N508MC

Part: ENGINE — UNSERVICEABLE (NR) · airframe 102,659 hrs · 19,015 cycles

AFTER TAKEOFF, DURING CLIMB NR 1 ENGINE EXPERIENCED MULTIPLE STALLS. POWER WAS REDUCED, 160,000 POUNDS OF FUEL WERE DUMPED. AIRCRAFT RETURNED TO FIELD AND MADE A SAFE LANDING. ENGINE WAS VISUALLY AND BORESCOPE INSPECTED PER BOEING MM 72-00-00 PAGE 680Q WITH NO FAULTS FOUND. ON GROUND POWER RUN, ENGINE COMPRESSOR STALLED, ENGINE WAS GIVEN A COMPLETE BORESCOPE, TWO 3 INCH CONNECTING CRACKS WITH MISSING MATERIAL WERE FOUND ON THE AIR CLEANER ASSY UTILIZING THE B-3-1 PORT. AIRCRAFT FERRIED TO HKG WHERE THE NR 1 ENGINE WAS REPLACED. AIRCRAFT RETURNED TO SERVICE.

Part: FLAP — DELAMINATED (RT WING) · airframe 102,342 hrs · 18,962 cycles

DURING B-CHECK, RIGHT INBOARD FORE FLAP WAS FOUND WITH DAMAGE, A 42 INCH LONG X 19 INCH WIDE PREVIOUS REPAIR, 45 INCHS FROM OUTBOARD END, DEPARTED FORE FLAP WITH 40% MATERIAL LOSS. ACCOMPLISHED REPAIR PER 747 SRM 51-40-12.

Part: HOUSING — CRACKED (NR 3 ENGINE) · airframe 101,354 hrs · 18,813 cycles

DURING CRUISE, AT 33,400 FEET, NR 3 ENGINE OIL QUANTITY AND OIL PRESSURE DROPPED RAPIDLY TOWARDS -0- PERFORMED PRECAUTIONARY SHUTDOWN. FLIGHT CONTINUED TO DESTINATION AND MADE A SAFE LANDING. INVESTIGATION REVEALED RADIAL DRIVE LEAKING, REPLACED RADIAL DRIVESHAFT HOUSING ASSY IAW 747MM 72-61-01 PG 401, 72-03-03 PG 401, 72-61-04, CW B747 FIM 79-01-00 PG 237 XQ. RUN AND LEAK CHECK SATISFACTORY. AIRCRAFT RETURNED TO SERVICE.

Part: CIRCUIT CARD — LOOSE (FIRE WARNING) · airframe 100,188 hrs · 18,631 cycles

CREW REPORTED ON ENGINE START, NR 4 ENGINE -B- LOOP HAD INTERMITTANT WARNING. NR 4 ENGINE -A- LOOP ON MEL. RESEATED FIRE WARNING CARD, OPS NORMAL PER 26-12-00.

Part: ACTUATOR — CRACKED (FLT CONTROLS) · airframe 100,103 hrs · 18,613 cycles

CREW REPORTED DURING CRUISE, NR 1 HYDRAULIC SYSTEM LOST ABOUT 1 GALLON IN 1 HOUR. TURNED ADP OFF AND EDP TO DEPR PER CHECKLIST. FOUND LEFT CCA LEAKING. REPLACED LEFT CCA IAW AMM 27-61-08. CHECKED FOUND ALL WORKING. ADDED HYDRAULIC FLUID TO SYSTEM NR 1 IAW 12-12-01.

Part: RELIEF VALVE — FAILED (NR 2 NACELLE) · airframe 100,032 hrs · 18,599 cycles

CREW REPORTED ON CLIMB, NR 2 ENGINE NACELLE TEMP WENT TO 9.0. AFTER RETARDING THROTTLES, TEMP STABILIZED. REPLACED NR 2 ENGINE RELIEF VALVE; APPARENT SPRING FAILURE. OPS NORMAL.

Part: METERING TUBE — LEAKING (NR 1 ENGINE) · airframe 99,208 hrs · 18,421 cycles

NR1 ENGINE FUEL LEAK AT FUEL METERING UNIT VBV ROD END TUBE. VBV ACTUATOR FUEL TUBE REPLACED AT FUEL CONTROL AND PERFORMED ENGINE RUN AND LEAK CHECK IAW MM 73-21-01.

Part: COUPLER — DEFECTIVE (COMPASS) · airframe 98,984 hrs · 18,378 cycles

FO'S HEADING, FLIGHT DIRECTOR, AND BOTH VOR FLAGS IN RMI CAME INTO VIEW WITH HEADING FLAG IN HSI. REMOVED AND REPLACED NR 2 COMPASS COUPLER IAW AMM 34-21-00.

Part: RUDDER — OUT OF POSITION · airframe 98,962 hrs · 18,375 cycles

CREW REPORTED LOWER RUDDER OFF TO LEFT 3 DEGREES WITH UPPER RUDDER NEUTRAL. CLEANED PLUG ON SURFACE POSITION INDICATOR, CYCLED RUDDER, ALL OPS AND INDICATIONS NORMAL IAW MM.

