N523MC

Part: MOUNT — DAMAGED (NLG WW) · airframe 110,130 hrs · 20,660 cycles

THE PURPOSE OF EO 4725A284  IS TO DOCUMENT A MAJOR REPAIR. DURING WALKAROUND INSP, MX FOUND THE ELECTRICAL CONDUIT AND CONNECTOR MOUNT HSG AT THE NLG DAMAGED. REPAIRED IAW EO 4725A284&NBSP.

Part: ACTUATOR — BROKEN (STEERING) · airframe 12,775 hrs · 20,731 cycles

BODY GEAR UNLOCKED LIGHT ILLUMINATED IN BOTH PRIMARY AND ALTERNATE POSITIONS WHEN LINED UP FOR TAKEOFF (FOUND RT BODY GEAR STEERING ACTUATOR BROKEN. R & R BODY GEAR STEERING ACTUATOR IAW MM 32-53-11, OPS CHECK OK)

Part: SKIN — DAMAGED (NR 2 INLET COWL) · airframe 100,931 hrs · 20,618 cycles

DURING WALKAROUND INSP, MX FOUND DAMAGE TO THE NR 2 ENG INLET COWL OUTER BARREL SKIN CRACK/DAMAGE (REF FIG 1). (DISPOSITION WAS MADE TO PERFORM A TIME LIMITED REPAIR AS DESCRIBED IN PART 1 WORK INSTRUCTIONS; SCHEDULE REPEAT INSPECTIONS AT EVERY 25 FC AND PERMANENT REPAIR PRIOR TO THE ACCUMULATION OF 1,000 FH (FLIGHT HOURS) AFTER PART 1. ACCOMPLISH REPAIR TO THE NR 2 ENGINE INLET COWL OUTER BARREL SKIN CRACK/DAMAGE (REF FIG 1) AS FOLLOWS: 1 . STOP DRILL CRACK IAW SRM 51-10-01. 2 . APPLY 3 LAYERS OF ALUMINUM FOIL TAPE (SPEED TAPE) COVERING THE DAMAGED AREA ENSURING THAT EVERY LAYER OVERLAPS A MINIMUM OF 1.5 INCHES IAW LAYER 3.

Part: A/C PACK — INOPERATIVE (NR 1) · airframe 100,844 hrs · 20,668 cycles

ATB, ELECTRICAL SMOKE SMELL IN COCKPIT. RAN ELECTRICAL SMOKE CHECKLIST, WHEN STEP 6 ACCOMPLISHED, SMOKE DISSIPATED (IAW VERBAL CREW COMMENT, DURING CLIMB, WITH NR 1 PACK ON IS WHEN THE ELECTRICAL SMOKE SMELL WAS NOTICED. UPON INSPECTION OF NR1 ACM, FOUND INOP. PACK DEACTIVATED AND DEFERRED. INSPECTED COCKPIT, UPPER DECK AND SHIPS BATTERY, ALL OK)

Part: FLOOR SUPPORT — CRACKED (BS 1900-1920) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, A SUPPORT LOCATED COMMON TO THE AFT CARGO FLOOR FROM BS 1900 TO BS 1920 FROM RBL 17- RBL 23 WAS BENT AND HAD 2 ELONGATED HOLES. (THE DAMAGE WAS TRIMMED OUT AND PERMANENTLY REPAIRED IAW SRM 51-40-02, FIG 2 AS DOCUMENTED ON NRC497. THE SUPPORT IS MADE 0.040 INCH THICK CLAD 7075-T6 IAW SRM 53-10-23 FIG 5, SHEET 7, ITEM 7. SEE FIG 1. THE DAMAGED PART WAS PERMANENTLY REPAIRED BY TRIMMING OUT THE DAMAGE AND REINFORCING IAW SRM 51-40-02 FIG 2 WITH AN 0.040 INCH THICK ZEE SECTION 7 INCHES LONG BY 6.5 INCHES WIDE MADE FROM 7075-T6 INSTALLED WITH BACR15BB6D RIVETS AND BACB30MY6K LOCK FASTENERS. THIS WAS DOCUMENTED ON NRC497. SEE FIG 2. THE SUBJECT REPAIRS ARE PERMANENT AN DO NOT AFFECT THE REPAIR ASSESSMENT PROGRAM IAW FAR 121.1109, THEREFORE NO SUPPLEMENTAL INSPECTIONS ARE REQUIRED.)

Part: SKIN — CORRODED (BS 1241) · airframe 100,703 hrs · 20,573 cycles

NRC 0740 (RA4174), "MAIN DECK" FOUND CORROSION ON THE WING CTR SECTION BOX UPPER SURFACE SKIN AT STA 1241, RBL 75 TO 80, WL 149 (THE WORK ACCOMPLISHED IAW REA: MF0068720008 AND RF7A: 00687-0008).

Part: INTERCOSTAL — DAMAGED (BS 1980) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, AN INTERCOSTAL LOCATED COMMON TO THE BULK CARGO FLOOR HAD DAMAGE THAT IS LISTED AS FOLLOWS: THE INTERCOSTAL AT BS1980, RBL30 WAS CRACKED SEE FIGURE 1, SHEET 2, ITEM 18 AS DOCUMENTED ON NRC518. (THE INTERCOSTAL AT BL30 IS MADE FROM BAC1517-1671, 7075-T6 EXTRUSION IAW SRM 53-10-23, FIG 5, SHEET 11, ITEM 18, FIG 1. THE REPAIR PARTS WERE AN ANGLE AND FILLER MADE FROM 0.040 7075-T6 AND INSTALLED WITH BACB30MY6K HI-LOKS AS DOCUMENTED ON NRC518. FIG 2. THE SUBJECT REPAIR IS PERMANENT AND DOES NOT AFFECT THE REPAIR ASSESSMENT PROGRAM IAW FAR 121.1109, THEREFORE NO SUPPLEMENTAL INSPECTIONS ARE REQUIRED.)

Part: SKIN — CORRODED (BS 2070-2180) · airframe 100,703 hrs · 20,573 cycles

NRC 041 LOWER FUSELAGE SKIN SUSPECT TO CORROSION ON LAP JOINT AT STR 46 BETWEEN STA 2070 TO 2180 LT SIDE. (THE WORK ACCOMPLISHED IAW REA MF00687R0001 AND RFTA NO 00687-0001 AND J/C 00041-I-1 REF.)

Part: FRAME — BENT (BS 760) · airframe 100,703 hrs · 20,573 cycles

NRC 1123, FWD CARGO FRAME UPPER CHORD IS BENT STA 760 BETWEEN 28-29 (THE WORK PREPAIRED IAW REA NR HF00687R00007, REV A, RFTA NR 00687-007).

Part: FRAME — BENT (BS 700) · airframe 100,703 hrs · 20,573 cycles

NRC: 1121 "FWD CGO" FRAME STA 700 (F/B) UPPER CHORD IS BENT BETWEEN RBL 17 - 21(THE WORK ACCOMPLISHED IAW REA NO MF00687-R0005 AND RFTA NR 00687-0005.)

Part: FRAME — CRACKED (BS 1860) · airframe 100,703 hrs · 20,573 cycles

NRC 1111 "MAIN DECK" FOUND CRACK ON FRAME, STA 1860, RT SIDE BETWEEN STR 12 TO 13. (THE WORK ACCOMPLISHED IAW PEA NR MF00687R0009 AND RFTAIN0 :00687-0009).

Part: FRAME — DAMAGED (BS 1040 S15-16R) · airframe 100,703 hrs · 20,573 cycles

NRC 1376 "MAIN DECK" DAMAGE WAS FOUND ON FRAME STA 1040, OTBD CHORD B/T SRT 15R-16R. (THE WORK ACCOMPLISHED IAW REA NR HF00687R0011 "A" AND RFTA NR 00687-004).

Part: FRAME — BENT (BS 720) · airframe 100,703 hrs · 20,573 cycles

NRC 1122 "FWD CRACK" FRAME 720 (F/B) UPPER CHORD IS BENT BETWEEN RBL 14 TO 18. (THE WORK ACCOMPLISHED IAW REA NO MF00687R0006 AND RFTA NO 00687-0006).

Part: INTERCOSTAL — CRACKED (BS 560-580) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, AN INTERCOSTAL LOCATED COMMON TO THE FWD CARGO FLOOR FROM BS 560 TO 580 UNDER RBL 45.5 CARGO TRACK HAD 2 CRACKS ON ITS UPPER FLANGE. (THE DAMAGE WAS TRIMMED OUT AND PERMANENTLY REPAIRED IAW SRM 51-40-03, FIG 1 AS DOCUMENTED ON NRC470. THE INTERCOSTAL IS MADE 0.050 INCH THICK CLAD 7075-T6 IAW SRM 53-10-21 FIG 5A, SHEET 3, DETAIL I ITEM 13. SEE FIG 1. THE REPAIR CONSISTED OF 0.063 INCH THICK 12 INCH BY 8 INCH CHANNEL AND 0.050 INCH THICK FILLER MADE FROM 7075-T6 INSTALLED WITH BACR15GF5D RIVETS AND BACB30MY5K LOCK FASTENERS IAW SRM 51-40-03 FIG 1 DETAIL III AS & NBSP; DOCUMENTED ON NRC470. SEE FIG 2.)

Part: INTERCOSTAL — BENT (BS 1920-1940) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, INTERCOSTAL LOCATED COMMON TO THE BULK CARGO FLOOR HAD DAMAGE. THE INTERCOSTAL AT BS 1920 TO 1940 LBL 37.5 WAS BENT,

Part: SKIN — CORRODED (BS 400 S44) · airframe 100,703 hrs · 20,573 cycles

NRC 024 CORNER OF EXISTING REPAIR IS BULGED ON EXT FUSELAGE SKIN RT SIDE AT STA 400 AND STR 44 AREA. (BULGED) 2.0" X 1.5" X 0.061"(THE WORK ACCOMPLISHED IAW REA NR : HF00687R0002 AND NO 00687-0002 AND JC 0024-I-1.)

