW MM 72-00-00. ACCOMPLISHED ENGINE RUN. ALL PARAMETERS CHECKED NORMAL. (M)

Part: FLOORBEAM — CRACKED (FUSELAGE)

DURING C-CHECK, MAIN DECK FLOORBEAM WEB AND BEAM FOUND CRAKCED AT BS 320 AND APPROXIMATE AT RBL 40. FLOORBEAM AND WEB REPAIR CARRIED OUT PE IAI REPAIR SCHEME AND 8110-3. REPAIR AREA BS 320, RBL 38 TO BE VISUAL INSPECTED, AT THE FOLLOWING INTERVAL, 1500 HOURS OR 200 CYCLES, WHICH EVER COMES FIRST. ATLAS AIR MCI NR A139 ISSUED FOR THE REINSPECTION. (M)

Part: PRESSURE PANEL — CRACKED (NLG WW)

DURING C-CHECK, NOSE GEAR WHEEL TOP AT BS 366 LBL 11 FOUND CRACK FROM EDGE AND EXTENDED INBOARD APPROXIMATE 1 INCH IN LENGTH. DEFECT FOUND DURING L-CHORD REPLACEMENT AT STATION BS 340, LBL 11.33. REPAIR CARRIED OUT AS PER BOEING TELEX SEP-SIN-03-40H AND 8110-3. TRIMMED CRACK AREA INCLUDING .030 INCHE INSURANCE CUT. PERFORMED HFEC INSPECTION TO INSURE CRACK FREE-CONDITION. INSTALLED THREE FILLERS AND A DOUBLER TO TOP PANEL WEB AND CHORD. (M)

Part: SKIN — CORRODED (CENTER TANK)

DURING C-CHECK, CENTER TANK UPPER SKIN FOUND CORRODED AT BS 1060, RBL 106-122 UNDER FLOORBEAM LOWER CHORD. PERMANENT REPAIR PER REF, CORROSION WAS REMOVED BY BLENDING. BLENDED AREA WAS SHOP PEENED, REFINISHED AND BMS 5-95 SEALANT WAS USED TO FILL THE BLENDED AREA TO PREVENT MOISTURE ACCUMULATION. NO REINFORCEMENT WAS REQUIRED. (M)

Part: SKIN — CORRODED (FUSELAGE)

DURING C-CHECK, AS PER XEO 53-06/04/03 FOUND AFT BELLY SKIN WITH CORROSION AND DENTS UNDER PREVIOUS REPAIR AT THE FOLLOWING STATIONS 2200-2240 STRINGER 45R-48L AND STATION 1977-2008 STRINGER 45R-48L REPAIR CARRIED OUT PER BOEING TELEX SEP-SIN-03-00036H AND 8110-3. (M)

Part: BULKHEAD — CRACKED (FUSELAGE)

DURING C-CHECK, FOUND CRACKS AT LT AND RT SIDES OF STATION 140, FORWARD PRESSURE BULKHEAD WEB, WL 205-227 AND WL 250-258. THE REPAIR TRIMS OUT THE CRACKS, HFEC INSPECTS THE TRIM. INSTALLED REPAIR DOUBLERS ON THE AFT SIDE PER REF AND MOD DOUBLERS ON THE FORWARD SIDE PER REF. FASTENER HOLES ARE HFEC INSPECTED. (M)

Part: SWITCH — INOPERATIVE (LIGHT PANEL)

ON DESCENT A STRONG ELECTRICAL ODOR COMING OUT OF GASPERS. ELECTRICAL SMOKE OR FIRE CHECK LIST INITIATED. AFTER ITEM NR 6, SMOKE STOPPED. AIRCRAFT REMAINED IN THIS CONFIGURATION AND LANDED. C/A: FOUND MELTED INSULATION AT WING ILLUMINATION LIGHT SWITCH TERMINAL. LIGHT INTERMITTENTLY INOPERATIVE, PULLED CIRCUIT BREAKER. TRANSFERRED TO DMI, MEL. REPLACED SWITCH AND WIRE ATTACHED TO TERMINAL NR1 ON SWITCH FOR THE WING ILLUMINATION LIGHTS IAW MM.

