N524MC
Operators of this aircraft
Who operated this tail, and how firmly we know it.
No operator established for this aircraft.
Accident & incident history
No NTSB accidents or incidents on file for this aircraft.
Maintenance disclosures
Service Difficulty Reports filed with the FAA for this airframe. Filing is largely voluntary — the number of reports is not a measure of reliability. To verify a report, search its control number at the FAA SDRS site.
142 reports on file, 1999-06-20 – 2011-11-22.
Part: THRUST REVERSER — DAMAGED (NR 3 ENGINE) · airframe 106,413 hrs · 22,034 cycles
DURING MX WALKAROUND, FOUND DAMAGE TO THE NR 3 ENGINE RT THRUST REVERSER TRANSLATING COWL EXTERNAL SKIN PUNCTURED (3 PLACES). THE DAMAGE IS LOCATED NEAR THE REVERSER BLOWOUT DOOR AT 6 O'CLOCK POSITION.
Part: LAMP — BURNED OUT (DOOR SLIDE) · airframe 106,327 hrs · 22,015 cycles
EMERGENCY UNARMED LIGHT BURNED OUT. RELAMPED BULBS IAW AMM 33-11-07.
Part: VENT — OPEN (CARGO DOOR)
DURING CLIMBOUT, AFT CARGO DOOR LIGHT CAME ON F/E PANEL. LIGHT WENT OUT DURING DURING DESCENT AT APPROX 3000FT. ON ARRIVAL, FOUND MAIN DECK CARGO VENT DOORS OPEN. INSPECTED DOOR, NO DEFECTS NOTED TO DOOR OR STRUCTURE. OPS CHECKED NORMAL. AFT CARGO DOOR INSPECTED, AND OPERATED DOOR AND VENT DOORS AND FUNCTIONAL CHECKS NORMAL. PRESSURIZATION CHECKS ACCOMPLISHED AND ALL NORMAL AND DOOR LIGHT INDICATIONS OK.
Part: MANIFOLD — CRACKED (LPT COOLING) · airframe 106,157 hrs · 21,980 cycles
UPON OPENING OF THE NR 1 ENGINE NACELLE, MX FOUND THE LOWER LPT COOLING MANIFOLD BROKEN AT SEVERAL LOCATIONS. REFER TO FIG 1 FOR DAMAGE LOCATION AND DETAILS. DUE TO PRESENCE OF CRACKS AROUND THE LPT COOLING MANIFOLD WAS OVER LIMITS WITH AMM 75-24-00, SUBMITTED THE PRE-EXISTING CONDITION TO GE AND PROPOSED TO CONTINUE THE ENGINE IN SERVICE "AS IS" FOR 5 FLIGHT CYCLES AFTER WHICH THE DAMAGED PART WILL BE REPAIRED AND/OR REPLACED. NOTE THAT THE SUBJECT ISSUE HAD BEEN COMMUNICATED WITH VIA SR NR 7-1-2589025022. (DISPOSITION IS TO INSPECT THE LPT COOLING MANIFOLD AREA WHERE THE CRACKS WERE FOUND FOR ANY DISTORTION/BURN MARK FOUND ON THE CASES, TUBING AND COMPONENTS ETC., IF NO DAMAGE IS FOUND APPLY THE FIBERFLECT TAPE. WITHIN 5 FLIGHT CYCLES REPLACE THE DAMAGED LPT COOLING MANIFOLD WITH A SERVICEABLE ONE.)
Part: SUPPORT — CRACKED (BS 1920) · airframe 105,974 hrs · 21,942 cycles
DURING MX, DAMAGE FOUND AT MAIN DECK - LT BS 1920 - SIDEWALL/LINER SUPPORT CONSISTING OF CRACK. LOCATED AFT OF THE MDSCD, MEASURING 1.5 IN. LONG (REF FIG 1). DISPOSITION WAS MADE TO PERFORM A TIME LIMITED REPAIR AS DESCRIBED IN PART 1 WORK INSTRUCTIONS. CONSISTING IN FABRICATING/INSTALLING A REPAIR DOUBLER MADE FROM CLAD 2024 T-3, 0.050 IN. WITH 2 ROWS OF FASTENERS AROUND THE DAMAGE; SCHEDULE REPEAT INSPECTIONS AT EVERY 5 FC (FLIGHT CYCLES) IAW PART 2 AND PERMANENT REPAIR PER PART 3 PRIOR PRIOR TO THE ACCUMULATION OF 750 FH (FLIGHT HOURS), AS SCHEDULED BY MX PLANNING.