Part: INTERCOSTAL — CRACKED (BS 260) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, THE INTERCOSTAL WAS CRACKED LOCATED COMMON TO THE FWD CANTED BULKHEAD WEB AT BS260 RBL 10 TO RBL 22 AND WL 188 TO WL 189. (THE CRACK WAS TRIMMED OUT AND REPAIRED WITH AN ANGLE AND FILLER AS DOUMENTED ON IAI NRC963 IAW SRM 51-40-03, FIG 1. THE 65B07394-1054 INTERCOSTAL IS MADE FROM 0.040 INCH THICK CLAD7075-T6 PER SRM 53-10-20 FIG 10 DETAIL II ITEM 35. SEE FIG 1. THE REPAIR PARTS CONSISTED OF AN 0.050 INCH THICK ANGLE 12 IN BY 4 IN FROM 7075-T6 ALUMINUM AND A FILLER ALL INSTALLED WITH BACR15BB5D RIVETS)

Part: STRINGER — DAMAGED (BS 500-520 S36R) · airframe 100,703 hrs · 20,573 cycles

NRC 1125, FWD CGO STRINGER 36R IS BENT BETWEEN STA 500-520 (DAMAGED PORTION OF STRINGER REMOVED, REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER PN N523MC, NRC 1125 1/2 IAW SRM 53-10-03 FIG 3 AND FASTENERS INSTL IAW SRM 51-30-02)

Part: STRINGER — DAMAGED (BS 320 S37R) · airframe 100,703 hrs · 20,573 cycles

NRC 0971: "LOWER DECK" JUST FWD OF STA 320 STR 37R ELONGAGED FASTENER HOLE ON STRINGER (DAMAGED AREA TRIMMED OUT. REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER PN N523MC NRC 971 1/2 IAW SRM 53-01-03, FIG 3, FASTENERS INSTL IAW SRM 51-30-02).

Part: STRINGER — BENT (BS 480-500 S38L) · airframe 100,703 hrs · 20,573 cycles

NRC: 1120 "FWD CGO" STRINGER 38L IS BENT BETWEEN STA 480 TO 500 (DAMAGED AREA TRIMMED OUT REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER AND FILLER PN N52MC, NRC 1120 1,2,3 IAW SRM 53-10-03, FIG 3. FASTENERS INSTALLED IAW SRM 51-30-02).

Part: STRINGER — BENT (BS 360-380 S35R) · airframe 100,703 hrs · 20,573 cycles

NRC: 0979 "LOWER DECK" B/T STA 360-380 S 35R STRINGER LOWER FLANGE IS BENT. (DAMAGED AREA TRIMMED OUT, REINFORCED AREA WITH STRINGER REPAIR AND FILLER P/N N523MC NRC 979 1/2 PER SRM 53-10-03 FIG 3. FASTENERS INSTL PER SRM 51-30-02)

Part: STRINGER — DAMAGED (BS 320 S28R) · airframe 100,973 hrs · 20,573 cycles

NRC: 0972 "LOWER DECK" STA 320, STR 28.7, R. DOUBLE HOLE ON THE STRINGER. (DAMAGED AREA TRIMMED OUT. REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER PN N523MC, NRC 972 1/2 IAW SRM 53-10-03, FIG 3 & AMP; FASTENERS INSTL IAW SRM 51-30-02.)

Part: STRINGER — TWISTED (BS 440 S41L) · airframe 100,703 hrs · 20,573 cycles

NRC: 1397, STA 440, STR 41-L FOUND TWIST STR AND NBSP; TURN TO AT LOWER DECK (P-6 AREA)(DAMAGED AREA TRIMMED OUT. REINFORCED AREA WITH NEW ZEE PN N523MC NRC 1397-1 IAW SRM 53-10-03 FIG 3, FASTENER INSTL IAW SRM 51-30-02).

Part: FLOOR SUPPORT — CRACKED (BS 910-1000) · airframe 100,703 hrs · 20,573 cycles

NRC 0925 'MAIN DECK FLOOR OMEGA' CRACK ON OMEGA LBL 75, CHANNEL BETWEEN STA 910 TO 1000 AND TWIST. (DAMAGED AREA TRIMMED OUT, REINFORCED AREA WITH NEW OMEGA AND SPLICE PN N523MC, NRC 925 1/2 IAW SRM 53-10-05, FIG 19. FASTENER INSTL IAW SRM 51-30-02).

Part: STRINGER — BENT (BS 380-400 S37R) · airframe 100,703 hrs · 20,573 cycles

NRC0974, LOWER DECK STA 380, 400 STR 37R STRINGER UPPER FLANGE IS BENT (DAMAGED PORTION OF STRINGER REMOVED. REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER REMOVED. REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER PN N523MC NRC 971 -/2 IAW SRM 53-10-03 FIG 3. FASTENER INSTL IAW SRM 51-30-02.)

Part: SEAT TRACK — DAMAGED (FUSELAGE) · airframe 100,703 hrs · 20,573 cycles

NRC 00924 "MAIN DECK" SEAT TRACK RBL 75 FLANGE IS TORN AT STA 920 (DAMAGED AREA TRIMMED OUT. REINFORCED AREA WITH TRACK AND SPLICE PN N523MC, NRC 924 1/2 IAW SRM 53-10-05, FIG 19 & AMP; FASTENERS INSTL IAW SRM 51-30-02).

Part: STRINGER — BENT (BS 380-400) · airframe 100,703 hrs · 20,573 cycles

NRC 0973 LOWER DECK STA 380-400, STR 39R, STRINGER UPPER FLANGE IS BENT. (DAMAGED PORTION OF TRIMMED OUT REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER PN 523 NRC 1/2 IAW SRTM 53-10-03 FIG 3. FASTENERS INSL IAW SRM 51-30-02).

Part: SKIN — CORRODED (BS 380-420) · corrosion level 2 · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, THE FUSELAGE SKIN AT BS 380 TO 420 AND STRINGERS 43 TO 46R NEAR THE NOSE LANDING GEAR WHEEL WELL THERE WAS AN EXISTING REPAIR WITH A BULGE.(THE EXISTING REPAIR WAS REMOVED AND LEVEL 2 CORROSION WAS PRESENT. THE CORROSION WAS REMOVED AND THE OLD REPAIR REPLACED WITH 4 NEW DOUBLERS AS DOCUMENTED ON IAI NRC024 IAW SB 747-53A2305 R2, AND IAI REA MF00687R0002. SEE FIG 1 FOR A VIEW OF THE REPAIR AREA AFTER OLD DOUBLERS WERE REMOVED. THE REPAIR WAS ACCOMPLISHED WITH 2 DOUBLERS MADE FROM 2024-T3 CLAD IAW QQ-A-250/5 ONE IS 0.071 INCHES THICK 20 INCHES BY 32 INCHES THE OTHER IS 0.063 INCHES THICK 14.2 INCHES BY 16.0 INCHES. 2 OTHER DOUBLERS WERE MADE FROM 0.050 INCH THICK CRES 301 1/2 HARD IAW MILS 5059 ONE 12.5 INCHES BY 16 INCHES AND (1) 8.5 INCHES BY 12 INCHES. THE REPAIR PARTS WERE INSTALLED WITH BACB30NX6K*Y, BACB30NW*K*X HI-LOKS AND BACR15CE RIVETS. SEE FIG 2 FOR A SKETCH OF THE REPAIR AND VIEW OF COMPLETED REPAIR.)

Part: SEAT TRACK — CRACKED (BS 910-1500) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, FLANGE OF SEAT TRACK AT BS 910-1500 LBL 75 CRACKED. DAMAGE CUT OUT AND REPLACED WITH NEW SECTIONS OF SEAT TRACK WITH SPLICE ANGLES INSTALLED AND WAS DOCUMENTED ON IAI NRC1325, NRC1378, NRC924, NRC925 AND NRC 1254 RESPECTIVELY. CLASS A PERMANENT REPAIR BASED UPON SRM 53-10-05 FIGURE 19.

Part: SEAT TRACK — CRACKED (BS 1480-1500) · airframe 100,703 hrs · 20,573 cycles

NRC: 1254 CRACK ON SEAT TRACK CHANNEL, RBL 75 BETWEEN STA 1480 TO 1500 (DAMAGED AREA TRIMMED OUT REINFORCED AREA WITH TRACK AND SPLICE PN N523MC, NRC 1254 1/2 IAW SRM 53-10-05, FIG 19. FASTENERS INSTL IAW SRM 51-30-02).

Part: SKIN — CORRODED (BS 460 S41-42L) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, A BULGE WAS DETECTED IN AN EXISTING REPAIR DOUBLER ON SKIN AT BS 460 AND S41-42L. DAMAGED REPAIR DOUBLER WAS REMOVED AND SUBSEQUENT DISCOVERED DRILL STARTS IN THE SKIN WERE TRIMMED OUT. THE DISCREPANT AREAS WERE THEN REPAIRED IAW NRC 0011 AND SRM 53-30-03, FIG 1, SHEET 8, DETAIL III FIG 1.

Part: FAIRING — CRACKED (HORIZONTAL STAB) · airframe 100,703 hrs · 20,573 cycles

RT LEST440-528 HORIZONTAL STAB L/E OTBD FAIRING HAS 6 CRACKS AT RIB ANGLES PERFORMED MAJOR REPAIR IAW RAM256 - NRC1141 - SRM 55-10-06 FIG 1.

Part: SKIN — DENTED (CARGO DOOR) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, A DENT WAS DETECTED IN THE OUTER SKIN 65B04514-3 OF BULK CARGO DOOR ASSY AT BS 1980-2000 S33R. DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 0062 AND SRM 52-00-03, FIG 9, SHEET 4, DETAIL I.

Part: SKIN — DENTED (RT WING TE FLAP) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, A DENT/WRINKLE WAS DETECTED IN SKIN OF RT FLAP NR 18 L/E AT 29 INCHES FROM THE INBD EDGE LOOKING AFT. DAMAGE WAS TRIMMED OUT AND REPAIRED IAW INRC 0386 AND SRM 57-50-03, FIG 3, SHEET 4, DETAIL III FIG 1.

Part: FLOOR SUPPORT — CRACKED (BS 560) · airframe 100,703 hrs · 20,573 cycles

NRC 1325 "MAIN DECK" STA 560 LBL 99 FLOOR SUPPORT IS CRACKED IAW SRM 53-10-05, FIG 19 AND FASTENERS INSTL IAW SRM. (DAMAGED AREA REMOVED NEW FABRICATED PN N523MC, NRC 1325 IAW SRM 53-10-05, FIG 19, FASTENERS INSTL IAW SRM 51-30-02).

Part: RIB — CRACKED (STAB FAIRING) · airframe 100,703 hrs · 20,573 cycles

STABILIZER LT L/E OTBD FAIRING LEST 440-496 HAS 4 CRACKS AT RIB ANGLES. INSTALLED 4 FILLERS AND 4 ANGLES. REPAIRED IAW SRM.

Part: SKIN — DENTED (BS 460-480) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, A DENT WAS DETECTED IN THE SKIN AT BS 460 - 480 AND S39-40R. DAMAGE WAS TRIMMED OUT AND REPAIRED IAW IAI NRC 0012 AND SRM 53-30-03, FIG 27, SHEET 5, DETAIL III FIG 1.