Part: SWITCH — INTERMITTENT (LIGHT PANEL)

ON DESCENT A STRONG ELECTRICAL ODOR COMING OUT OF GASPERS. ELECTRICAL SMOKE OR FIRE CHECK LIST INITIATED. AFTER NR 6, SMOKE STOPPED. AIRCRAFT IN THIS CONFIGURATION AND LANDED. FOUND MELTED INSULATION AT WING ILLUMINATION LIGHT SWITCH TERMINAL. LIGHT INTERMITTENTLY INOPERATIVE. PULLED CIRCUIT BREAKER. REPLACED SWITCH AND WIRE ATTACHED TO TERMINAL NR 1 ON SWITCH FOR THE WING ILLUMINATION LIGHTS.

Part: SWITCH — INOPERATIVE (WING ILL LTS)

ON DESCENT A STRONG ELECTRICAL ODOR COMING OUT OF GASPERS. ELECTRICAL SMOKE OR FIRE CHECK LIST INITIATED. AFTER ITEM NR 6, SMOKE STOPPED. AIRCRAFT REMAINED IN THIS CONFIGURATION AND LANDED. C/A: FOUND MELTED INSULATION AT WING ILLUMINATION LIGHT SWITCH TERMINAL. LIGHT INTERMITTENTLY INOPERATIVE, PULLED CIRCUIT BREAKER. TRANSFERRED. REPLACED SWITCH AND WIRE ATTACHED TO TERMINAL NR 1 ON SWITCH FOR THE WING ILLUMINATION LIGHTS IAW MM.

Part: CLAMP — LOOSE (NR 3 ENGINE)

AFTER TAKEOFF NR 3 ENGINE FIRE WARNING LIGHT CAME ON AND NACELLE HEAT FOR NR 3 ENGINE READ 8 ON BOTH SIDES. AFRTER LEVELING OFF AND REDUCING POWER, THE LIGHT WENT OUT. ENGINE SHUT DOWN PERFHB AIRCRAFT RETURNED TO AIRPORT. C/A: FOUND 14TH STAGE DUCT CLAMPS LOOSE AT 3 POSITION. RESECURED DUCT. INSPECTED ALL ENGINE DUCTS AND PERFORMED LEAK CHECK PER PG.

Part: FIRE WARNING — FALSE INDICATION (COCKPIT)

ATB - DUE LOWER AFT CARGO FIRE LIGHT ON AT ROTATION. NR 1 BOTTLE DISCHARGED (FALSE INDICATION). LOWER AFT CARGO INSPECTED. NO SIGNS OF FIRE (NO CARGO IN SECTION). ITEM TRANSFERRED TO DMI PAGE 03049 AND DEFERRED PER MEL 26-14-2D AND ALL DDPG PROCEDURES FOLLOWED M01-050. (M)

Part: FIRE WARNING — FALSE INDICATION (COCKPIT)

ATB DUE LOWER AFT CARGO FIRE LIGHT ON AT ROTATION NR 1 BOTTLE DISCHARGED, FALSE INDICATION. LOWER AFT CARGO INSPECTED. NO SIGNS OF FIRE (NO CARGO IN SECTION). ITEM TRANSFERRED TO DMI PAGE 03049 AND DEFERRED PER MEL 26-14-2D AND ALL DDPG PROCEDURES FOLLOWED. (M)

Part: FITTING — CORRODED (BS 1480)

DURING INSPECTION FOUND BS 1480 LEFT AND RIGHT INBOARD HORIZONTAL SUPPORT FITTINGS CORRODED AT THE ATTACHMENT TO THE BODY GEAR TRUNNION, VERTICAL SUPPORT FITTING. REMOVED BUSHINGS FROM BOLT HOLES. BLENDED LOCAL CORROSION. SPOT FACED AREA AROUND BOLT HOLES. PERFORMED OPEN HOLE HFEC INSPECTION TO INSURE NO CORROSION OR CRACKS. PERFORMED PENETRANT INSPECTION TO INSURE NO CRACKS OR CORROSION. NO ADDITIONAL CORROSION OR CRACKS FOUND. FLAP PEENED AREA, TREATED AND PRIME PAINTED AREA. FABRICATED NEW SHORTER BUSHING AND INSTALLED. FILLED SPOT FACE VOID WITH BMS-95 SEALANT DURING REINSTALLATION PROCESS. (M)

Part: SKIN — CORRODED (HORIZ STAB)

DURING INSPECTION FOUND CORROSION ON HORIZONTAL STABILIZER SKIN PANELS RIGHT STAB STATION 160 LOWER SKIN FRONT SPAR, RIGHT STAB STATION 173 AT SPLICE STRINGER LOWER SKIN AFT PANEL, LEFT STAB STATION 173 SPLICE STRINGER LOWER FORWARD SKIN AND AT LEFT STABILIZER STATION 165.75 UPPER FRONT SKIN PANEL. (M)