Part: WIRE — BURNED (AILERONS) · airframe 109,568 hrs · 21,882 cycles
WIRE BUNDLES BURNED INSIDE THE CONDUIT USED FOR THE AILERON LOCK OUT ACTUATOR, THE LATERAL NR 1 HYD SOV AND NR 1 REFUEL VALVE PERFORMED A TIME LIMITED REPAIR IAW PART 1.
Part: FRAME — CRACKED (BS 240) · airframe 105,635 hrs · 21,872 cycles
DISCOVERED 2 CRACKS, 1- 0.875" AND ANOTHER 0.75", IN THE FRAME DOUBLER AT BS 240, S24AL, REF SHEET 1 OF FIG 1. REPAIRED.
Part: STRINGER — CRACKED (BS 940 S8L) · airframe 105,635 hrs · 21,872 cycles
A 1.3" CRACK IN STRINGER AT BS 940, S-8L. CRACK WAS FOUND DURING ROUTINE INSPECTIONS. REPAIRED WAS ACCOMPLISHED IAW SRM 53-10-03, FIG 4.
Part: FRAME — CRACKED (BS 360 S17L) · airframe 105,635 hrs · 21,872 cycles
DISCOVERED 2 EA 0.5" CRACKS IN THE FRAME DOUBLER AT BS 360, S-17L, REF SHEET 3 OF FIG 1. REPAIRED.
Part: SPAR — CORRODED (RT WING TE FLAP) · airframe 105,635 hrs · 21,872 cycles
RT INBD AFT FLAP MOST OTBD MIDDLE EDGE AREA CORROSION FOUND. CORROSION AREA TRIMMED AWAY AND REPAIR CARRIED OUT IAW HRS NR R57-50-37178 RVC REV B AND EO 4757A519 PART 1.
Part: NOZZLE — CRACKED (EXHAUST) · airframe 105,635 hrs · 21,872 cycles
DURING AN ENGINE CHANGE AT AN A-CHECK, MX FOUND 3 EA CRACKS ON THE NR 4 ENGINE FIXED COWL EXHAUST NOZZLE FOWARD FLANGE CORE COWL SUPPORT ASSY (REF FIGURE 1). REPAIRED IAW EO 4778A148.
Part: FRAME — CHAFED (BS 1980) · airframe 105,635 hrs · 21,872 cycles
INSPECTION VISUALLY FOUND CHAFING DAMAGE ON FRAME PN 65B04600-7 AT STA 1980 AND COMMON TO STRINGERS 22R AND 23 R. THIS WAS DOCUMENTED ON NRC 51305. (THE DAMAGE WAS REPAIRED BY BLENDING OUT THE CHAFE MARKS. THE BLENDED AREAS WERE HFEC INSPECTED TO ENSURE CRACK FREE CONDITION. REPAIR REINFORCEMENT ANGLE AND FILLERS WERE MADE FROM 7075-T6 MATERIAL. THE PARTS AND REPAIR AREA WERE TREATED AND PRIMED IAW SRM AND FAY SEALANT USED BETWEEN ALL PARTS.)
Part: FRAME — CRACKED (BS 2231) · airframe 105,635 hrs · 21,872 cycles
DURING C4/A6 CHECK, DETECTED 6 EA CRACKS ON THE FRAME STRAP FASTENER HOLES; 2 EA CRACKS ON THE FWD INNER CHORD FASTENER HOLES; 3 EA CRACKS ON THE AFT INNER CHORD FASTNER HOLES AND 2 EA CRACKS ON THE DOOR REVEAL PANEL FASTENER HOLES. THE DETAIL OF THE CRACK FINDINGS IS SHOWN IN FIGURE 1 AND IS DOCUMENTED BY NRC: 51518 AND 51010. THE DAMAGE WAS REMOVED BY TRIMMING OFF ALL CRACKED AREAS OF THE DOOR REVEAL PANEL, THE AFT INNER CHORD AND THE FWD INNER CHORD AND BY CUTTING THE CRACKED AREA OF THE FRAME STRAP AND REPAIRED USING 3 DOUBLERS, FILLERS AND OTHER MISCELLANEOUS PARTS FIG 2 AND RS: R-53-62-37184, REV A FOR REPAIR DETAILS.