Part: STRINGER — CRACKED (BS 420 S35L) · airframe 100,703 hrs · 20,573 cycles

NRC 1115 "LOWER DECK" CRACK ON STR 35L UPPER FLANGE AT STA 420 (DAMAGED AREA TRIMMED OUT, REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER PN N523MC, NRC 1115 1/2 IAW SRM 53-10-03 FIG 3 FASTENER INSTL IAW SRM 51-30-02)

Part: STRINGER — CORRODED (BS 1880-1940) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK IN TLV LEVEL 2 CORROSION WAS FOUND IN THE STRINGER BETWEEN BS1900 TO BS1920 AND STRINGER 48R. THE DAMAGE WAS CUT OUT, REMOVED AND SPLICED AT BS1880, BS1920 AND BS1940 IAW SRM 53-10-03 FIGURE 8.

Part: SKIN — CORRODED (BS 1900-1920) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK IN TLV LEVEL 2 CORROSION WAS FOUND IN THE 65B04142-3 SKIN AT BS 1900 TO BS 1920 S48R. DAMAGE TRIMMED OUT, REPAIRED IAW SRM 53-30-03 FIG 1 AS A CATEGORY B PERMANENT REPAIR AND DOCUMENTED ON NRC028.

Part: STRINGER — BENT (BS 380-400 S40R) · airframe 100,703 hrs · 20,573 cycles

NRC: 0975 "LOWER DECK" B/T STA 380 - 400 STR 40R STRINGER UPPER FLANGE IS BENT. (DAMAGED AREA TRIMMED OUT, REINFORCED AREA WITH NEW SEGMENT AND REPAIR - STRINGER PN N523MC, NRC 0975 1/2 IAW SRM 53-10-03, FIG 3. FASTENERS INSTL IAW SRM 51-30-02).

Part: CARGO TRACK — DAMAGED (BS 1500-1520) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK IN TLV UPPER FLANGE OF THE AFT CARGO COMPARTMENT CARGO TRACK BETWEEN BS 1500 TO BS 1520 RBL 45.5 WAS FOUND BROKEN. (THE DAMAGE WAS CUT OUT, REMOVED AND SPLICED IAW SRM 53-10-05 FIG 5 AS CATEGORY A PERMANENT REPAIR DOCUMENTED ON NRC467. SEE FIG 1. RBL 45.5 TRACK IS MADE FROM BAC1520-1682 7178-T6511 EXTRUSION IAW SRM 53-10-23 FIG 5. REPAIR PARTS ARE INSTALLED USING LOCK FASTENERS. PART 1 OF THIS EO DOCUMENTS THE TRACK SPLICE REPAIR IAW IAI NRC 467 AND SRM 53-10-05 FIG 5.

Part: STRINGER — BENT (BS 360-380 S38R) · airframe 100,703 hrs · 20,573 cycles

NRC 0978 "LOWER DECK" B/T STA 360 - 380 STR 38R STRINGER LOWER FLANGE IS BENT. (DAMAGED AREA TRIMMED OUT, REINFORCED AREA WITH ENW REPAIR. STRINGER AND FILLER PN B523MC NRC 978 1/2 IAW SRM 53-10-03, FIG 3. INSTALL FASTENERS IAW SRM 51-30-02).

Part: SKIN — CORRODED (BS 1241 S10-11R) · airframe 100,703 hrs · 20,573 cycles

FUSELAGE SKIN CORRODED AT- BS 1241, S10-11R. MAJOR REPAIR PERFORMED IAW THE RAM 177- NRC960 IAW SRM 53-30-03, FIG 47.

Part: SKIN — DENTED (BS 360-380) · airframe 100,704 hrs · 20,573 cycles

DURING C-CHECK, A DENT WAS FOUND IN THE SKIN AT BS 360-380 S-38R TO -39R. DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 022 AND SRM 53-30-03, FIG 26.

Part: STRINGER — CRACKED (BS 500-520 S38R) · airframe 100,703 hrs · 20,579 cycles

NRC: 1124 FWD CARGO, CRACK ON STR 38R BETWEEN STA 500-520 (DAMAGED PORTION OF STRINGER REMOVED, REINFORCED AREA WITH NEW SEGMENT AND REPAIR. STRINGER PN B523MC NRC 1124 1-2 REPAIR IAW SRM 53-10-03, FIG 3 & AMP; FASTENER INSTL IAW SRM 51-30-02).

Part: SKIN — CORRODED (BS 440-460) · airframe 100,704 hrs · 20,573 cycles

NRC: 011 -BULGE BY 2.5" X 2.3" X 0.037" ON EXT FUSELAGE, SKU EXISTING REPAIR DOUBLER EDGE BS 440-460 AND STR 43L-44L. (EXISTING REPAIR REMOVED THE WORK ACCOMPLISHED IAW J/C NO 0B011-R1 USING DOUBLER PN N523MC, NRC 011-1 FASTENERS INSTALLED IAW SRM 51-30-02).

Part: STRINGER CLIP — CRACKED (BS 360 S7R) · airframe 100,703 hrs · 20,573 cycles

NRC: STA 360 AFTER REMOVAL CRACKED STR CLIP FOR REPLACEMENT WAS FOUND CRACK ON THE STR 7R.(DAMAGED AREA TRIMMED OUT AREA REINFORCED WITH REPAIR STRINGER AND SPLICE PN N523MC, NRC 1333 1/3 IAW SRM 53-10-03, FIG 3, FASTENERS INSTL IAW SRM 51-30-02).

Part: RIB — CRACKED (STAB FAIRING) · airframe 100,703 hrs · 20,573 cycles

NRC 1142 :HORIZ STAB" LT STAB L/E OTBD FAIRING HAS 4 CRACKS AT RIB ANGLE. (CRACKED AREA TRIMMED OUT. REINFORCED AREA WITH ANGLE AND FILLER PN N523MC NRC 1142 1/2 IAW SRM 55-10-06 FIG 1 AND FASTENERS INSTL IAW SRM 51-30-02).

Part: STRINGER — CRACKED (BS 320 S35R) · airframe 100,703 hrs · 20,573 cycles

NRC: 964 "LOWER DECK" STA 320, 2 EA CRACKS (1 EA ON STR UPPER FLANGE AND 2 ON STR WEB) ON STR 35R. (DAMAGED AREA TRIMMED OUT. REINFORCED AREA WITH NEW SEGMENT AND REPAIR STRINGER PN N523MC, NRC 964 1/2 IAW SRM 53-10-03 FIG 3 AND FASTENERS ISNTL IAW SRM 51-30-02).

Part: CARGO TRACK — DAMAGED (BS 1900-1920) · airframe 100,703 hrs · 20,573 cycles

NRC 0494 SWELLING ON AFT CARGO TRACK UPPER FLANGE BETWEEN STA1900-1920 RBL 25 (DAMAGED AREA TRIMMED OUT IAW SRM 51-10-01, REINFORCED WITH EXTRUDED REPAIR ANGLE, REPAIR STRIP, TRACK SECTION PN B523MC 494 1,2,3 IAW SRM 53-1-05 FIG 5 FASTENERS INSTL IAW SRM 51-30-02)

Part: SKIN — BULGED (BS 2160-2180) · airframe 100,703 hrs · 20,573 cycles

BULGE BY 1.2 X 1.1 X 0.013" ON EXT. FUSELAGE SKIN STA 2160-2180 STR 42L-44L (THE BULGE FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01, FIG 1A.)

Part: SKIN — DAMAGED (BS 160-180) · airframe 100,703 hrs · 20,573 cycles

DAMAGED AREA BY 6.0 X 3.0" ON EXTERNAL FUSELAGE SKIN AT STRINGER AREA BS 160-180 S-42AL (DAMAGED AREA FOUND TO BE WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01, FIG 1A).

Part: SKIN — BULGED (BS 2140) · airframe 100,703 hrs · 20,573 cycles

BULGE BY 1.3 X 1.0 X 0.025" ON EXT FUSELAGE SKIN STA 2140 STR 36L-37L (STA AREA) (THE BULGE WAS FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-00, FIG 1A.)

Part: SKIN — CORRODED (BS 1720) · airframe 100,703 hrs · 20,573 cycles

CORROSION ON EXT FUSELAGE SKIN STA 1720 STR 45R-46R (CORROSION REMOVED IAW SRM 51-10-01. FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01, FIG 1 AFTER CLEANUP AND AREA PROTECTED IAW SRM 51-10-02.)

Part: SKIN — BULGED (BS 520-540) · airframe 100,703 hrs · 20,573 cycles

BULGE BY 2.0 X 2.0 X 0.022" ON EXTERNAL FUSELAGE SKIN BS 520-540 S42R-43R (BULGE FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01.)

Part: SKIN — BULGED (BS 320-340) · airframe 100,703 hrs · 20,573 cycles

BULGE BY 1.0 X 0.8 X 0.025" ON EXTERNAL FUSELAGE SKIN BS 320-340 ABOVE S-39R (BULGE FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01, FIG 1A.)

Part: SKIN — DENTED (BS 380-400) · airframe 100,703 hrs · 20,573 cycles

2 EA ADJACENT DENTS ON INSP; EXTERNAL FUSEALGE SKIN BS 380-400 S-37R-38R UPR 1.25 X 1.0 X 0.008" AND LWR 0.8 X 0.7 X 0.010" (2 EA DENTS FOUND WITHIN ALLOWABLE DAMAGE AND INSP;LIMITS IAW SRM 53-30-01 FIG 1A)

Part: SKIN — DAMAGED (BS 380-400) · airframe 100,703 hrs · 20,573 cycles

PREVIOUSLY REWORKED AREA ON EXTERNAL FUSELAGE SKIN BS 380-400 S-38R-39R BY 2.0 X 1.6 X 0.011 X 0.010" (NOTED AREA FOUND WITHIN ALLOWABLE DAMAGE; LIMITS IAW SRM 53-30-01, FIG 1.)

Part: SKIN — DENTED (BS 380-400) · airframe 100,703 hrs · 20,573 cycles

DENT BY 1.8 X 1.5 X 0.016" ON EXTERNAL FUSEALGE SKIN BS 380-400 ABOVE S-41L(DENT FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01, FIG 1A)

Part: SKIN — DENTED (BS 500-520) · airframe 100,703 hrs · 20,573 cycles

DENT ON EXTERNAL FUSELAGE SKIN BY 4.0 X 2.5 X 0.039" BS 500-520 S-35R-36R (DENT FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01, FIG 1A).

Part: SKIN — BULGED (BS 540-560) · airframe 100,703 hrs · 20,573 cycles

2 EA BULGES BY MAX 1.0 X 1.0 X 0.024" ON EXTERNAL FUSELAGE SKIN BS 540-560 S-41R-42R (2 EA BULGES FOUND WITHIN ALLOWABLE LIMITS).