Part: FRAME — CRACKED (BS 480)

DURING INSPECTION FOUND FRAME WEB CRACKED AT BS 480 BETWEEN STRINGER 15 AND 16R CUT OUTS. STOP DRILLED CRACKS. FABRICATED REPLACEMENT DOUBLER. INSTALLED DOUBLER PER STANDARD PRACTICES OF THE SRM. CONTINUE CURRENT INSPECTION REQUIREMENTS PER SB 747-53A2265 UNTIL SB 53-2272 IS COMPLETED AT OR BEFORE 20,000 CYCLES. (M)

Part: WEB — CRACKED (BS 500)

DURING INSPECTION FOUND FRAME WEB CRACKED AT BS 500, STRINGER 9L AND STRINGER 8 TO 10AR. STOP DRILLED ALL CRACKS. FABRICATED REPLACEMENT DOUBLERS. INSTALLED DOUBLER AT STRINGER 9L LOCATION AND AT STRINGER 8 TO 10AR LOCATION PER STANDARD PRACTICES OF THE SRM. CONTINUE CURRENT INSPECTION REQUIREMETNS PER SB 747-53A2265 UNTIL SB 53-2272 IS COMPLETED AT OR BEFORE 20,000 CYCLES. (M)

Part: FRAME — CRACKED (BS 460)

DURING INSPECTIN FOUND FRAME WEB CRACKED AT BS 460, STRINGER 13AL AT TWO LOCATIONS COMMON TO THE FRAME AND DOUBLER. HFEC INSPECTED EXISTING FASTENER HOLES IN WEB FOR CRACK CONTAINMENT. NO ADDITIONAL CRACKS FOUND. FABRICATED REPLACEMENT DOUBLERS, FILLERS AND NEW STRINGER TIE CLIP. INSTALLED PER STANDARD PRACTICES IAW SRM. CONTINUE CURRENT INSPECTION REQUIREMENTS PER SB 747-53A2265 UNTIL SB 53-2272 IS COMPLETED AT OR BEFORE 20,000 CYCLES. (M)

Part: SKIN — CORRODED (LT WING)

DURING INSPECTION, FOUND CORROSION INSIDE THE LEFT WING BOOST PUMP HOUSING AT WS 677 ON THE UPPER WING SKIN SURFACE LIP EXPOSED WITHIN THE HOUSING. CORROSION REMOVED, POLISHED, SHOT PEENED, TREATED AND MEASURED. AREA FILLED IN WITH EPOCAST. ROTART DOOR LATCH CHANGED TO NYLON ASSEMBLY. (M)

Part: FITTING — CORRODED (FUSELAGE)

DURING INSPECTION FOUND CORROSION AT BS 1480 LEFT AND RIGHT BULKHEAD CAP FITTINGS. CORROSION BLENDED PER SRM 51-10-01. PERFORMED HFEC OF BLENDED AREA TO INSURE CRACK AND CORROSION FREE. NO CRACKS OR CORROSION. MEASURED BLENDED AREAS. OVERSIZED EXISTING HOLES AND INSTALLED SLEEVED BOLTS IN HOLES. SPOT FACED HOLES TO REMOVE SURFACE CORROSION. FABRICATED FILLER WASHER TO MAINTAIN ORIGINAL THICKNESS. TREATED AND PRIME PAINTED AREA AND REPAIR FILLERS. REPLACED OUTER CHORD P/N 65B14681U3 ON BOTH LEFT AND RIHT SIDE. (M)

Part: WEB — CRACKED (BS 380)

DURING INSPECTIN FOUND FRAME WEB CRACKED AT BS 380 FROM STRINGER 23L CUTOUT. TRIMMED AWAY CRACKED AREA. FABRICATED REPLACEMENT DOUBLER AND TWO ANGLES. INSTALLED PER STANDARD PRACTICES. CONTINUE CURRENT INSPECTION REQUIREMENTS PER SB 747-53A2265 UNTIL SB 53-2272 IS COMPLETED AT OR BEFORE 20,000 CYCLES. (M)