Part: CHECK VALVE — FAILED (NR 3 ENGINE) · airframe 98,579 hrs · 18,300 cycles

AT FL 37.0 NR 3 ENGINE COMPRESSOR STALLED, ALL PARAMETERS NORMAL. OPS OK AT LOWER ALTITUDE. BORESCOPE PER MM 72-00-00 PG 680P, NO FINDINGS. FOUND 8TH STAGE CHECK VALVE FAILED. REPLACED SAME, OPS NORMAL PER 36-11-02.

Part: ENGINE — FAILED (NR 1) · airframe 97,728 hrs · 18,118 cycles

AFTER TAKEOFF NR 1 ENGINE FAILED. SHUT DOWN ENGINE AND JETTISON FUEL IAW CHECK LIST. AFTER SHUT DOWN OIL PRESSURE ZERO. NR 1 ENGINE REPLACED PER ENGINE CHANGE FORM 00-AA-45. RUN UP OK PER MM 71-00-00 TEST NR 3, 8 AND 9.

Part: PANEL — BROKEN (WING) · airframe 97,637 hrs · 18,099 cycles

NR 22 LEADING EDGE PANEL BROKEN. REPLACED NR 22 LEADING EDGE PANEL, 2 ROTARY ACTUATORS AND TORQUE TUBE. RIGGED AND OPS CHECK PER MM 27-81-00.

Part: TORQUE TUBE — DAMAGED (WING LE) · airframe 97,637 hrs · 18,099 cycles

NR 22 LEADING EDGE PANEL BROKEN. REPLACED NR 22 LEADING EDGE PANEL, 2 ROTARY ACTUATORS AND TORQUE TUBE. RIGGED AND OPS CHECK PER MM 27-81-00.

Part: ACTUATOR — FAILED (L/E DEVICES) · airframe 97,637 hrs · 18,099 cycles

NR 22 LEADING EDGE PANEL BROKEN. REPLACED NR 22 LEADING EDGE PANEL, 2 ROTARY ACTUATORS AND TORQUE TUBE. RIGGED AND OPS CHECK IAW MM 27-81-00.

Part: WHEEL — FAILED (MLG) · airframe 97,565 hrs · 18,083 cycles

CREW REPORTED HEARING TWO LOUD BANGS AFTER TAKEOFF. FOUND NR 8 TIRE BLOWN AND PANEL 193E MISSING. REPLACED NR 7 & 8 WHEEL ASSY'S.

Part: BULKHEAD — CRACKED (FUSELAGE) · airframe 97,548 hrs · 18,080 cycles

BS 1241 LEFT SIDE CANTED BULKHEAD HAS CRACK IN WEB AREA ABOVE BULKHEAD FITTING. ACCOMPLISHED REPAIR PER BOEING INSTRUCTIONS 1-1I9Y5F AND FAA FORM 8100-9.

Part: SKIN — CRACKED (NR 4 PYLON) · airframe 97,548 hrs · 18,080 cycles

NR 4 PYLON INBOARD ACCESS PANEL CUTOUT AT NAC STATION 275-295 CRACKED AT EDGE. ACCOMPLISHED REPAIR PER BOEING INSTRUCTIONS 1-1HGUJB AND FAA FORM 8100-3.

Part: STIFFENER — CRACKED (NR 4 DOOR) · airframe 97,548 hrs · 18,080 cycles

NR 4R DOOR INTERNAL STIFFENER JUST FORWARD OF WINDOW CUT-OUT FOUND CRACKED. ACCOMPLISHED REPAIR PER BOEING 1-1I26OS AND FAA FORM 8100-3.

Part: STRUCTURE — CRACKED (NLG WW) · airframe 97,548 hrs · 18,080 cycles

NOSE GEAR WHEEL BOX STRUCTURE FOUND SEVERAL CRACKS AT STATION 320L BETWEEN WL 140 AND 150, AT STATION 300R BETWEEN WL 170 AND 180, AT STATION 300L AT WL 175. ACCOMPLISHED INTERIM REPAIR PER BOEING INSTRUCTIONS SEP-SIN-05-00574C AND 1-1HZQME AND FAA FORM 8100-9.

Part: SKIN — WORN (NR 2 PYLON) · airframe 97,548 hrs · 18,080 cycles

NR 2 PYLON INBOARD ACCESS PANEL CUTOUT AT NAC STATION 280-300 WORN AT EDGE. ACCOMPLISHED REPAIR PER BOEING INSTRUCTIONS 1-1IO8DO AND FAA FORM 8100-3.

Part: SKIN — CRACKED (NR 2 PYLON) · airframe 97,548 hrs · 18,080 cycles

NR 2, 3 AND 4 PYLON PRECOOLER CUTOUT CRACKED AT AFT LOWER CORNER. ACCOMPLISHED REPAIR PER BOEING INSTRUCTIONS 1-1I08HV AND FAA FORM 8100-3.

Part: SKIN — CHAFED (LT ELEVATOR) · airframe 97,548 hrs · 18,080 cycles

LEFT INBOARD ELEVATOR TOP LEADING EDGE SKIN FOUND CHAFED. ACCOMPLISHED REPAIR PER BOEING INSTRUCTIONS 1-1HR8MP AND FAA FORM 8100-9.

Part: SKIN — DEFORMED (DORSAL FIN) · airframe 97,548 hrs · 18,080 cycles

DORSAL FIN FOUND WITH DEFECTS DEFORMED AT TOP EDGE. ACCOMPLISHED REPAIR PER BOEING INSTRUCTIONS 1-1I9VRK AND FAA FORM 8100-3.