Part: SKIN — BULGED (BS 580-600) · airframe 100,703 hrs · 20,573 cycles

BULGE BY 1.5X 1.0 X 0.024" AND ADJACENT DENT BY 3.2 X 1.5 X 0.014" ON EXTERNAL FUSELAGE SKIN BS 580-600 S-44R-45R (BULGE AND DENT FOUND IN ALLOWABLE DAMAGE LIMITS IAW SRM 53-30-01 FIG 1A.)

Part: SKIN — DENTED (BS 340-380) · airframe 100,703 hrs · 20,573 cycles

SEVERAL SMALL DENTS BS 340-380L S-39L-40L ON EXTERNAL FUSELAGE SKIN (SEVERAL SMALL DENTS FOUND WITHIN ALLOWABLE DAMAGE LIMITS IAW SRM).

Part: FUEL FILTER — DIRTY (NR 3 ENGINE)

NR 3 ENGINE AT DESCENT NOTICED LOW POWER AND SHUT DOWN. LOW FUEL FLOW. ENGINE FAILURE/SHUT DOWN CHECK LIST ACCOMPLISHED NO ABNORMAL INDICATIONS SO ATTEMPTED RESTART WITH INFLIGHT START. LOW FUEL FLOW 200KGS, LESS THAN 26 PERCENT N1 LESS THAN 30 PERCENT N2, 300 EGT NR 3 ENGINE INLET/OUTLET INSPECTED FOR FOD NONE FOUND. CDP TUBES DRAIN HOLES AND MECH CHECKED NO FAULT. CHECK FUEL PUMP FILTER AND FUEL PUMP CARTRIDGE SCREEN. FOUND FUEL FILTER PARTIALLY DIRTY. REPLACED FILTER, INSPECTED FUEL HEAT EXCHANGER. CARRY OUT MPA RUN ALL FOUND NORMAL. LEAK CHECK ENGINE NO LEAKS NOTED IAW AMM 73-11-02 AND 73-11-04, 79-21-01, 71-00-00 TEST 4.

Part: NOZZLE — CRACKED (NR 4 ENGINE) · airframe 100,297 hrs · 20,498 cycles

NR 4 ENG EXHAUST NOZZLE ASSY FOUND 3 LOCATIONS CRACKED AT FWD FLANGE AREA. NR 4 ENG EXHAUST ASSY 3 LOCATIONS CRACK REPAIR CARRIED OUT AS PER EM CF6-50 REPAIR O2 PROCEDURE B (1) AND EO 4778A148.

Part: NOZZLE — CRACKED (NR 4 ENG EXHAUST)

DURING AN ENGINE CHANGE AT AN A-CHECK, MX FOUND 3 EA CRACKS ON THE NR 4 ENG FIXED COWL EXHAUST NOZZLE FWD FLANGE COWL SUPPORT ASSY. THE CRACKS CAN BE REPAIRED IAW THE ESM TASK 78-33-05. REPAIR 002. THE REPAIR CALLS FOR A POST WELD HEAT TREATMENT AND THERMAL SPRAY. MX DOES INTO HAVE THE EQUIPMENT TO ACOMPLISH THE REQUIRED HEAT TREATMENT AND THERMAL SPRAY. (DISPOSITION IS TO ACCOMPLISH THE ESM 78-33-05. REPAIR, EXCLUDING THE POST WELD HEAT TREATMENT AND THERMAL SPRAY, AND PERMANENT REPAIR AT THE NEXT C-CHECK.)

Part: SLIDE — UNWANTED DEPLOY (RT PAX DOOR) · airframe 98,804 hrs · 20,189 cycles

DURING A-CHECK UPPER DECK RT DOOR SLIDE WAS ACCIDENTALLY DEPLOYED INSIDE THE ACFT BY MX PERSONNEL. SLIDE WAS NOT IN POSITION FOR NORMAL SUCCESSFUL DEPLOYMENT. SLIDE AND BOTTLE WAS REPLACED IAW AMM 25-68-02.

Part: PDU — UNSERVICEABLE (ZONE 200) · airframe 96,815 hrs · 20,212 cycles

GROUND CREW REPORTED MAIN DECK PDU 15 R SMOKING DURING OFFLOAD. DEACTIVATED AND DEFERRED THE PDU. REPLACED DOWN LINE.

Part: SKIN — DENTED (LT WING TE FLAP) · airframe 98,066 hrs · 20,042 cycles

LT WING OUTBOARD AFT FLAP HAS A DENT ON TOP SURFACE SKIN. AT WBL 525.32 AND 14 INCHES FROM TRAILING EDGE. DENT IS 1.750 INCHES IN DIAMETER. PERMANENT REPAIR ACCOMPLISHED AS PER SRM 51-40-09, FIG 5, SHEETS 7 AND 8, 250 DEGREE CURE PER SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO 4757A480.

Part: NOZZLE — DAMAGED (ENGINE EXHAUST) · airframe 98,096 hrs · 20,040 cycles

PUNCTURE ON THE LONG FIXED CORE EXHAUST NOZZLE (LFCEN) ON THE NR 2 ENGINE. THE PUNCTURE IS APPROX 0.25" WIDE, APPROX 5.0 INCHES FROM THE T/E OF THE EXHAUST SLEEVE AT THE 3:00 POS. SMOOTH THE EDGES OUT USING STANDARD PRACTICES AND ELEMENTARY OPERATIONS. REPLACE NOZZLE AT THE NEXT "A" CHECK. EO 4778A145.

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 97,618 hrs · 19,950 cycles

DURING DESCENT ELECTRICAL ARCING WAS NOTICED IN THE CENTER CONSOLE NEAR TAWS AND GPS. INSPECTED ALL WIRING BEHIND CENTER CONSOLE. FOUND ALL SECURED. FOUND BLINKING LED LIGHT INSIDE TAWS INDICATOR. TAWS CHECKED OUT NORMAL THE BLINKING LIGHT WAS NORMAL. AIRCRAFT CLEARED OKAY FOR SERVICE.

Part: PANEL — DELAMINATED (ZONE 600) · airframe 97,363 hrs · 19,900 cycles

RT WING UPPER SURFACE FIXED T/E PANEL AT WBL 445.0 JUST FWD OF INBD AILERON SMALL AREA OF DELAMINATION. AREA IS 3.5 BY 1.250 INCHES. PERMANENT REPAIR ACCOMPLISHED IAW SRM 51-40-09, FIG. 2 SHEET 2 AND 5, PREPREG LAYUP 250 DEGREES F CURE IAW SRM 51-40-12. ALSO, EO NO. 4757A473.

Part: COMPUTER — FAILED (AUTO PILOT) · airframe 96,852 hrs · 19,800 cycles

WHEN "A" AUTOPILOT ENGAGED AIRCRAFT STARTED UNCOMMANDED LEFT ROLL. DISENGAGED "A". "B" WOULD NOT ENGAGE. CYCLED YOKE SWITCHES AND YOKES NEITHER WOULD ENGAGE. FINALLY GOT "B" TO ENGAGE BUT IT WOULD NOT FOLOW ANY COMMANDS. REPLACED "A" CHANNEL CCA IAW 22-13-02. RESEATED PUSHED BACK PINS 14, 15, 16 ON "B" CHANNEL CCA IAW 20-61-00. REPLACED AUTOPILOT ACC BOX NR 2 PER MM 22-11-03. ACCOMPLISHED CHECKS ON BOTH A & B A/P CHANNELS BOTH CHECK OK.

Part: AUTOPILOT SYS — MALFUNCTIONED (COCKPIT) · airframe 96,852 hrs · 19,800 cycles

AIR TURNBACK, WHEN A/P "A" IS ENGAGED THE AIRCRAFT STARTED UNCOMMANDED LEFT ROLL. DISENGAGED "A" A/P. "B" A/P WOULD NOT ENGAGE. CYCLED YOKE SWITCH NIETHER "A" OR "B" A/P WOULD ENGAGE. FINALLY GOT "B" TO ENGAGE BUT IT WOULD NOT FOLLOW ANY MODE CONTROL PANEL COMMANDS. ITEM IS OPEN AS TO THE AIRCRAFT IS ON THE GROUND IN WORK.

Part: AUTOPILOT SYS — MALFUNCTIONED · airframe 96,644 hrs · 19,014 cycles

ATB BOTH AUTOPILOTS A AND B WILL NOT ENGAGE. BOTH TESTED OK ON GROUND. A/P A AND B PITCH AND ROLL COMPUTERS, FLIGHT CTL HYD PWR SHUT OFF SWITCHES ALL CHECKED IN ON POSITION. ACCESS BOXES INSTALLATION OCCURRED OK. MSP ELECT CONNECTORS INSPECTION NO FAULTS.

Part: NONE — NONE (NONE)

ATB. BOTH AUTOPILOTS A AND B WILL NOT ENGAGE (BOTH TESTED OK ON GROUND). A/P A AND B PITCH AND ROLL COMPUTERS, ASTU AND M AND LU BITE CHECK ALL OK. FLT CTL HYD POWER SHUT OFF SWITCHES ALL CHECKED IN ON POSITION. A/P ACCESS BOXES INSTALLATION SECURED. MSP ELECT CONNECTORS INSPECTION, NO FAULTS (SEE LOG PAGES). (K)

Part: FRAME — DENTED (BS 1740 S12-13R)

BS 1740 FRAME BETWEEN S-12R AND S-13R DENT. REPAIRED IAW MFG SERVICE REQUEST 1-954640770 APPROVED BY FORM 8100-9 DATED 12 SEP 2008, DETAILS OF WORK KEPT AT EO -4753B201. (K)

Part: DOOR FRAME — CRACKED (FUSELAGE)

LT NR 1 MAIN ENTRY DOOR FWD FRAME UPPER HINGE CUTOUT AREA CRACKED. REPAIRED IAW MFG SERVICE REQUEST 1-948230971 APPROVED BY FORM 8100-9 DATED 4 SEP, 2008, DETAILS OF WORK KEPT AT EO-4752A153. (K)

Part: BEAM — CORRODED (FUSELAGE)

RT NR 5 MAIN ENTRY DOOR FWD EDGE BEAM AND LOWER HINGE CUTOUT AREA CORROSION. REPAIRED IAW SERVICE REQUEST 1-954744333 APPROVED BY FORM 8100-9 DATED 5 SEPT, 2008, DETAILS OF WORK KEPT AT EO-4752A154. (K)

Part: FRAME — DENTED (BS 1780 S12-13R)

BS 1780 FRAME BETWEEN S-12R AND S-13R DENT. REPAIRED IAW MFG SERVICE REQUEST 1-954640956 APPROVED BY FORM 8100-9 DATED 12 SEPT 2008, DETAILS OF WORK KEPT AT EO 4753B201. (K)

Part: SKIN — CORRODED (FUSELAGE)

CENTER SECTION UPPER SKIN PANEL AT REAR SPAR LBL 100.0, LBL 108.65 CORROSION. REPAIRED IAW MFG SERVICE REQUEST 1-957658161 APPROVED BY FORM 8100-9 DATED 9 SEPT 2008, DETAILS OF WORK KEPT AT EO-4752A462. (K)

Part: SEAT TRACK — CRACKED (BS 1785) · airframe 95,369 hrs · 19,490 cycles

MAIN DECK CARGO SEAT TRACK DAMAGED AT BS 1785, LBL 99. ACCOMPLISHED PERMANENT REPAIR AS PER B747-200 SRM 53-10-05, FIG 1A, SHEET 1, 2 AND 4. ALSO, REFERENCE ATLAS AIR EO NR 4753B139.