Part: FRAME — CRACKED (BS 380) · airframe 105,635 hrs · 21,872 cycles
DURING C4/A6 CHECK, INSPECTION DETECTED 2 EA CRACKS, APPROX 0.50 INCH LONG RUNNING INBD AND 1.8 INCHES LONG RUNNING OTBD AT S-23L CUTOUT AND ANOTHER CRACK APPROX 0.50 INCH LONG, RUNNING INBD AT S-24AL CUTOUT ON THE LT SIDE, BS 380 FRAME.
Part: STRINGER — CRACKED (BS 520-540) · airframe 105,635 hrs · 21,872 cycles
REPAIR DOUBLER WAS REMOVED TO FACILITATE A REPAIR TO STRINGER 27L. THE STRINGER CRACK WAS COMMON TO THE EXISTING EXTERNAL REPAIR DOUBLER BETWEEN STRINGERS 26L AND 28L. THIS WAS DOCUMENTED ON NRC FVY516326. THE INITAL REPAIR DOUBLER WAS EVALUATED AND HAD SUPPLEMENTAL INSPECTIONS FOR IT DOCUMENTED BY EO 4753A832. THE DOUBLER WAS REMOVED AND THE SKIN WAS CUT TO FACILITATE THE STRINGER REPAIR AND A NEW DOUBLER WAS INSTALLED IAW SRM 53-30-03, FIG 47, DETAILS I.
Part: PRESSURE PANEL — CRACKED (BS 1241) · airframe 105,635 hrs · 21,872 cycles
DURING THE PRESENT C4/A6 CHECK, INSPECTION ON THE DATUM ACFT REVEALED CRACKS ON BOTH BS1240 PRESSURE DECK CLOSEOUT PANELS AS SHOWN IN FIGURE 1:- LT SIDE (LBL 75.92 TO 98.58): CRACK WAS REPORTED AT 3" LONG, ALL DATA WAS RECORDED IN NRC 512291. REPAIRED BOTH PANELS USING SB 747-53-2329R2, FIG 6. THESE TYPE OF REPAIRS ARE TIME LIMITED AND SUBJECT TO SUBSEQUENT INSP EVERY 1,000 FH AND REPLACEMENT NO LATER THAN 18 MONTHS AFTER THE REPAIR INSTALLATION.
Part: PRESSURE PANEL — CRACKED (BS 1241) · airframe 105,635 hrs · 21,872 cycles
DURING C4/A6 CHECK, REVEALED CRACKS ON BOTH BS1240 PRESSURE DECK CLOSEOUT PANELS AS SHOWN IN FIG 1:- RT SIDE (RBL 75.92 TO 98.58): CRACK WAS REPORTED AT 0.5" LONG, ALL DATA WAS RECORDED IN RAM 25 - NRC 512309. REPAIRED BOTH PANELS USING SB 747-53-2329R2, FIG 6.
Part: SKIN — CORRODED (RT WING) · airframe 105,635 hrs · 21,872 cycles
DURING THE "C4 PLUS A6 CHECK, CORROSION DAMAGE WAS DETECTED AT THE UPPER SURFACE OF RT WING LOWER SKIN PANEL BETWEEN WS 1289 - WS 1312. THE CORROSION DAMAGE WAS SPREAD OVER A WIDTH OF 15" WITH A DEPTH OF 3" AS DOCUMENTED IAW NRC 50723. AFTER BLENDING, THE REMAINING THICKNESSES OF THE REWORKED MATERIAL FROM THE REWORKED EXCEEDED THE MAXIMUM ALLOWABLE OF SRM 57-30-01, FIG 1.
Part: MOUNT — CRACKED (NR 4 ENGINE) · airframe 105,635 hrs · 21,872 cycles
DURING INSP OF THE NR 4 PYLON REAR ENGINE MOUNT NAC STA 270 BULKHEAD, 1 CRACK WAS FOUND ON THE SUBJECT UPPER SIDE RT BULKHEAD CHORD (PN 65B94107-54) FROM THE MOST INBD FLANGE TOWARDS THE SECOND FASTENER HOLE. THE CRACK IS APPROX 1.72" LONG. (THE DAMAGE WAS REMOVED FROM THE FRAME FLANGE BY TRIMMING. THE REPAIR AREA WAS DET AND HFEC INSPECTED TO ENSURE ABSENCE OF CRACKS OR OTHER DAMAGE. NEW REPAIR ANGLES WERE INSTALLED ON BOTH THE FWD AND AFT SIDES OF PYLON NR 4. THE REPAIR PARTS WERE INSTALLED WITH HI-LOK FASTENERS AND BMS 5-95 SEALANT.