Part: CLAMP — LOOSE (NR 2 HIGH STAGE) · airframe 97,533 hrs · 18,077 cycles

ON TAKEOFF GROUND ROLL & SETTING TAKEOFF THRUST AT 105.4 DEGREES. SET ROLLING APPROXIMATELY 90 KNOTS. NR 2 ENGINE FIRE LIGHT CAME ON, ABORTED TAKEOFF WITH THROTTLES BACK AT IDLE & SHUT DOWN NR 2 ENGINE. BOTH A & B LOOPS READING 8 UNITS. BRAKE TEMPS ALL GREEN. FOUND NR 2 HIGH STAGE VALVE CLAMP LOOSE. RESEATED & RETORQUED CLAMP PER MM 36-11-05. ACCOMPLISHED DUCT LEAK CHECK PER MM 05-51-30, NO LEAKS. ACCOMPLISHED HIGH ENERGY STOP PER 05-51-10.

Part: SHUTOFF VALVE — FAILED (NR 1 ENGINE) · airframe 97,497 hrs · 18,069 cycles

DURING CLIMBOUT, NR 1 ENGINE NACELLE LOOPS A & B WENT INTO RED, SET WARNING BELLS OFF. ENGINE SHUTDOWN. OIL PRESSURE 45 PSI. REPLACED NR 1 ENGINE HIGH PRESSURE SHUTOFF VALVE PER MM 36-11-05. LEAK CHECK OIL, OPS CHECK NORMAL ON HIGH POWER RUN UP PER MM 71-00-00 TEST NR 4. ENGINE FIRE WARNING NORMAL DURING ALL PARAMETERS.

Part: REGULATOR VALVE — MALFUNCTIONED (NR 1 ENGINE) · airframe 97,490 hrs · 18,068 cycles

DURING CLIMBOUT NR 1 ENGINE NACELLE LOOPS A & B WENT INTO THE RED - SET BELL OFF - ENGINE SHUT DOWN OIL PRESSURE 45 PSI. REPLACED ENGINE PRESSURE REGULATING VALVE, LEAK CHECK OK. OPS CHECKED OK DURING ENGINE HIGH POWER ASSURANCE RUN, MM 36-11-19 & MM 36-11-00 AND TESTED PER MM 71-00-00 TEST NR 4.

Part: ENGINE — STALLED (NR 3) · airframe 96,837 hrs · 17,937 cycles

DURING CRUISE AT FL 310, NR 3 ENGINE COMPRESSOR STALLED, EGT WENT TO 500 DEGREES, N1 50 PERCENT, N2 40 PERCENT. PERFORMED RESTART THE ENGINE WOULD NOT START PAST 30 PERCENT N1, 40 PERCENT N2, WITH EGT AT 625 DEGREES & F/F AT 400 PPH. THROTTLE MOVEMENT HAD NO EFFECT. ENGINE SHUT DOWN. REMOVED AND REPLACED NR 3 ENGINE PER MM 71-00-02. PERFORMED ENGINE RUN PER 71-00-00. ALL PARAMETERS & INDICATION NORMAL.

Part: LINK — MISSING (BLOCKER DOOR) · airframe 96,457 hrs · 17,859 cycles

NR 4 ENGINE T/R BLOCKER DOOR LINK MISSING AT 4 O'CLOCK POSITION. REMOVED BLOCKER DOOR AND BROKEN LINK PER CDL 78-31-1. T/R LOCKED OUT PER DDPG 78-1.

Part: REGULATOR VALVE — FAILED (NR 2 ENGINE) · airframe 96,457 hrs · 17,856 cycles

ON TAXI OUT DUCT LOW PRESS LIGHT CAME ON WITH DROP IN DUCT PRESSURE ON GAGE. ISOLATED LEFT WING PRESS LESS THAN 15 PSI. REPLACED PRESSURE REGULATOR VALVE ON ENGINE NR 2 PER MM 36-1114. PERFORMED ENGINE RUN PER MM 71-00-00. OPS CHECK OK.

Part: WIRE — CHAFED (BLEED VALVE) · airframe 95,673 hrs · 17,689 cycles

NR 3 ENGINE BLEED VALVE CLOSED, LIGHT STAYS ON AT CRUISE PWR & POPPED C/B AT LANDING. REPAIRED CHAFED WIRE PYLON TO HIGH STAGE BLEED VALVE PER WPM CH 20-10-13, OPERATIONAL CHECK OK.

Part: TRANSDUCER — FAILED (ANTI SKID SYS) · airframe 95,026 hrs · 17,551 cycles

AUTO BRAKES INOP. REPLACED ANTI-SKID TRANSDUCER NR 3 POSITION, SPIN CHECK NORMAL (NO LIGHT ILLUMINATE PER MM 32-43-00).

Part: CONNECTOR — LOOSE (RUDDER CONTROL) · airframe 94,992 hrs · 17,544 cycles

RUDDER RATIO LIGHT CAME ON DURING CLIMBOUT, 220KTS, FLAPS 1 DEGREE. RESEATED CONNECTOR TO RUDDER RATIO CONTROLLER AND SERVO ACTUATOR IAW AMM 27-21-00..