Part: ANGLE

DURING INSPECTION FOUND NR 4 PYLON REAR ENGINE MOUNT OUTBOARD UPPER BULKHEAD ANGLE CRACKED AT FIRST FASTENER COMMON TO THE CENTER LINE OF PYLON. PYLON HAS KIN CAP IN PLACE (PCW). TRIMMED AWAY CRACKS. FABRICATED STRAP AND ANGLE. OVERSIZED EXISTING HOLES IN REPAIR AREA AND INSTALLED PARTS PER STANDARD PRACTICES REPLACING EXISTING COLLARS WITH STEEL COLLARS RELATED TO STEEL PARTS AND ALUMINUM COLLARS RELATED TO ALUMINUM OR TITANIUM PARTS. (M)

Part: FRAME — CRACKED (BS 440)

DURING INSPECTION FOUND FRAME AN INNER CHORD CRACKED AT BS 440 STRINGER 15R TO EXISTING FASTENER. HFEC INSPECTED EXISTING FASTENER HOLE TO INSURE CONTAINMENT OF CRACK. NO ADDITIONAL CRACKS FOUND. FABRICATED REPLACEMENT DOUBLER AND NEW CLIP. PROCURRED NEW REPLACEMENT INNER CHORD. INSTALLED DOUBLER, CLIP AND INNER CHORD PER STANDARD PRACTICES OF THE SRM. CONTINUE CURRENT INSPECTION REQUIREMENTS PE SB 747-53A2265 UNTIL SB 53-2272 IS COMPLETED AT OR BEFORE 20,000 CYCLES. (M)

Part: SHIM (BS 1241)

DURING INSPECTION FOUND SHIMS MIGRATING FROM BS 1240 LEFT/RIGHT BULKHEAD UPPER CHORD FITTING. REMOVED BOLTS IN AFFECTED AREA, TRIMMED SECTION OF MIGRATED SHIM. FABRICATED REPLACEMENT SHIM FROM SOLID MATERIAL, ALODINED AND PRIME PAINTED. REINSTALLED REMOVED BOLTS. AREA TO BE REINSPECTED EVERY C-CHECK UNTIL ENTRIRE SHIM IS REPLACED. (M)

Part: FRAME — CRACKED (BS 440)

DURING INSPECTION FOUND FRAME AND CHORD CRACKED AT BS 440, STRINGER 13AL/14L. CRACK IS APPROX 1 INCH LONG. CHORD IS COMPLETELY SEVERED. HFEC INSPECTED EXISTING FASTENER HOLE IN FRAME FROM CRACK CONTAINMENT. NO ADDITIONAL CRACKS FOUND. FABRICATED REPLACEMENT DOUBLERS, FILLERS AND TWO NEW STRINGER TIE CLIPS. INSTALLED PER STANDARD PRACTICES. REPLACED SEVERED CHORD WITH NEW CHORD. INSTALLED PER STANDARD PRACTICES IAW SRM. CONTINUE CURRENT INSPECTION REQUIREMENTS PER SB 747-53A2265 UNTIL SB 53-2272 IS COMPLETED AT OR BEFORE 20,000 CYCLES. (M)

Part: FITTING — CORRODED (LT/RT TRUNNION)

DURING INSPECTION FOUND BOTH LEFT AND RIGHT MAIN LANDING BODY GEAR UPPER TRUNNION FITTING HAVE CORROSION IN THE FORWARD BOLT HOLE POCKET. REMOVED CORROSION PER SRM 51-10-01. MEASURED AND SPOT FACED AREA. PERFORMED PENETRANT INSPECTION PERFORMED. NO CRACKS FOUND. OPEN HOLE HFEC INSPECTION PERFORMED. NO CRACKS FOUND. AREA FLAP PEENED AND TREATED. SHORTER BOLT SUBSITUTED. LANDING GEAR REINSTALLED. (M)

Part: FRAME — CRACKED (BS 400)

DURING INSPECTION FOUND FRAME CRACKED AT BS 400, STRINGER 15L CUT OUT. CRACK IS APPROXIMATELY .30 INCH LONG RUNNING FROM STRINGER CUT OUT TO FASTENER HOLE. HFEC INSPECTED EXISTING FASTENER HOLE FOR CRACK CONTAINMENT. NO ADDITIONAL CRACKS FOUND. FABRICATED REPLACEMENT DOUBLER AND TIRPLER AND NEW STRINGER TIE CLIP. INSTALLED PER STANDARD PRACTICES. CONTINUE CURRENT INSPECTION REQUIREMENTS PER SB 747-53A2265 UNTIL SB 53-2272 IS COMPLETED AT OR BEFORE 20,000 CYCLES. (M)