Part: STIFFENER — CRACKED (BS 1920) · airframe 95,369 hrs · 19,490 cycles

AFT CARGO COMPARTMENT VERTICAL STIFFENER CRACKED AT DOOR WAY. ACCOMPLISHED PERMANENT REPAIR AS PER B747-200 SRM 51-40-04, FIG 1, SHEET 1,2,3 AND 4. ALSO, REFERENCE ATLAS AIR EO NR 4753B142.

Part: PANEL — DELAMINATED (LT WING) · airframe 95,369 hrs · 19,490 cycles

LT WING UPPER FIXED LEADING EDGE ON UPPER SURFACE HAS AN AREA OF 30.0 INCHES BY 10.0 INCHES OF DELAMINATION. ACCOMPLISHED PERMANENT REPAIR AS PER B747-200 SRM 51-40-09, FIG 18, SHEET 3 AND 5, PREPREG 250 DEGREES F CURE PER SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO NR 4757A425.

Part: COMPRESSOR — STALLED (ENGINE) · airframe 94,816 hrs · 19,375 cycles

COMPRESSOR STALL ON ENGINE 1. N1 DECREASED FROM 105 PERCENT TO 100 PERCENT REDUCED THRUST TO 33 PERCENT N1 STABILIZED FL 390, TAT -21 DEGREES. ON LANDING ROLLOUT, NR 1 N1 DECREASED AND EGT INCREASED TO 900 DEGREES. REPLACED ENGINE.

Part: PANEL — DELAMINATED (ZONE 500) · airframe 94,647 hrs · 19,340 cycles

LT WING UPPER FIXED L/E PANEL HAS AREA OF DELAMINATION, 4.0 INCH WIDE BY 45.0 INCH LONG. PERMANENT REPAIR ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 18 SHEET 3 AND 5, PREPREG 250 DEGREE CURE PER SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO NR 4757A409.

Part: DRIVE SYSTEM — BROKEN (THRUST REVERSER) · airframe 94,004 hrs · 19,203 cycles

NR 3 REVERSER DID NOT DEPLOY DURING LANDING. NO AMBER THRUST REVERSER LIGHT. REVERSER WOULD NOT GO PAST INTERLOCK. INSPECTED AND FOUND BROKEN DRIVE CABLE ON THE OUTBOARD SIDE OF NR 3 ENGINE. ITEM TRANSFERRED TO DMI M07-241 PER MEL 78-1-5 CAT C LOCKED OUT PER DDPG.

Part: PANEL — DELAMINATED (RT WING) · airframe 93,946 hrs · 19,193 cycles

RT WING UPPER SURFACE L/E FIXED PANEL AT WING STA 526.0 HAS A 3.0 INCH BY 4.0 INCH AREA OF DELAMINATION. PERMANENT REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 18, SHEETS 1 THRU 5 AND SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO NR 4757A400.

Part: SKIN — DELAMINATED (NR 11 SPOILER) · airframe 93,946 hrs · 19,193 cycles

RT WING NR 11 SPOILER TRAILING EDGE HAS A 1.0 INCH BY 2.0 INCH AREA OF DELAMINATION. PERMANENT REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-06 FIG 3 AND 4, SHEET 1 AND SRM 51-40-20. ALSO, REFERENCE ATLAS EO NR 4757A399.

Part: SEAT TRACK — DAMAGED (BS 1880) · airframe 93,946 hrs · 19,193 cycles

SEAT TRACK AT MAIN DECK STA 1880L AND LBL 99 HAS WORN AND TORN CROWN LUGS. PERMANENT REPAIR ACCOMPLISHED AS PER B747-200 SRM 53-10-05 FIG 1A, SHEETS 1 THRU 4. ALSO, REFERENCE ATLAS AIR EO NR 4753B098.

Part: BLEED VALVE — UNRESPONSIVE (NR 4 ENGINE) · airframe 92,680 hrs · 18,927 cycles

WHILE TAXIING AFTER ENGINE START NR 4 ENGINE BLEED VALVE, VALVE CLOSED LIGHT ON, FOUND NO DUCT PRESSURE, WHEN ISOLATED FOR TROUBLE SHOOTING. PER MEL 36-5-1 TRANSFERRED TO FROM T0219M, DMI M07-100 ISSUED BY MCC HECTOR, ORANGE PLACARD INSTALLED.

Part: SKIN — CRACKED (FUSELAGE) · airframe 92,606 hrs · 18,914 cycles

NR 3R DOOR CUTOUT AFT LOWER CORNER SKIN AND BEARSTRAP CRACKED. REPAIRED BY TRIMMING OUT CORROSION AND CRACKS ON THE SKIN AND BEARSTRAP AND INSTALLING THREE STEEL DOUBLERS AS PER BOEING MESSAGE 1-321361058-2.

Part: TENSION TIE — CRACKED (BS 840) · airframe 92,606 hrs · 18,914 cycles

BS 840L FRAME TO TENSION TIE CONNECTION FOUND HOLES 4, 15 AND 19 CRACKED AT FORWARD CHANNEL. REPAIRED TENSION TIES BY TRIMMING OF THE DAMAGED TENSION TIR CHANNELS AND SPLICING IN NEW CHANNELS SIMILAR TO SRM 53-10-11 FIGURE 1 AS PER BOEING MESSAGE 1-317931689-31-1.

Part: PRESSURE PANEL — CRACKED (BS 294) · airframe 92,606 hrs · 18,914 cycles

LEFT NWW SIDE PANEL BS 294 WL 140 CRACKED AT WEB. THE CRACK WAS REPAIRED BY TRIMMING DAMAGED AREA AND INSTALLING TWO REPAIR DOUBLERS USING .050 2024T3 AS PER BOEING MESSAGE 1-321296136-2.

Part: HINGE FITTING — CRACKED (RT STAB) · airframe 92,606 hrs · 18,914 cycles

RIGHT STABILIZER C/S HINGE AREA HOLE 14 AND 29 CRACKED. LEFT STABILIZER C/S HINGE ARE HOLES 5, 7 AND 27 CRACKED. HINGE FITTING REPAIRED PER SB 747-55A2050 R1 AND BOEING MESAGE 1-319880689-1.

Part: BULKHEAD — CRACKED (BS 2598) · airframe 92,606 hrs · 18,914 cycles

BS 2598 BULKHEAD AT STABILIZER HINGE SUPPORT FITTING ONE HOLE IS CRACKED. CRACK IN THE AFT INNER CHORD REPAIRED BY TRIMMING OUT DAMAGED MATERIAL AND INSTALLING A FILLER AND A REPAIR STRAP AS PER BOEING MESSAGE 1-320247988-6.

Part: TENSION TIE — CRACKED (BS 880) · airframe 92,606 hrs · 18,914 cycles

BS 880R FRAME TO TENSION TIE CONNECTION FOUND CRACK AT FRAME. REPAIRED BY TRIMMING OF DAMAGED TENSION TIE CHANNELS AND SPLICING IN A NEW CHANNEL SIMILAR TO SRM 53-10-11 FIGURE 1 AS PER BOEING MESSAGE 1-317931893-3.

Part: ATTACH ANGLE — CRACKED (NR 4 PYLON) · airframe 92,606 hrs · 18,914 cycles

NR 4 PYLON AFT MOUNT BULKHEAD FITTING CAP SKIN ATTACH ANGLE BOTH SIDES FOUND CRACKED. THE CHORD CRACKED FLANGES WERE REMOVED BY TRIMMING PER SRM 51-10-01. THE EDGES AND FASTENER HOLES WERE NDT INSPECTED. FILLERS AND REPAIR ANGLES WERE INSTALLED ON FORWARD AND AFT SIDES OF THE LEFT AND RIGHT CHORDS PER BOEING DOCUMENT 1-321346972-4.

Part: ATTACH ANGLE — CRACKED (NR 1 PYLON) · airframe 92,606 hrs · 18,914 cycles

NR 1 PYLON AFT MOUNT BULKHEAD FITTING CAP SKIN ATTACH ANGLE BOTH SIDES FOUND CRACKED. THE CHORD CRACKED FLANGES WERE REMOVED BY TRIMMING PER SRM 51-10-01. THE EDGES AND FASTENER HOLE WERE NDT INSPECTED. FILLERS AND REPAIR ANGLES WERE INSTALLED ON FORWARD AND AFT SIDES OF THE LEFT AND RIGHT CHORDS PER BOEING DOCUMENT 1-320850399-1.

Part: ATTACH ANGLE — CRACKED (NR 1 PYLON) · airframe 92,606 hrs · 18,914 cycles

NR 1 PYLON AFT MOUNT BULKHEAD FITTING CAP SKIN ATTACH ANGLE STATION 286 BOTH SIDES CRACKED. THE CHORDS CRACKED FLANGES WERE REMOVED BY TRIMMING PER SRM 51-10-01. ALL FASTENERS HOLES WERE NDT INSPECTED. REPAIR FILLERS AND ANGLES WERE INSTALLED ON FORWARD AND AFT SIDES OF THE LEFT AND RIGHT SIDE CHORDS AS PER BOEING MESSAGE 1-320850399-4.

Part: ATTACH ANGLE — CRACKED (NR 3 PYLON) · airframe 92,606 hrs · 18,914 cycles

NR 3 PYLON AFT MOUNT BULKHEAD FITTING CAP SKIN ATTACH ANGLE BOTH SIDES FOUND CRACKED. THE CHORD CRACKED FLANGES WERE REMOVED BY TRIMMING PER SRM 51-10-01. THE EDGES AND FASTENER HOLES WERE NDT INSPECTED. FILLERS AND REPAIR ANGLES WERE INSTALLED ON FORWARD AND AFT SIDES OF THE LEFT AND RIGHT CHORDS PER BOEING DOCUMENT 1-320831752-4.

Part: STRINGER — CRACKED (BS 460-480 S28L) · airframe 92,606 hrs · 18,914 cycles

BS 460-480 STRINGER 28L FOUND SEVERAL HOLES ELONGATED. FOUND BS 460-480 STRINGER 28L REPLACED AS PER SRM 51-10-01 PAGE 9 AND AS PER SRM 51-30-02.