Part: COMPARATOR — INOPERATIVE (RUDDER) · airframe 94,952 hrs · 17,536 cycles

RUDDER RATIO LIGHT CAME ON AFTER TAKEOFF. REMOVED AND REPLACED RUDDER RATIO COMPARATOR.

Part: PRESSURE VALVE — INOPERATIVE (NR 3 ENGINE) · airframe 94,905 hrs · 17,527 cycles

DURING ENGINE START NR 3 ENGINE ROTATION WAS SLOW, LIGHT OFF NORMAL BUT WOULD NOT ACCELERATE PAST 30 PERCENT. REPLACED NR 3 ENGINE PRESSURE RELIEF VALVE, OPERATIONAL CHECK GOOD IAW MM 36-11-00.

Part: CHARGER — SMOKE (MAIN BATTERY) · airframe 950,821 hrs · 17,562 cycles

SMOKE IN COCKPIT. MAIN BATTERY CHARGER FAULTY. SWAPPED MAIN CHARGER WITH APU CHARGER, OPS CHECK OK PER AMM 24-31-00. DEFERRED APU BATTERY CHARGER PER MEL 24-24.

Part: INDICATOR — INOPERATIVE (AIRSPEED) · airframe 94,611 hrs · 17,467 cycles

FLIGHT OFFICER AIRSPEED INDICATOR INOPERATIVE, NO MOVEMENT. REPLACED INDICATOR OPS CHECK OK, IAW MM 34-17-03.

Part: VALVE — FAILED (HIGH STAGE) · airframe 94,505 hrs · 17,446 cycles

NR 3 ENGINE FIRE WARNING CAME ON DURING CLIMB, A & B LOOPS READ 7 TO 10 UNITS, THAN STABILIZED TO 4 UNITS SCALE WHEN THROTTLE MOVED TO IDLE. FOUND NR 3 ENGINE HIGH-STAGE BLEED VALVE LEAK. REMOVED AND REPLACED NR 3 ENGINE HIGH STAGE BLEED VALVE AS PER MM 36-11-03. NO LEAKS.

Part: LINE — LOOSE (NR 3 BRAKE) · airframe 94,161 hrs · 17,379 cycles

NR 3 BRAKE LEAK, FOUND ON PRE-FLIGHT. TIGHTENED NR 3 BRAKE LINES AS PER MM 32-41-03, LEAK CHECK OK.

Part: WIRE — BROKEN (ELEVATOR) · airframe 86,091 hrs · 18,886 cycles

ON ENGINE START, ELEVATOR FEELS LIGHT. DID NOT COME ON WITH HYD SYST NR 2 PRESSURIZED AND SYST 3 UNPRESSURIZED. FOUND BROKEN WIRE AT MISOI, REPAIRED IAW 20-10-13. PERFORMED SYST CHECK PER 27-31-00, SYST OPS NORMALLY.

Part: LOGIC CARD — DAMAGED (MLG)

TLV/AMS - ON CALL BEFORE LANDING CHECK, GEAR INDICAT DOWN, INTERMITTENT BEEPING WAS HEARD. GEAR LIGHT WENT RED. PRIMARY AND ALTERNATE CHECK SHOWED RIGHT BODY AND RIGHT WING GEAR NO DOWN. CREW INITIATED GO AROUND, LEFT GEAR DOWN AND LEVEL OFF GEAR LIGHT WENT GREEN AND CHECKED IN BOTH ALTERNATE AND PRIMARY. CONFIGURED FLAPS FOR LANDING 2ND TIME AND HAD ALL GREEN. GEAR WENT RED AGAIN BUT INDICATED GEAR DOWN IN PRIMARY. ALTERNATE SHOWED RIGHT BODY GEAR AND RIGHT WING GEAR NOT DOWN. INDICATION FINALLY SETTLED WITH RIGHT WING NO DOWN IN ALTERNATE POSITION. REMOVED AND REPLCED BOTH PRIMARY AND ALTERNATE LOGIC (P/N 65B4750867) BOXES IAW AMM 31-61-14. OPERATION CHECK ALL NORMAL. (M)

Part: ENGINE — STALLED (NR 1)

DOV/RMS DIVERSION TO JFK, IN CRUISE AT FL350 NR 1 ENGINE BEGAN TO SHUDDER/STALL WITH DROP OF N1 ONLY. PULLED THRUST LEVER BACK. IT THEN DID IT AGAIN AND CONTINUED TO DO IT. SHUT DOWN ENGINE IAW QRH. DIVERTED TO JFK. NO FUEL DUMPED. REMOVED AND REPLACED NR 1 ENGINE PER ATLAS AIR TASK CARD 01-AA-45. ACCOMPLISHED GROUND RUN UP TESTES 3, 4 AND 8 PER MM 71-00-00. OPS AND LEAK CHECK NORMAL. NO DEFECTS NOTED. CLOSED AND SECURED ALL PANELS, COWLINGS AND FAIRINGS. ENGINE S/N ON 517265. (M)

Part: ENGINE — MALFUNCTIONED (NR 3)