Part: WEB — CORRODED (BS 1480)

DURING INSPECTION FOUND WEB CORRODED BEHIND BS 1480 INBOARD BODY GEAR VERTICAL TRUNNION SUPPORT. CORROSION BLENDED PER SRM 51-10-01. PERFORMED HFEC OF BLENDED AREA TO INSURE CRACK AND CORROSION FREE. NO CRACKS OR CORROSION. MEASURED BLEND AREAS. FABRICATED FILLERS AND CONTOURED TO FIT THE BLEND OUT AREAS. ALODINED AND PRIME PAINTED FILLERS AND BLENDED AREA. OVERSIZED EXISTING HOLES, REINSTALLED FASTENERS. (M)

Part: FITTING — CORRODED (BS 1480)

DURING INSPECTION FOUND LEFT AND RIGHT BODY GEAR INBOARD TRUNNION SUPPORT FITTINGS CORRODED AT BS 1480 AFT SIDE OF LUG AT LONGERON ATTACH POINT. CLEANED CORROSION, SPOT FACED AFFECTED AREAS, FLAP PEENED, TREATED, PRIME PAINTED. PENETRANT INSPECTION PERFORMED. NO CRACKS FOUND. HFEC INSPECTION PERFORMED. NO CRACKS FOUND. FABRICATED REPLACEMENT HOLE BUSHINGS EQUAL TO THE NEW THICKNESS. FABRICATED FILLER WASHERS TO RETURN TO ORIGINAL THICKNESS. INSTALLED FILLERS AND BUSHINGS. REINSTALLED SERVICEABLE BOLTS AND RESTORED AREA. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING INSPECTION FOUND FRAME WEB CRACKED AT BS 500, STRINGER 9L AND STRINGER 8 TO 10AR. STOP DRILLED ALL CRACKS. FABRICATED REPLACEMENT DOUBLERS. INSTALLED DOUBLER AT STRINGER 9L LOCATION AND AT STRINGER 8 TO 10AR LOCATION PER STANDARD PRACTICES OF THE SRM. (M)

Part: SKIN — CRACKED (BS 1814)

DURING HFEC INSPECTION FOUND THE LOWER AFT CARGO COMPARTMENT DOOR CUTOUT, UPPER FORWARD CORNER SKIN CRACKED AT STATION 1814, STRINGER 27R. CRACK TRIMMED AWAY. FILLER AND REPAIR DOUBLER FABRICATED AND INSTALLED PER STANDARD PRACTICES IAW SRM 53-30-03 FIG 60 TYPE 1. REINSPECTION REQUIRED AFTER INSTALLATION OF REPAIR AT 15000 CYCLES INITIAL AND REPETITIVLY AT 3000 CYCLES THEREAFTER. (M)

Part: FLOORBEAM — CRACKED (FUSELAGE)

DURING INSPECTION FOUND FLOORBEAM WEB CRACKED AT BS 270 NEAR STRINGER 13 BOTH LEFT AND RIGHT SIDE. FASTENERS REMOVED, OPEN HOLE HFEC INSPECTION PERFORMED TO ENSURE NO OTHER CRACKS. NO ADDITIONAL CRACKS FOUND. FABRICATED REPLACEMENT DOUBLERS AND CLIP. INSTALLED PER STANDARD PRACTICES. (M)

Part: WARNING SYSTEM — ACTIVATED (NR 4 ENGINE)

FLT GT051 - MIA/BOG-ATB, NR 4 ENGINE A AND B LOOP FIRE WARNING LIGHTS ILLUMINATED AND BELL SOUNDED. BOTH LOOPS WENT TO 5. AIRCRAFT RETURN TO MIA WAS UNEVENTFUL. MAINTENANCE FOUND CLAMP TO 8TH STAGE DUCT FAILED AND THRUST REVERSER HALVES DAMAGED. REPLACED ALL PARTS AND ENGINE RUN-UP NORMAL. (M)

Part: BOLT — CRACKED (FUSELAGE)

DURING INSPECTION OF LEFT KICK PLATE, AFT FACE CENTER TANK, LOWER SPAR PER SB747-57A2309, TWO BOLTS WERE FOUND SHEARED. ATLAS QC INSISTED ON AND U/T INSPECTION AND DISCOVERED AN ADDITIONAL TWO BOLTS FAILED. FAILED BOLTS REMOVED, HOLES CLEANED, INSPECTED, REINSTALLED NEW INCONEL BOLTS PER SB. ATLAS RECOMMENDS DOING AN U/T INSPECTION REGARDLESS OF THE VISUAL FINDINGS. CURRENT VISUAL INSPECTION PROCEDURES PER SB ARE WEAK AT BEST. (M)