Part: STRINGER — DAMAGED (BS 460-480) · airframe 92,606 hrs · 18,914 cycles

BS 460-480 STRINGER 28R FOUND SEVERAL HOLES ELONGATED. BS 460-480 STRINGER 28R REPLACED AS PER SRM 51-10-01 PAGE 9 AND AS PER SRM 51-30-02.

Part: RELIEF VALVE — FAILED (A/C PACK) · airframe 94,827 hrs · 17,100 cycles

DURING PASSING 3000' WHEN PACKS WERE TURNED ON DUCT PRESS LOW LIGHT ILLUMINATED. DUCT PRESS 9 PSI. ENGINE BLEED VALVES 2, 3 AND 4 OPEN. REMOVED AND REPLACED NR 4 PRESS RELIEF VALVE. LEAK CHECKED COMPLIED WITH, NO DEFECTS AT THIS TIME REF AMM 71-00-00.

Part: CSD — LEAKING (NR 3 ENGINE) · airframe 92,070 hrs · 18,802 cycles

DIVERSION TO JFK WHILE AIRCRAFT WAS EN ROUTE TO PIK FROM CHS. AT LEVEL OFF AT FL 33.0 #3 ENGINE OIL QTY DROPPED TO 2 GALLONS. 15 MIN LATER DROPPED TO 0.5 GALLONS. ENGINE POWER REDUCED TO IDLE. REINSTALLED PREVIOUSLY DEFERRED GENERATOR AND REPLACED THE CSD.

Part: MEC — UNSERVICEABLE (NR 3 ENGINE) · airframe 91,854 hrs · 18,749 cycles

NR 3 ENGINE ROLLED BACK IN CLIMB TO 42.6 PERCENT N1, 663KGS/HR FUEL FLOW WOULD NOT RESPOND TO THROTTLE MOVEMENT TO ADD POWER. LOW THRUST CONFIRMED BY HIGH STAGE LIGHT ON, BLEED VALVE CLOSED LIGHT ON. REPLACED NR 3 MEC ,FUEL PUMP,AND CIT SENSOR. ACCOMPLISHED TEST 5 MPA RUN PER AMM.

Part: SKIN — CRACKED (ZONE 200) · airframe 91,203 hrs · 18,612 cycles

L-1 DOOR UPPER HINGE CUT-OUT, LOWER AFT CORNER HAS A CRACK. ACCOMPLISHED PERMANENT REPAIR AS PER BOEING SB 747-52-2144 REV 2. ALSO REFERENCE ATLAS AIR XEO NR 52-112406.

Part: SKIN PANEL — DELAMINATED (RT WING) · airframe 91,203 hrs · 18,612 cycles

RT WING UPPER FIXED TRAILING EDGE PANELS AT WBL 353 AND WBL 445 AND UPPER FIXED LEADING EDGE PANEL AT WBL 363 HAVE DEGRADED AND DELAMINATED EXISTING COMPOSITE REPAIRS. ACCOMPLISHED PERMANENT REPAIRS AT WBL 353 ON 12 INCH LONG BY 10 INCH WIDE SECTION, WBL 445, 5 INCH LONG BY 7 INCH WIDE SECTION AND WBL 363, 12 INCH LONG BY 12 INCH WIDE SECTION. PERMANENT REPAIRS WERE ACCOMPLISHED AS PER BOEING 747 SRM 51-40-09 FIG 2 AND FIG 18 AND BOEING 747 SRM 51-40-12. ALSO, REFERENCE ATLAS AIR XEO NR 57-112406.

Part: SKIN — DENTED (LT WLG) · airframe 90,543 hrs · 18,472 cycles

L/G LT WLG I/B STRUT DOOR EXT SURFACE DENT CAUSE BY TIRE BLOWN AT AFT UPPER PORTION. FILLER REPAIR CARRIED OUT AS PER SRM 51-40-01.

Part: SKIN — DENTED (T/E FLAP) · airframe 90,543 hrs · 18,472 cycles

DURING VISUAL INSPECTION FOUND, LHW I/B AFT FLAP LWR SURFACE PANEL WITH DENT MARKS CAUSED BY TIRE BLOWN AT NR 4 CANOE FAIRING AREA. FILLER REPAIR CARRIED OUT AS PER SRM 51-40-01.

Part: FAIRING — CRACKED (FUSELAGE) · airframe 90,543 hrs · 18,472 cycles

DURING VISUAL INSPECTION FOUND (1)BODY FAIRING 293C & 293D INNER SURFACE CRK (2) FOUND BODY FAIRING 194B, 193C, 193D, 193G,WITH DENT MARKS CAUSED BY TIRE BLOWN. COMPOSITE REPAIR CARRIED OUT AS PER SRM 51-40-12 FIG 9.

Part: STIFFENER — GOUGED (LT MLG WW) · airframe 90,543 hrs · 18,472 cycles

L/G LBLG W/W CEILING DECK STIFFENER FOUND GOUGE AT STA 1365 LBL 60-LBL 80 AND STA 1378 LBL 40-LBL 55 CAUSED BY TIRE BLOWN. SMOOTHED OUT GOUGE MARK AS PER SRM 51-10-01, RE-PROTECTED AS PER SRM 51-10-02 AND PERFORMED CRACK FREE CHECK AT REWORKED AREA PER SOPM 20-20-02.

Part: STIFFENER — GOUGED (LT MLG WW) · airframe 90,543 hrs · 18,472 cycles

L/G LBLG W/W CEILING DECK STIFFENER FOUND GOUGE AT STA 1365 LBL 60-LBL 80 AND STA 1378 LBL 40-LBL 55 CAUSED BY TIRE BLOWN. SMOOTHED OUT GOUGE MARK AS PER SRM 51-10-01, RE-PROTECTED AS PER SRM 51-10-02 AND PERFORMED CRACK FREE CHECK AT REWORKED AREA PER SOPM 20-20-02.

Part: SKIN — DELAMINATED (T/E FLAP) · airframe 90,543 hrs · 18,472 cycles

DURING VISUAL INSPECTION ON LHW I/B AFT FLAP LWR SURFACE T/E FOUND DELAMINATED AT 15" - 25" FROM I/B SIDE CAUSED BY TIRE BLOWN. COMPOSITE REPAIR CARRIED OUT AS PER SRM 51-40-12 FIG 9.

Part: FAIRING — DELAMINATED (T/E FLAP) · airframe 90,543 hrs · 18,472 cycles

DURING VISUAL INSPECTION ON LHW I/B AFT FLAP LWR SURFACE L/E FAIRING FOUND DELAMINATED AT 10" - 20" FROM I/B SIDE CAUSED BY TIRE BLOWN. COMPOSITE REPAIR CARRIED OUT AS PER SRM 51-40-12 FIG 9.

Part: FAIRING — DENTED (FUSELAGE) · airframe 90,543 hrs · 18,472 cycles

DURING VISUAL INSPECTION OF BODY FAIRING 194C FOUND DENT MARKS CAUSED BY TIRE BLOWN. COMPOSITE REPAIR CARRIED OUT AS PER SRM 51-40-15 FIG 7.

Part: TIRE — FAILED (MLG) · airframe 90,539 hrs · 18,470 cycles

AIR TURN BACK: DUE TO MULTIPLE TIRE FAILURE. PERFORMED INSPECTION PER 5-51-25 AND 5-51-34. REMOVED AND REPLACED NR 7 AND NR 8 BRAKE, ANTI-SKID CHECKED OK AS PER MM 32-41-15, BRAKE SYSTEM CHECKED FOR LEAK FOUND OK. REMOVED AND REPLACED NR 5, NR 6, NR 7 AND NR 8 WHEEL ASSY AS PER MM 32-45-01, LEAK CHECK OK.

Part: SEAT TRACK — CRACKED (FUSELAGE) · airframe 89,860 hrs · 18,327 cycles

MAIN DECK SEAT TRACK AT STATION 1900 LT, LBL 99 HAD A 2.5 INCH CRACK. SEAT TRACK WAS PERMANENT REPAIRED WITH A 20 INCH SECTION OF EXTRUSION P/N BAC1520-1566, SPLICED BETWEEN STATIONS 1890 AND 1910 AT LBL99 AS PER 747 SRM 53-10-05 FIG 1A. ALSO, REFERENCE ATLAS EO 4753A798.

Part: DRAG BRACE — CHAFED (NR 3 PYLON) · airframe 89,860 hrs · 18,327 cycles

NR 3 PYLON DIAGONAL BRACE HAS 2 AREAS OF CHAFING DUE TO CONTACT WITH HYD COMPART DOOR LATCH BOLTS. BRACE WAS BLENDED WITH A TIME LIMITED REPAIR AS PER 747 SRM 51-41-01 FIG 3. FWD BLEND IS ON BRACE ZONE "4", BLENDED TO 2 5/8 INCH LONG BY 1 5/8 INCH WIDE AND 0.127 INCH DEEP, WHICH IS OUT OF THE LIMITS ALLOWED. AFT BLEND IS ZONE "5", BLENDED TO 1 3/4 INCH LONG BY 3/4 INCH WIDE AND 0.030 INCH DEEP, THIS IS WITHIN THE LIMITS ALLOWED. FPI WAS ACCOMP AND NO DEFECTS NOTED AS PER ASTM1417-05. AREA WAS PEENED AS PER SOPM 20-10-03. TREATED AND PRIMED AREA AS PER SRM 51-10-02. FAA FORM 8100-9 WAS ISSUED TO RE-INSPECT FWD BLEND AT EVERY A-CHECK AND REPLACE BRACE AT NEXT C-CHECK, NOT TO EXCEED 18 MONTHS. ALSO, REF AT

Part: SKIN — GROUND DAMAGE (NLG DOOR) · airframe 89,860 hrs · 18,327 cycles

LEFT NOSE GEAR STRUT DOOR FORWARD SECTION OF DOOR SKIN WAS DAMAGED WITH STEP LADDER UNDER DOOR WHILE INSTALLING NR 2 ENGINE. DOOR WAS REMOVED FOR SHEETMETAL REPAIR AND HINGES WERE VISUALLY INSPECTED FOR DEFECTS, FOUND OK AS PER 747 MM 32-22-02. ACCOMPLISHED PERMANENT DOUBLER REPAIR AND REPLACED DAMAGED SECTION OF CLOSURE ANGLE AS PER 747 SRM 52-80-02 FIG 1, 51-20-01 AND 51-30-10. INSTALLED DOOR AND ACCOMPLISHED NLG RETRACTION CHECK FOR DOOR FIT, CHECKED GOOD AS PER MM 32-22-02 AND MM 32-34-00. ALSO, REFERENCE ATLAS EO 4752A104.