DURING TAKEOFF NR 3 ENGINE HAD EXCEEDANCE OF PEAK TEMPERTURE OF 994 DEGREES FOR A 91 SECOND DURATION. THRUST LEVER WAS RELATIVE TO THE SAME POSITION AS OTHERS. TAKEOFF N1 WAS 113.5 DUE TO EXCEEDING 990 DEGREES THE ENGNE WAS SHUT DOWN. APPROXIMATELY 23,000 KGS OF FUEL DUMPED EN ROUTE TO AMS. EGT OVERTEMP ALREADY ON DMI N03-029. PERFORMED VISUAL INSPECTION IAW MM 72-00-00 PAGE 680 FV. OPENED ENGINE COWLS AND VISUALLY INSPECTED COOLING DUCT ETC. ALL SATISFACTORY. ENGINE TO BE REPLACED AT JFK 7/12/03. REMOVED AND REPLACED NR 3 ENGINE PER ATLAS FORM 01-AA-45 AND ACCOMPLISHED ENGINE RUNS PER MM 71-00-00, TEST 1, 3, 8 AND 4. NIL LEAKS NOTED. (M)

Part: DUCT — RUPTURED (NR 1 ENGINE)

JFK-ORD - AIR TURNBACK, AT 10,000 FEET WITH CRUISE POWER, LOUD BANG AND BUMP. NR 1 ENGINE EGT CLIMBED TO 850 DEGREES AND NACELLE TEMPS TO 4.5 BLEED VALVE CLOSED. EGT CONTINUED ABOUT 100 DEGREES ABOVE OTHER ENGINES. SAW T/R BLOW-OUT PANEL OPEN. RETURNED TO JFK. NO FUEL DUMPED. FOUND INTERMEDIATE CHECK VALVE, Y-DUCT AND ELBOW FAILED. REPLACED CHECK VALVE PER MM 36-11-02. REPLACED DUCT ASSEMBLY P/N 65B94819-2 PER MM 36-11-01. LEAK CHECK OK. REPLACED MANIFOLD P/N 1756M94603 PER MM 36-11-00. REPLACED TUBE ASSEMBLY 9057M85G02 PER MM 36-11-00. OPS AND LEAK CHECK OK. (M)

Part: SKIN — DAMAGED (NR 3 PYLON)

DURING CURRENT C CHECK AT SIAEC FOUND NR 3 PYLON OUTBOARD SIDE LOWER AFT ACCESS PLATE CUTOUT DAMAGED ON RETAINING LIP, NAC 286 ABOVE WL 136. SKIN AND DOUBLER WERE TRIMMED TO REMOVE DAMAGE. HFEC INSPECTED AREA OF REMOVED DAMAGE. NO ADDITIONAL CRACKING FOUND. FABRICATED FILLER AND REPAIR DOUBLERS. REPAIR DOUBLERS AND FILLER WERE INSTALLED IAW SRM.

Part: MODULE — FAULTY (CONTROL MODULE)

IN CRUISE, FL 290 MAIN DECK CARGO FIRE WARN LTS ILLUM STEADY. EMER ACTION AND LANDING CARRIED OUT. FUEL JETTISONED IAW CHECKLIST. MAIN DECK CARGO SMOKE DET LTS ILLUMINATED STEADY ON DESCENT, WENT OUT AND CAME ON INTERMITTENTLY THROUGHOUT DESCENT UNTIL THEY REMAINED OUT AFTER 10,000 FEET. DIVERTED, FUEL DUMPED +/- 40.8 TONS. C/A: MAIN DECK CARGO FIRE DETECTION A AND B CONDITION CHECKED OK. FLIGHT, DPS/MEL ITEM REPEATED ON DESCENT. MAIN DECK CNTRL PANEL CHECKED AND TESTED OK. ALL SMOKE DETECTORS ON MAIN DECK CHECKED, OK. FIRE WARNING LIGHTS ILLUM ON TAXI IN. UNABLE TO DUP DEFECT ON GROUND REPLACED CONTROL MODULE IAW MM AS PRECAUTION. ALL SMOKE DETECTORS ON MAIN DECK CHECKED AND SYS TESTED OK IAW MM.

Part: SKIN — WORN (PYLON) · airframe 88,570 hrs · 16,251 cycles

DURING CURRENT (C) CHECK, INSPECTION OF NR 3 PYLON ACCESS PLATE (473AR) CUTOUT, FOUND HEAVY WEAR AT ONE OF THE LATCH POSITIONS. WEAR AREA TRIMMED AWAY FROM SKIN AND DOUBLER. DOOR ACCESS SIZE INCREASED ON RETAINING LIP. FABRICATED REPAIR DOUBLER AND FILLERS. ALL HOLES AND ACCESS CUTOUT NDT INSPECTED FOR CRACKS. NO CRACKS FOUND. SKIN AND REAIR FILLERS BONDED TO EXISTING STRUCTURE PER SRM. NR 1 FASTENERS INSTALLED IAW SRM. AREA SEALED IAW SRM WITH BMS SEALANT.