Part: FRAME — DAMAGED (BS 1000 BULKHEAD) · airframe 105,635 hrs · 21,872 cycles
CRACK DAMAGE WAS DETECTED IN RADIUS OF BULKHEAD CHORD AT BS 1000 BETWEEN S38L - S39L. THE CRACK DAMAGE WAS THROUGH THE FULL THICKNESS OF THE CHORD AS DOCUMENTED IAW NRC 50190 FOR REPAIR ACTIONS (SEE FIG 1). REPLACED BULKHEAD CHORD AS REQUIRED IAW TLS EO 4753A495, REV B AND SB 747-53A2471 REV 1.
Part: STRINGER — CRACKED (BS 525 S27L) · airframe 105,635 hrs · 21,872 cycles
INSPECTION FOUND VISUALLY, A CRACK AT BS 525 IN STRINGER 27L DURING ROUTINE INSPECTION. THE STRINGER CRACK IS COMMON TO AN EXTERNAL REPAIR DOUBLER BETWEEN STRINGERS 26L AND 28L THAT HAS A REPETITIVE INSPECTION REQUIREMENT ACCOMPLISHED BY EO 4753A832. SEE FIG 1 FOR VIEWS OF DAMAGE. THIS WAS DOCUMENTED ON NRC FVY512036. (THE DAMAGE WAS REMOVED BY CUTTING THE STRINGER AT STA 550 AND REPLACING THE CRACKED SECTION WITH A NEW STRINGER SECTION FROM PRODUCTION SPLICE AT STA 520 TO REPAIR SPLICE AT STA 550. THE STRINGER AT STA 550 WAS SPLICED IAW 747-0/200/300, SRM 53-10-03, FIG 1 DETAILS I & III. SEE FIG 2 FOR DETAILS OF THE REPAIR.)
Part: FRAME — CRACKED (BS 780 S6L) · airframe 105,635 hrs · 21,872 cycles
DECK FRAME AT BS 760 BETWEEN S-5L AND S-7L FOUND CRACKED AND WAS FOUND DURING THE SECTION 42 UPPER LOBE INSP ACCOMPLISHED IAW EO 4753A165, REV C (SB 747-53-2349 REV 3, AD 2009-18-07). THE CRACK WAS LOCAL ONLY TO THE FRAME AND WAS LOCATED AT S-6L. THE CRACK WAS APPROX 0.5" INCH IN LENGTH. THE SUBJECT DAMAGE WAS RECORDED ON NRC 511491. THE CRACKED WEB WAS REPAIRED IAW SRM 53-10-04, FIG 54 DETAIL IV. THE SRM REPAIR STOP DRILLS THE CRACK AND INSTALLS A DOUBLER OVER THE AREA.
Part: FRAME — CRACKED (BS 760 S6L) · airframe 105,635 hrs · 21,872 cycles
FRAME AT BS 760 BETWEEN S-5R AND S-7R FOUND CRACKED AND WAS FOUND DURING THE SECTION 42 UPPER LOBE INSPECTION ACCOMPLISHED IAW EO 4753A165, REV C (SB 747-53-2349 REV 3, AD 2009-18-07). THE CRACK WAS LOCAL ONLY TO THE FRAME PN AND WAS LOCATED AT S-6R. THE CRACK WAS APPROX 0.75 INCH IN LENGTH. THE SUBJECT DAMAGE WAS RECORDED ON NRC 511483. THE CRACKED WEB WAS REPAIRED IAW SRM 53-10-04, FIG 54. THE SRM REPAIR STOP DRILLS THE CRACK AND INSTALLS A DOUBLER OVER THE AREA.
Part: FRAME — CRACKED (BS 380 S18R) · airframe 105,635 hrs · 21,872 cycles
RT BS 380, STR 18R FRAME OTBD FLANGE FOUND CRACKED AT RT BS 38 BETWEEN STR 17R AND STR 18R, FRAME REPAIRED IAW 53-23-37165, REV A.