Part: DRAG BRACE — CHAFED (NR 4 PYLON) · airframe 89,860 hrs · 18,327 cycles

NR 4 PYLON DIAGONAL BRACE WAS CHAFED ON OUTBOARD SIDE, DUE TO CONTACT WITH HYDRAULIC COMPARTMENT DOOR ROD. AREA WAS BLENDED AND 0.070 INCH OF MATERIAL WAS REMOVED AND FOUND WITHIN LIMITS AS PER 747 SRM 54-41-01 FIG 3. ALSO, REFERENCE ATLAS XEO 54-062906. FPI WAS ACCOMPLISHED NO DEFECTS NOTED AS PER ASTM 1417-05. AREA WAS PEENED AS PER SOPM 20-10-03. AREA WAS TREATED AND PRIMED AS PER SRM 51-10-02.

Part: PRESSURE VALVE — FAILED (BLEED AIR SYS) · airframe 89,860 hrs · 18,327 cycles

WHILE CLIMBING TO FLT LEVEL 320, THE NR 4 ENG FIRE WARNING CAME ON, BOTH LOOP WERE INDICATING 8.5 ON THE GRAVINER SCALE, ALL OTHER PARAMETERS WERE NORMAL. ACCOMPLISHED ENG FIRE PROCEDURE AS PER QRH AND NR 4 ENG WAS SHUTDOWN. SINCE THE FIRE WARNING LIGHT ON NR 4 FIRE HANDLE WENT OUT WHEN THROTTLE WAS CLOSED IT WAS NOT NECESSARY TO DISCHARGED THE FIRE BOTTLE. REMOVED AND REPLACED PRV IAW MM 36-11-03. REMOVED AND REPLACED HSV IAW MM 36-11-60. REMOVED AND REPLACED PRV IAW 36-11-19. REMOVED AND REPLACED A&B FIRE WARNING HARNESS PER MM 26-11-00, OPS CK OK. PERFORMED NR 4 ENG RUN-UP IAW MM 71-00-00 OPS, LEAK AND INDICATIONS TEST NORMAL.

Part: CONTROL SYSTEM — INTERMITTENT (ILS)

AFTER ROLLING OUT 360 DEGREES, VOR COURSE INBOUND, ALL NAV INDICATIONS, OK. AFTER DESCENDING TO FL 10.0 JUST PRIOR TO CROSSING THE VOR SELECTED ILS FREQ ON CAPT AND FO MCP, BOTH HIS SELECTOR SWITCHES WERE SET TO ILS AND NAV MODE ON ILS. CPT HAD COURSE AND G/S INDICATIONS W/NO FLAGS IN VIEW. FO INDICATING TO G/S INDICATIONS WITH LOC TO THE RIGHT. AFTER EXTENDING GEAR CAPTS SIDE BECAME INTERMITTENT AND FLAGS IN VIEW SIMULTANEOUSLY HEARD PULL UP TERRAIN WARNING. FIREWALL THRUST FLAPS 20 EXECUTED. DIVERTED. ILS RECEIVERS 1 AND 2 SELF TEST PERFORMED, SYSTEM CHECKED NORMAL ON THE GROUND. (K)

Part: ACTUATOR — LEAKING (NR 8 SPOILER)

DURING CLIMB-OUT, NR 4 HYDRAULIC SYSTEM LOW QUANTITY LIGHT CAME ON WITH A DROP OF SYSTEM QUANTITY OIL FROM 8.5 TO 2.5, SYSTEM WAS SHUTDOWN. QUANTITY REMAINED AT 2.5. TURNED ADP TO CONTINUOUS, QUANTITY STARTED DROPPING, SYSTEM SHUTDOWN. REF: LOG PAGE 537018, FUEL JETTISONED FROM 82.7 TO 47.1. REMOVED AND REPLACED NR 8 SPOILER ACTUATOR IAW MM 27-61-04. OPS AND LEAK CHECK OK. REMOVED SPOILER ACTUATOR, PN 33205001, SN 452423.

Part: INDICATOR — MALFUNCTIONED (AIRSPEED)

ABORTED TAKEOFF, CAPTAINS AIRSPEED INDICATED 80 KNOTS. FIRST OFFICERS INDICATED 0. AIRCRAFT RETURNED TO BLOCKS CAPTAIN IND 100 KNOTS, F/O'S IND 0. CHECKED BRAKE TEMPERATURE FOR POSSIBLE HIGH ENERGY STOP. INDICATED NORMAL RANGE, NO FURTHER INSPECTION REQUIRED PER MM 5-5-10. REINSTALLED BOTH INDICATORS AFTER CHECKED HOSES AND CONNECTIONS. PERFORMED PITOT-STATIC TEST WITH TESTER, AIR DATA TEST SET. SYSTEM LEAK CHECKED NORMA, INSPECTION NORMAL AS PER MM 34-11-00 AND 34-13-05. REF TO DMI NR M04-069/ F/O'S MACH IND HAS FLA IN VIEW. (M)

Part: FUEL TANK — CORRODED (CENTER WING)

FOUND DURING D-CHECK, AT SIN, CORROSION AT WING CENTER SECTION UPPE SKIN AT REAR SPAR BETWEEN BL 0 AND RBL 11.33. CORROSION WAS BLENDED USING A 20:1 RATIO, 125 RHR OR BETTER AND REMAINING THICKINESS TO BE .381 INCH OR GREATER. BLENDED AREA WAS SHOP/FLAP PEENED AND REFINISHED WITH ALODINE 600 AND BMS 10-11, TYPE PRIMER. OPEN HOLES WERE HFEC INSPECTED TO ENSURE NO DEFECTS EXIST. BACB30PT FASTENERS WRE REPLACED WITH BACB30NZ10KX OR BACB30NW10KX HI-LOCKS WITH BACC30M10 COLLARS IN .0005/.0035 INCH INTERFERENCE FIT HOLES. BLENDED AREAS FILLED WITH SEALANT TO PREVENT ACCUMULATION OF MOISTURE. RESTORED FUEL BARRIER WITH MNS 5-81 TYPE 2. (M)

Part: FITTING — CRACKED (NR 1 PYLON)

FOUND DURING D-CHECK AT SIN, DAMAGE WAS FOUND AT FASTENER HOLE IN THE FITTING AFT VERTICAL FLANGE. THE DAMAGE WAS COMPLETELY REMOVED BY OVERSIZING THE HOLE TO .4521-4541 INCHES DIAMETER. AN OVERSIZE FASTENER AS THE SAME DESIGN TYPE REQUIRED, WAS INSTALLED AT THE AFFECTED LOCATION. ALL OTHER FITTING REWORK AND REFINISH ACCOMPLISHED IAW TERMINATING ACTION. (M)

Part: HOUSING — CORRODED (TE FLAPS)

DUIRNG SCHEDULED MAINTENANCE, FOUND CORROSION DAMAGE AT THE MAIN BEARING HOUSING BORE OF THE LEFT WING INBOARD TRAILING EDGE MID-FLAP CARRIAGE BEARING HOUSINGS ASSEMBY. REAMED BORE TO 6.100 INCHES DIAMETER AND REMOVED LOCAL SURFACE DAMAGE FROM AFFECTED AREA OF HOUSING. SMOOTH BLENDED AND REFINISHED HOUSING TO DESIGN CONDITION. DYE PENETRANT INSPECTED TO ENSURE MACHINED BORE IS DAMAGE AND CRACK FREE. VISUAL AND HFEC INSPECTED SATELLITE HOLES TO ENSURE HOLES ARE ROUND AND CRACK FREE. REFINISHED AND INSTALLED OVERSIZE REPAIR SLEEVE PER THE REQUIREMENTS OF OHM 57-52-35. SHOT PEENED MAIN BORE AND RESTORE FINISH. (M)

Part: SKIN — CRACKED (NR NACELLE)

DURING SCHEDULE MAINTENANCE, FOUND CRACK DAMAGE AT PRE-COOLER EXHAUST CUTOUT LOWER AFT CORNER AT NACELLE STATION 248, NR 2 PYLON. TRIMMED THE NR 3 STIFFENER BASE BOTTOM TO REMOVE THE CRACK. TRIMMED THE SKIN ASSEMBLY AND WINDOW STRAP. NDT INSPECTED EACH REPAIR AREA, INCLUDING HFEC INSPECTION OF ALL REPAIR FASTENER LOCATIONS AND TRIMMED EDGES TO ENSURE ABSENCE OF CRACKS, CORROSION AND ANY OTHER DAMAGE. INSTALLED ALUMINUM FILLER AT EACH TRIMMED AREA. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NACELLE STATION 235 TO NACELLE STATION 254. THE RIB INSTALLATION AT NACELLE STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: SKIN — CRACKED (NR 1 NACELLE)

DURING SCHEDULE MAINTENANCE, FOUND CRACK DAMAGE AT PRE-COOLER EXHAUST CUTOUT LOWER AFT CORNER AT NAC STATION 248, NR 1 PYLON. TRIMMED THE NR 3 STIFFENER BASE BOTTOM TO REMOVE THE CRACK. TRIMMED THE SKIN ASSEMBLY AND WINDOW STRAP. NDT INSPECTED EACH REPAIR AREA, INCLUDING HFEC INSPECTION OF ALL REPAIR FASTENER LOCATIONS AND TRIMMED EDGES TO ENSURE ABSENCE OF CRACKS, CORROSION AND ANY OTHER DAMAGE. INSTALLED ALUMINUM FILLER AT EACH TRIMMED AREA. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NAC STATION 235 TO NAC STATION 254. THE RIB INSTALLATION AT NACELLE STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: SKIN — CRACKED (NR 3 PYLON)

DURING SCHEDULED MAINTENANCE, FOUND CRACK DAMAGE AT PRE-COOLER EXHAUST CUTOUT LOWER AFT CORNER AT NACELLE STATION 248, NR 3 PYLON. TRIMMED THE NR 3 STIFFENER BASE BOTTOM TO REMOVED THE CRACK. TRIMMED THE SKIN ASSEMBLY AND WINDOW STRAP. NDT INSPECTED EACH REPAIR AREA, INCLUDING HFEC INSPECTION OF ALL REPAIR FASTENER LOCATIONS AND TRIMMED EDGES TO ENSURE ABSENCE OF CRACKS, CORROSION AND ANY OTHER DAMAGE. INSTALLED ALUMINUM FILLER AT EACH TRIMMED AREA. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NACELLE STATION 235-254. THE RIB INSTALLATION AT NACELLE STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: SKIN — CRACKED (NR 4 PYLON)

DUIRNG SCHEDULE MAINTENANCE, FOUND CRACK DAMAGE AT PRE-COOLER EXHAUST CUTOUT LOWER AFT CORNER AT NACELLE STATION 248, NR 4 PYLON. TRIMMED THE NR 3 STIFFENER BASE BOTTOM TO REMOVE THE CRACK. TRIMMED THE SKIN ASSEMBLY AND WINDOW STRAP. NDT INSPECTED EACH REPAIR AREA, INCLUDING HFEC INSPECTION OF ALL REPAIR FASTENER LOCATIONS AND TRIMMED EDGES TO ENSURE ABSENCE OF CRACKS, CORROSION AND ANY OTHER DAMAGE. INSTALLED ALUMINUM FILLER AT EACH TRIMMED AREA. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NACELLE STATION 235-254. THE RIB INSTALLATION AT NACELLE STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: SLIDE — DEPLOYED (UPPER DECK DOOR)

DURING TEST, THE UPPER DECK SLIDE FAILED TO FULLY DEPLOY. SLIDE (PN 7A14124, SN GU148 WAS REMOVED AND REPLACED WITH A NEW SLIDE PN 7A1248-36, SN G639.