Part: CONNECTOR — DIRTY (FIRE LOOP)

AIR TURN BACK-AT TOP OF CLIMB ALL MAIN DECK FIRE WARNING LIGHTS ("A" AND "B" LOOPS) ILLUMINATED AT THE SAME TIME. AFTER 4 MINUTES ALL LIGHTS EXTINGUISHED SIMULTANEOUSLY. LOAD MASTER WENT DOWN TO THE MAIN DECK AND VERIFIED THAT NO FIRE WAS PRESENT. CREW DECIDED TO RETURN TO RMS. SYSTEM WAS TROUBLESHOT PER WDM. CLEANED CONNECTORS ON TEST PANEL, CHECKED CONNECTOR ON NR 1 A & B SMOKE DETECTOR. CHECKED CONNECTORS FOR CLEANLINESS AND FOUND OK. SYSTEM TEST NORMAL. AIRCRAFT OK FOR SERVICE.

Part: COMPUTER — FAULTY (AUTOPILOT SYS)

AIT TURNBACK, DURING CLIMB-OUT FROM JFK EN ROUTE TO MIA LOWER RUDDER DEFLECTION 5 DEGREES LEFT TO 3 DEGREES RIGHT CONTINUOUSLY. RETURNED TO JFK. DEFLECTIONS CONTINUED DURING DESCENT AND APPROACH. MAINTENANCE USED PITOT STATIC TEST EQUIPMENT TO FIND FAULT. IT WAS DETERMINED THAT THE YAW DAMPER COMPUTER WAS AT FAULT. REMOVED AND REPLACED THE LOWER RUDDER YAW DAMPER COMPUTER AND OPS CHECKED NORMAL PER MM 22-16-00. (M)

Part: FRAME — CRACKED (BS 280)

DURIN HFEC INSPECTION PER AD 96-26-04 REFERENCE SB 747-53A2293 FOUND FRAME STATION 280 LEFT CRACKED AT TWO PLACES. EACH CRACK WAS APPROXIATELY .250 INCH LONG, ONE EMINATING FROM AN INSULATION BLANKET STUD MOUNTING HOLE, THE OTHER FROM A GUSSET FASTENER HOLE TO END OF FRAME. REMOVED FRAME AND CRACKED GUSSET ANGLE. FABRICATED REPLACEMENT GUSSET ANGLE PER BOEING DRAWING 65B07942, TREATED AND PRIME PAINTED PER SRM 51-10-02. REPLACED FRAME WITH P/N 65B07942-335 AND GUSSET ANGLE PER SB 747-53A2293 IAW SRM 51-30-02. (M)

Part: FRAME — CRACKED (BS 320)

DURING HFEC INSPECTION PER AD 96-26-04 REFERENCES SB 747-53A2293 FOUND FRAME STATION 320 RIGHT CRACKED AT AN INSULATION BLANKET STUD MOUNTING HOLE. REMOVED FRAME. REPLACED FRAME WITH P/N 65B07942-564 PER SB 747-53A2293 IAW SRM 51-30-02. (M)

Part: FRAME — DAMAGED (FUSELAGE)

UPON REMOVAL OF FRAME SPLICE DOUBLER IAW SB747-53A-2272, FOUND ELONGATED HOLES IN FRAME WEB AT BS 300 RIGHT, JUST ABOVE STRINGER 14R BETWEEN RBL 60 AND RBL 70. TRIMMED OUT EXISTING WEB IN AREA OF ELONGATED HOLES. MANUFACTURED FILLER, REPAIR DOUBLERS AND SPLICES. INSTALLED PER STANDARD PRACTICES. (M)

Part: SKIN — CRACKED (FUSELAGE)

DURING INSPECTION OF AFT LOWER LOBE CARGO DOOR CUTOUT, A CRACK WAS DISCOVERED AT THE UPPER FORWARD CORNER, STATION 1814 APPROX 1.3 INCH. TRIMMED OUT CRACK, MANUFACTURED FILLER AND EXTERNAL DOUBLER FROM .063 2024T3 ALUMINUM. INSTALLED PER SRM 53-30-03. (M)

Part: FRAME — MISDRILLED (FUSELAGE)

DURING INSPECTION OF THE NOSE WHEEL FRAME STATIONS, FOUND NINE HOLES ON FRAME WEB BS 300 L/S SHORT EDGE DISTANCE. TRIMMED AWAY AFFECTED AREA. MANUFACTURED FILLERS, REPAIR STRAPS AND DOUBLERS. INSTALLED PER SRM 53-10-04. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING ACCOMPLISHMENT OF SB 747-53-2272 FOUND ONE CRACKED HOLE BS 380 R/S AT STRINGER 14R. STOP DRILLED CRACK, INSTALLED REPAIR DOUBLER PER STANDARD PRACTICES IN A NON-MANDATORY ZONE. AMOC APPROVED PER PAR 9 OF AD 91-11-01. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING ACCOMPLISHMENT OF SB 747-53-2272 FOUND ONE CRACKED HOLE BS 360 LEFT ABOVE STRINGER 15L. STOP DRILLED CRACK, INSTALLED REPAIR DOUBLERS PER STANDARD PRACTICES IN A NON-MANDATORY ZONE. AMOC APPROVED PER PAR (9) OF AD 91-11-01. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING ACCOMPLISHEMENT OF SB 747-53-2272 FOUND TWO CRACKED HOLE BS 360 R/S AT STRINGER 14R AND STRINGER 15R. STOP DRILLED CRACK, INSTALLED REPAIR DOUBLERS PER STANDARD PRACTICES IN A NON-MANDATORY ZONE. AMOC APPROVED PER PAR 9 OF AD 91-11-01. (M)