Part: ANGLE — CORRODED (BS 1241) · airframe 105,635 hrs · 21,872 cycles
DURING THE PRESENT C4/A6 CHECK, INSPECTION ON THE DATUM ACFT REVEALED CORROSION ON THE BS 1241 CANTED PRESSURE WEB ANGLE COMMON TO WING CENTER SECTION. THE CORROSION WAS REPORTED AT APPROX RBL 80 AND PENETRATED THE A SECTION OF THE ANGLE WHICH WAS TRIMMED IAW FIG 1. OPEN HOLE AND SURFACE HFEC CONFIRMED NO DEFECT WAS FOUND BEYOND THE CORROSION. OPEN HOLE AND SURFACE HFEC CONFIRMED NO DEFECT WAS FOUND BEYOND THE CORROSION.
Part: FRAME — CRACKED (BS 360) · airframe 105,635 hrs · 21,872 cycles
M/D LT BS 360 BETWEEN STR 23L AND STR 26L FRAME CRACKED 10 LOCATIONS. FRAME REPAIRED IAW HXRS, NR 53-12-37160, REV B.
Part: FUSE PIN — CRACKED (NR 4 NACELLE) · airframe 105,635 hrs · 21,872 cycles
NR 4 PYLON UPPER LINK FWD MOUNT BOLT THREAD SEIZED AND NDT FOUND CRACKED AT THREAD ROOT AREA. FUSE PIN REPLACED IAW AMM 54-10-03.
Part: FRAME — CRACKED (BS 320) · airframe 105,635 hrs · 21,872 cycles
M/D LEFT BS 320 STR 14EL FRAME WEB CRACK AT STRINGER CUT OUT. FRAME WEB REPAIRED IAW HXRS NR 53-12-37169, REV A.
Part: FITTING — DAMAGED · airframe 105,635 hrs · 21,872 cycles
DURING ACCOMPLISHMENT OF EO 4753B354 (SB 747-53A2562, AD 2006-22-15) REPLACEMENT FITTING WAS FOUND TO HAVE (2) ATTACH PILOT HOLES WITH THE CENTER SHIFTED APPROX. 0.080 INCH COMPARED TO THE EXISTING STRUCTURE. (THE MISALIGNED HOLES WERE REPAIRED BY INSTALLATION OF FREEZE PLUGS IAW SRM 51-10-08 USING A 0.050 INCH MINIMUM WALL THICKNESS. ORIGINAL DIAMETER FASTENERS WERE USED TO INSTALL THE FITTING.)
Part: FRAME — CRACKED (BS 480) · airframe 105,635 hrs · 21,872 cycles
DURING THE PRESENT C4-CHECK, CRACKS WERE FOUND AT BS 480 SIDE BETWEEN S-27L AND S-28L. BOTH CRACKS WERE REPORTED AT 2 FASTENER HOLES RUNNING FWD WITH LENGTHS 0.25" AND 0.125" RESPECTIVELY. (CARRIED OUT A CATEGORY B REPAIR BASED ON SRM 53-30-03, FIG 1 (WITH SUBSEQUENT INSPECTIONS IAW TABLE IV). DAMAGED AREA WAS TRIMMED, A FILLER PLUS A DOUBLER WERE INSTALLED AS SHOWN IN FIG 1.)
Part: STRINGER — CORRODED (BS 890-910 S42L) · airframe 105,635 hrs · 21,872 cycles
STRINGER 42L WAS FOUND WITH A CORROSION LOCATED AT BS 890 TO BS 910. THE CORROSION WAS FOUND DURING NORMAL CHECK INSPECTIONS OF THE FWD CARGO COMPARTMENT BILGE AREA. THE CORROSION WAS APPROX 1INCH WIDE BY 3 INCH LONG AND APPROX 0.034 INCH DEEP. THE CORRODED STRINGER WAS REPAIRED IAW SRM 53-10-03, FIG 1. THE SRM REPAIR TRIMS THE DAMAGED AREA, FABRICATES A REPLACEMENT SECTION AND INSTALLS A DOUBLER AT EACH END.