Part: BOLT — CRACKED (FUSELAGE)

DURING INSPECTION OF RIGHT KICK PLATE, AFT FACE CENTER TANK, LOWER SPAR PER SB747-57A2309, ONE NUT WAS FOUND SHEARED. ATLAS QC INSISTED ON AN U/T INSPECTION AND DISCOVERED AN ADDITIONAL TWO BOLT FAILED. FAILED BOLTS REMOVED, HOLES CLEANED, INSPECTED, REINSTALLED NEW INCONEL BOLTS PER SB. NUT REPLACED. ATLAS RECOMMENDS DOING AN U/T INSPECTION REGARDLESS OF THE VISUAL FINDINGS. CURRENT VISUAL INSPECTION PROCEDURES PER SB ARE WEAK AT BEST. (M)

Part: WEB — CORRODED (FUSELAGE)

SPOT CORROSION UNDER FRAME SUPPORT FITTING LEFT WHEEL WELL OUTBOARD FORWARD CORNER, AFT FACE CENTER TANK WEB, STATION 1264 LBL 100. CORROSION REMOVED, AREA MEASURED AND WITHIN LIMITS, SURFACE TREATED AND PAINTED IAW SB 747-57-2263R2 AND SRM 51-40-02 REVE 86. REF KLM 747-2000-024 DATA REPORTING FORM. (M)

Part: TIRE — FAILED (RT MLG)

FLT EK9990 - AMS/DXB - ATB - DURING TAKEOFF ROLL, AIRFRAME VIBRATION OCCURRED AT 160 KNOTS. VIBRATION INCREASED AS AIRSPEED INCREASED. ALL OTHER INDICATION NORMAL. ON CLIMB-OUT, AMS CONTROL ADVISED THAT PIECES OF RUBBER WERE FOUND ON THE RUNWAY. ATLAS AIR OPERATIONS CONTROL CENTER, JFK ADVISED CREW TO RETURN AMS. MAINTENANCE FOUND NR 11 TIRE SEPARATED AND DAMAGE TO WHEEL WELL CONDUIT, TE FLAP RODS, BODY GEAR STEERING MODULE, SEVERAL FAIRING PANELS DAMAGED AND LOWER CHORD CRACKED AT STATION 1480. ALL DAMAGED COMPONENTS/EQUIPMENT REPLACED. ALL SYSTEM NOW OPERATIONAL. (M)

Part: WHEEL — FAILED (LT MLG)

FLT 1871 - BTB - DURING TAXI OUT, CREW REPORTED THAT THEY FELT A BUMP AND HEARD A LOUD BANG. AIRCRAFT STOPPED AND AREA CHECKED. FOUND NR 8 WHEEL RIM BROKE, DAMAGE TO NR 11 RIM, LEFT BODY GEAR DOORS, WIRING CONDUITS AND TRUCK BEAM. PERFORMED FAILED TIRE INSPECTION IAW MM 5-51-34 AND NO FURTHER DAMAGE FOUND. REPLACED BODY GEAR DOOR ASSEMBLIES, CONDUIT, TRUCK AND WHEEL ASSEMBLIES/BRAKES FOR POSITIONS NR 7, 8 AND 11. OPERATIONAL CHECKS SATISFACTORY. (M)

Part: ACTUATOR — DAMAGED (NR 7 SPOILER)

CREW REPORTS: ON MAINTENANCE WALK-A-ROUND CHECK, FOUND RT INBD MID T/E FLAP, AFT T/E FLAP, AND SPOILER NR 7 DAMAGED. FURTHER INVESTIGATION REVEALED THAT NR 7 SPOILER ACTUATOR ALSO DAMAGED. BELIEVE SPOILER FAILURE CAUSED DAMAGE TO T/E FLAPS. SPOILER PANEL PN 65B02310-1 AND SPOILER ACTUATOR PN 1211245-010 REPLACED. RT INBD MID AND AFT T/E FLAPS REPAIRED PER E.O. 4757A032. T/E FLAPS TO BE INSPECTED EVERY 5 CYCLES TO ENSURE SERVICEABILITY. PARTS TO BE REPLACED DURING NEXT A-CHECK (APPROXIMATELY 7-1-97). (X)