Part: FITTING — INTERFERENCE (BS 1480)

DURING ROUTINE IMPLEMENTATION OF SB 747-53A2390, FASTENER INTERFERENCE OCCURRED AT THE NR 7 AND NR 8 HOLES IN BOTH THE LEFT AND RIGHT SPLICE AREAS. THE NUTS IN THE SUBJECT AREA INTERFERE WITH THE FLANGE OF THE SPLICE FITTINGS ABOVE THE FASTENER HOLES. RESOLVED INTERFERENCE BY ENLARGING HOLES TO 05781 INCHES, INSTALLED BUSHINGS AND SMALLER DIAMETER BOLTS PER BOEING TELEX NR TLS-AMS-99-0087TE; TLS-AMS-99-0017H; TLS-AMS-99-0089TE, AND IAW KLM DATA FAX 99-87. FORM 8110-3 ISSUED. (X)

Part: BEAM — CRACKED (WING)

DURING ROUTINE INSPECTION OF THE WING TRAILING EDGE AREA, FOUND THE UPPER CHORD SUPPORT BEAM CRACKED IN THE VICINITY OF THE LINK ASSEMBLY. MADE PERMANENT REPAIR BY SPLICING IN A REPLACEMENT SECTION IAW KLM ENGINEERING AND MAINTENANCE REPORT NR 1H105453 AND BOEING TELEX NR TLS-AMS-99-0085TE. FORM 8110-3 ISSUED. (X)

Part: TEE CHORD — CRACKED (NR 1 PYLON)

DURING ROUTINE INSPECTION OF NR 1 AND NR 4 PYLONS, CRACKS WERE DISCOVERED IN THE RT UPPER TEE CHORD, FORWARD HORIZONTAL FLANGE, NACELLE STA 270. CRACK LENGTH IN NR 1 PYLON WAS 2.25 INCHES, NR 4 PYLON WAS 1.25 INCHES. REPAIRS ACCOMPLISHED IAW KLM DATA FAX 99-088 AND BOEING TELEX NR TLS-AMS-99-0091TE; TLS-AMS-99-00021H; IN ADDITION TO SB 747-54-2125, AND DLM ENGINEERING AND MAINTENANCE REPORT NR KLM 990714. FORM 8110-3 ISSUED. REF: OPER CNTRL NR 99ZZZX3052. (X)

Part: TEE CHORD — CRACKED (NR 4 PYLON)

DURING ROUTINE INSPECTION OF NR 1 AND NR 4 PYLONS, CRACKS WERE DISCOVERED IN THE RT UPPER TEE CHORD, FORWARD HORIZONTAL FLANGE, NACELLE STA 270. CRACK LENGTH IN NR 1 PYLON WAS 2.25 INCHES, NR 4 PYLON WAS 1.25 INCHES. REPAIRS ACCOMPLISHED IAW KLM DATA FAX 99-088 AND BOEING TELEX NR TLS-AMS-99-0091TE; TLS-AMS-99-00021H; IN ADDITION TO SB 747-54-2125, AND DLM ENGINEERING AND MAINTENANCE REPORT NR KLM 990714. FORM 8110-3 ISSUED. REF: OPER CNTRL NR UIEA99059.

Part: WIRE — CHAFED (MLG WW)

FLT CI 346 - DURING COCKPIT PREFLIGHT CHECKS, WHEN MASTER DIM AND TEST SWITCH PLACED TO 'TEST' POSITION, CIRCUIT BREAKER NR 152 POPPED AND SMOKED. TROUBLESHOT SYSTEM AND FOUND WIRING CHAFING IN OVERHEAD P5 PANEL GOING TO 'WHEEL WELL FIRE DETECTION MODULE'. REPAIRED WIRING AND MASTER DIM AND TEST SYSTEM OPERATION NORMAL. (M)

Part: SMOKE DETECTOR — MALFUNTIONED (NR 4)

FLT CI328 - MAIN DECK SMOKE DETECTOR (NR 1) RED WARNING LIGHT ILLUMINATED AND BELL SOUNDED AND NR 4 SMOKE DETECTOR (A) LIGHT INTERMITTENTLY FLASHED A FEW TIMES DURING THE FIRST THREE HOURS OF FLIGHT. THEY CAN ON AT THE SAME TIME AND WERE ONLY ON FOR A SHORT PERIOD OF TIME. OPERATIONAL CHECK OF SYSTEM REVEALED NO ABNORMALITIES. (M)

Part: SMOKE DETECTOR — DEFECTIVE (CARGO COMPT)

FLT CI326 - MAIN DECK SMOKE DETECTOR SECTION 1 GAVE TOW MOMENTARY FIRE WARNINGS. INSPECTED MAIN DECK AND DETERMINED WARNING TO BE FALSE. MAIN SMOKE DETECTOR REPLACED. OPERATIONAL CHECK NORMAL. (M)

Part: LINE — LEAKING (HYDRAULIC SYSTEM)