Part: TRUNNION — LACK OF LUBE (NLG)

NOSE LANDING GEAR WOULD NOT EXTEND NORMALLY. EXTENDED OK WITH ALTERNATE SWITCH. LUBRICATED NOSE LANDING GEAR TRUNNIONS PER MM 12-21-01. JACKED AIRCRAFT PER MM 7-11-02. RESET ALTERNATE GEAR SYSTEM PER 32-36-00 AND ACCOMPLISHED NOSE LANDING GEAR SWING PER 32-34-00. OPS CHECK NORMAL. (M)

Part: SENSOR — MALFUNCTIONED (NR 1 ENGINE)

JFK/MXP - INFLIGHT ENGINE SHUTDOWN. NR 1 ENGINE N1 EXCEEDANCE DURING DESCENT PROFILER WHILE A/T ENGATED AND THROTTLES MOVING FORWARD. N1 136.9 PERCENT FOR 11 SECONDS. EGT 666, N2 92.4, F/F 3218. NR 1 ENGINE SHUTDOWN IAW FHB. PERFORMED ENGINE OVERSPEED INSPECTION IAW 72-00-00 PAGE 680. NIL FOUND. SUSPECTED BAD N1 TRANSMITTER. REMOVED AND REPLACED NR 1 ENGINE N1 FAN SPEED SENSOR IAW 77-12-01-401. OPERATED NR 1 ENGINE MAX POWER ASSURANCE TEST 4. ALL FIGURES WITHIN LIMITS. N1 INDICATION NORMAL IAW 71-00-00. (M)

Part: ANTI-ICE SYSTEM — MALFUNCTIONED (COCKPIT)

DURING CLIMB-OUT, THE CREW NOTICED A STRONG BURNING SMELL IN THE COCKPIT. TURNED OFF R2 AND 3 WINDOW HEAT AND THE SMELL DISSIPATED. PULLED CB'S FOR L2-R3 AND L3-R2 WINDOW HEAT. AFTER APPROXIMATELY 3 MORE HOURS THE ODOR RETURNED. THIS TIME SMOKE CAME FROM LOWER LEFT CORNER OF L1 WINDOW. SCORCHING OBSERVED ON GLASS. SWITCHED OFF AND CB PULLED. A/C DIVERTED TO DXB. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING VISUAL INSPECTION OF AFT FUSELAGE INTERNAL RIGHT SIDE WALLS FOUND BENT KICKPLATE AT BS 1800. AFTER OPENING SIDE WALLS FOUND BS 1800 FRAME CRACK 3.5 INCHES BETWEEN STRINGER 10R AND 11R. FOUND FRAME STATION 1820 INNER CHORD DENTED BELOW STRINGER 12R. PERFORMED REPAIR IAW SRM 51-20-01, 51-30-02, 51-10-02, 51-10-00 AND SOPM 20-41-02. REF BSAA00042. (M)

Part: SKIN — CORRODED (LT WING)

DURING VISUAL INSPECTION OF LEFT WING LOWER SURFACE, FOUND SKIN CORROSION AROUND FASTENER HEADS AT WING STATION 1300 COMMON TO THE MID SPAR. REMOVED FASTENER, REMOVED CORROSION FROM SKIN SURFACE IAW SRM 57-30-01. PERFORMED HFEC INSPECTION OF SKIN AND FASTENER HOLE NO CRACKS PRESENT. OVERSIZED HOLE, ROTOPEENED REWORKED AREA, INSTALLED OVERSIZED FASTENER. SEALED FASTENERS IN FUEL TANK AND PAINTED EXTERNAL SKIN SURFACE. REPAIRED IAW SRM''S 57-30-01 AND 57-30-03. (M)

Part: SKIN — CORRODED (RT WING)

DURING VISUAL INSPECTION OF RT WING LOWER SURFACE, FOUND BULGING OF FIXED LEADING EDGE PANEL AT WING STATION 1322, FSSO 1339. REMOVED FASTENER AND FRONT SPAR FITTING. FOUND LOWER SKIN UPPER SURFACE PAD AREA CORRODED FORWARD OF FRONT SPAR. REMOVED CORROSION FROM SKIN SURFACE IAW SRM 51-10-01. PERFORMED HFEC INSPECTION OF SKIN AND FASTENER HOLE NO CRACKS PRESENT. PERFORMED DYE PENETRANT INSPECTION OF REWORKED AREA TO BE FREE OF CORROSION. SHOT/FLAP PEENED AREA. INSTALLED OVERSIZED FASTENER AND REPAIR STRAPS. REPAIRED IAW SRMS 51-10-01 AND 57-30-03. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

DURING VISUAL INSPECTION OF FUSELAGE, THE MED NR 1L FORWARD LOWER REVEAL (STA 434) WAS FOUND CRACKED 1 INCH IN LENGTH HORIZONTALLY BELOW STOP NR 1 ON LOWER REVEAL. STOP DRILLED IAW SRM 51-10-01 AND BOEING TELEX AND 81180-3. TO BE REPLACED PRIOR TO 1,500 CYCLE OR 15 MONTHS WHICHEVER DONE FIRST. FORM 8110-3 ISSUED. (X)

Part: SPAR — CORRODED (CENTER WING)

DURING VISUAL INSPECTION OF CENTER WING REAR SPAR, FOUND WEB CORROSION TO THE UPPER CHORD AT BS 1241 LBL 4. REMOVED CORROSION FROM WEB SURFACE IAW SRM 57-10-01. REMOVED FASTENERS IN UPPER CHORD. PERFORMED HFEC INSPECTIONS OF WEB AND FASTENER HOLES, NO CRACKS PRESENT. OVERSIZED HOLES AND INSTALLED NEW OVERSIZED FASTENERS. SEALED FASTENERS IN FUEL TANK AND PAINTED EXTERNAL SKIN SURFACE. REPAIRED IAW SRM''S 57-10-01. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING VISUAL INSPECTION OF AFT FUSELAGE INTERNAL RIGHT SIDE WALLS FOUND BENT KICKPLATE AT BS 1800. AFTER OPENING SIDE WALLS FOUND BS 1800 FRAME CRACK 3.5 INCHES BETWEEN STRINGER 10R AND 11R. FOUND FRAME STATION 1820 INNER CHORD DENTED BELOW STRINGER 12R. PERFORMED REPAIR IAW SRM 51-20-01, 51-30-02, 51-10-02, 51-10-00 AND SOPM 20-41-02. (M)

Part: STRUCTURE — CRACKED (PAX DOOR)

LT LA7143 - MIA/ASU-ATB, AFTER TAKEOFF, CREW ADVISED THAT THEY WERE UNABLE TO PRESSURIZE THE AIRCRAFT. AFTER ABNORMAL CHECKLIST ACCOMPLISHED, CHECK OF MAIN DECK REVEALED NO ABNORMALITIES. DUMPED 80 KGS OF FUEL AND RETURNED TO MAI WAS UNEVENTFUL. MAINTENANCE FOUND A I CRACK IN R5 MAIN ENTRY DOOR. REPLACED R5 MED AND PRESSURIZATION CONTROLLER. PRESSURIZATION CHECK NORMAL. (M)

Part: IGNITOR — ERODED (NR 1 ENGINE)

FLT 2087 - ANC-KIX - DURING DESCENT THROUGH 4000 FT, NR 1 ENGINE FLAMED OUT. FLIGHT CRWE DID NOT ATTEMPT TO RE-START ENGINE. AIRCRAFT LANDING AT KIX UNEVENTFUL. MAINTENANCE PERFORMED TROUBLESHOOTING AS PER MM 71-00-42. NO FAULTS FOUND. BOTH IGNITERS WERE REPLACED. REMOVED IGNITERS SHOWED SIGNS OF HEAVY EROSION. MPA PERFORMED ON NR 1 AND NR 4 ENGINES. ACCELERATION/DECELERATION NORMAL. (M)

Part: STRUCTURE — DAMAGED (BS 1920)

FLT GT363 - ON ARRIVAL, GROUND OPERATIONS FOUND WHEN THE REAR LOWER LOBE CARGO DOOR WAS OPENED, [ALLET POSITION NR 9 HAS SHIFTED AFT GOING OVER THE END STOPS. THERE WAS STRUCTUAL DAMAGE TO THE BRACE POST ON BOTH SIDES OF THE COMPARTMENT THAT SEPARATE THE BULK COMPARTMENT FROM THE MAIN SECTION OF THE LOWER AFT CARGO COMPARTMENT AT STA 1920. ON FURTHER INVESTIGATION, MAINTENANCE FOUND THAT PALLET LOCKS FOR AFT END OF PALLET WERE IN DOWN POSITION. OPERATIONAL CHECK OF LOCKS AFTER PALLET WAS REMOVED WERE NORMAL. (M)

Part: ENGINE — FAILED (NR 1)

CREW REPORTS: ABORTED TAKEOFF FLT SK5086/06, SHJ/GOT...DURING TAKEOFF, FLIGHT CREW REPORTED A LOUD BANG AT 90-100 KNOTS AND ABORTED TAKEOFF DUE NR 1 ENGINE FAILURE (SN 528419). INSPECTION OF ENGINE REVEALED AFT CENTERBODY DEPARTED AIRCRAFT. LPT BLADE PENETRATED THE LPT CASE AND CORE COWL IN THE SIX O'CLOCK PLANE. NO AIRCRAFT DAMAGE EXISTED. ENGINE WAS CHANGED, EXHAUST NOZZLE AND CENTERBODY WERE REPLACED. CAUSE OF FAILURE TO BE DETERMINED AT ENGINE TEAR-DOWN. (X)

Part: SEAT TRACK — BROKEN (BS 1810-1850)

DURING A-CHECK, FOUND SEAT TRACK BROKEN AT STA 1810 TO STA 1850 ON MAIN CARGO DECK AND FLOOR FITTING DAMAGED. FLOOR FITTING REPLACED AND SEAT TRACK REPLACED PER SRM 53-10-05, FIG 33, SHEET 4.