FLT C1353 - ATL/ANC - DIVERTED TO JFK DUE NR 1 HYDRAULIC SYSTEM STARTED TO LOSE FLUID VERY SLOWLY IN FLIGHT. USED ABNORMAL CHECKLIST PROCEDURE AND SYSTEM STILL LOST FLUID VERY SLOWLY. WITH ADP OFF AND EDP IN SUPPLY OFF, SYSTEM IS COMPLETELY EMPTY. HAD TO EXTEND GEAR AND TE FLAP WITH ALT SYSTEMS. LANDING WAS UNEVENTFUL. FOUND NR 1 HYD SYSTEM RETURN LINE FROM PRESSURE BULKHEAD (TAIL COMPT), LEAKING (REF IPC 29-11-16, FIG 1, ITEM 423). REPAIRED LINE PER MM 20-11-05. SERVICED NR 1 HYD SYSTEM AND PERFORMED LEAK CHECK AND BLED SYSTEM. NO LEAKS FOUND. SYSTEM OPERATION NOW NORMAL. (M)

Part: CAM — BROKEN (PAX DOOR)

FLT 1327 - ATB - ANC - AFTER TAEKOFF, DOOR OPEN L-1 LIGHT CAME ON. AIRCRAFT DEPRESSURIZATION CHECKLIST COMPLETED. ABORTED FLIGHT, FUEL DUMP CHECKLIST COMPLETED. LANDING UNEVENTFUL. AFTER LANDING, MAINTENANCE FOUND UPPER AFT CRANK ROLLER CAM BROKEN ON L1 MAIN ENTRY DOOR. EO 4752A017 ISSUED FOR ONE TIME FLIGHT FROM ANC TO TPE. TPE MAINTENANCE REPLACED L1 MAIN ENTRY DOOR UPPER AFT CRANK ROLLER CAM ASSY. DOOR OPERATIONAL CHECKS PER MM 52-11-07 NORMAL. (M)

Part: DRIVE MOTOR — SEIZED (TE FLAPS)

CREW REPORTS: DURING FLAP RETRACTION AFTER TAKEOFF, OUTBOARD TRAILING EDGE FLAPS SLOWED APPROACHING 4 DEGREES AND STALLED COMPLETELY AT 2 DEGREES. INBOARD FLAPS OPERATED NORMALLY. OUTBOARD FLAPS FAILED TO OPERATE IN EITHER NORMAL OR ALTERNATE MODES. ACCOMPLISHED SPLIT FLAP LANDING AT TPE AFTER JETTISONING 81.6 KGS FUEL 40NM N.E.APG VOR, LANDING G.W.285.0 KGS. MAINTENANCE FOUND OUTBOARD T.E. FLAP ALTERNATE DRIVE MOTOR SEIZED. REPLACED MOTOR ASSEMBLY. FLAP OPERATION NOW NORMAL. (X)

Part: START VALVE — LEAKING (NR 4 ENGINE)

FLT CI314 - 7PE-ANG - NR 4 ENGINE SHUTDOWN AND AIR TURN BACK TO TAIPEI, DUE TO HIGH NACELLE TEMP. FOUND START VALVE DIAPHRAGM LEAK AND 'A' LOOP WIRE RUBBING HORIZONTAL FIREWALL. REPLACED VALVE AND PERFORMED HIGH POWR RUN OPS OK. (M)

Part: SCAVENGE PUMP — FAILED (NR 1 ENGINE)

BANKOK/TAIPEI, CI346/07 - EN ROUTE, INCURRED NR 1 ENGINE SHUT DOWN IN FLIGHT-DESCENT PHASE FOR LOSS OF OIL PRESSURE AND N2 RPM. ON ARRIVAL, CHECKED MAIN OIL SCREEN AND CHIP DETECTORS ALL OK. FOUND LUBE AND OIL SCAVENGE PUMP DRIVE SHAFT SHEARED. DRAINED ENGINE OIL, REPLACED SCAVENGE PUMP, SERVICED ENGINE. ENGINE RUN-UP, OPS CHECK OK. (X)

Part: FUEL PUMP — MALFUNCTIONED (NR 2 ENGINE)

AIRCRAFT EXPERIENCED FLAME OUT NR 2 ENGINE TWO HOURS OUT OF ANCHORAGE. PER CREW ALL PARAMETERS DROPPED OFF AND ENGINE SHUT DOWN. ATTEMPTED RESTART UNSUCESSFUL. RETURNED TO ANCHORAGE WITH UNEVENTFUL LANDING. ACCOMPLISH AIRCRAFT HARD LANDING INSPECTION MM 5-51-05 AND ENGINE TROUBLESHOOTING MM 71-00-42. REPLACED MAIN ENGINE CONTROL AND FUEL PUMP. PERFORM GROUND MAX POWER ASSURANCE RUN ENGINE OPERATIONS NORMAL. (M)

Part: TR DUCT — CHAFED (NR 4 ENGINE)

DURING CLIMB-OUT, NR 4 PYLON VALVE CLOSE LIGHT CAME ON FOLLOWED BY HI-STAGE OPEN LIGHT, FOLLOWED BY FIRE WARNING ALMOST FULL SCALE. FIRE WARNING AND HI-STAGE OPEN LIGHT WENT OUT WHEN THROTTLE PULLED BACK. DUMP FUEL, AIR TURN BACK. FOUND REVERSER BLEED AIR DUCT CHAFING AGAINST REVERSER GROUND AIR DUCT. REPLACED DUCTS. OPERATES NORMAL. (X)