Part: SHEAR WEB — CRACKED (BS 380-400) · airframe 105,635 hrs · 21,872 cycles
THE PURPOSE OF THIS EO, IS TO DOCUMENT A CATEGORY B REPAIR ACCOMPLISHED DURING C4 / A6 CHECK, DURING JULY 2011. INSP VISUALLY FOUND A CRACK IN THE SHEAR WEB AT S-14R BETWEEN BS 380 AND 400 DURING ROUTINE INSPECTION. THE CRACK WAS 4 IN LONG WHEN FOUND AND DOCUMENTED ON NRC FVY505261 (THE DAMAGE WAS REPAIRED BY TRIMMING OUT THE CRACK AND INSTALLING A DOUBLER, FILLERS AND ANGLES IAW SRM 53-10-04, FIG 55. SEE FIG 1 FOR DETAILS OF THE REPAIR.)
Part: FRAME — CRACKED (BS 320) · airframe 105,635 hrs · 21,872 cycles
DURING C4/A6 CHECK, INSP DETECTED 2 EACH CRACKS ON THE RT SIDE , BS 320 FRAME AT S-15R CUTOUT. THE FIRST CRACK IS FOUND ON THE WEB LAYER ONLY AND IS APPROX 2 IN LONG RUNNING INBD AND DOWNWARD. THE SECOND CRACK IS ALSO ON THE WEB LAYER ONLY AND IS APPROX 0.50 INCH LONG RUNNING OTBD AND UPWARDS TO ADJACENT FASTENER HOLE. WHILE PERFORMING OPEN HOLE INSP ON THE REPAIR AREA, ADDITIONAL 4 EA CRACKS WERE DETECTED ON BS 320 FRAME. 3 CRACKS ARE LOCATED ON THE INBD FLANGE OF THE FRAME ORIGINATING FROM FASTENER HOLES AND RUNNING OTBD AND 1 EA CRACK (APPROX 0.375INCH) RUNNING INBD. REFER TO FIG 1 FOR A SKETCH OF CRACK LOCATIONS. STOP DRILLED CRACKS WITH 0.250 DIA. HOLES; PERFORMED INSPECTION OF REPAIRED AREA TO ENSURE DEFECT FREE CONDITION AND FABRICATE REPAIR ANGLES; HEAT TREAT TO T6 AFTER FORMED AND INSTALLED REPAIR ANGLES.
Part: FRAME — CRACKED (BS 380) · airframe 105,635 hrs · 21,872 cycles
DURING INSPECTION, DETECTED 2 EACH CRACK ON THE RT SIDE , BS 380 FRAME AS SHOWN IN FIG 1. THE FIRST CRACK IS FOUND ON THE WEB LAYER ONLY AND IS APPROX 0.5 INCH LONG RUNNING INBD AND UPDWARD. THE SECOND CRACK IS ALSO ON THE WEB LAYER ONLY AND IS APPROX 0.125 INCH LONG RUNNING OTBD AND UPWARDS. REFER TO FIG 1 FOR A SKETCH OF CRACK LOCATIONS AND PROPOSED REPAIR. THESE FINDINGS ARE DOCUMENTED NRC: FVY505345. (SINCE THERE IS NO SRM REPAIR AVAILABLE FOR THE AFOREMENTIONED CRACKS, MFG PROPOSED A REPAIR SCHEME WHICH INCLUDES INSP OF REPAIR AREA TO ENSURE DEFECT FREE CONDITION AND FABRICATE REPAIR ANGLE FROM 0.063 INCH THICK 2024-0 ALUMINUM ; HEAT TREAT TO 2024-T42 AFTER FORMING AND INSTALL REPAIR ANGLE WITH OTHER MISCELLANEOUS STRUCTURAL PARTS AS SHOWN IN FIGURE 1. REFER TO RS: R-53-12-37164, REV A FOR REPAIR DETAILS.)
Part: FRAME — CRACKED (BS 2231) · airframe 105,635 hrs · 21,872 cycles
DURING THE ACCOMPLISHMENT OF EO 4753B324, REV B (SB 747-53A2450, REV 6, AD 2010-20-08). ONE FASTENER HOLE ON THE FRAME STRAP (PN 65B01849-26) WAS FOUND WITH A 0.0625 INCH CRACK EXTENDING IN THE AFT DIRECTION AS SEEN IN THE REF /2/ RS R53-62-37168 REV A. IN ADDITION TO THE SUBJECT DAMAGE AN EXISTING REPAIR WAS FOUND BETWEEN S-17R AND S-18R WITH 2 EXISTING DOUBLERS AND A SPLICED SECTION OF THE REVEAL PANEL (PN 65B05000-70). AN OPEN HOLE INSPECTION WAS ACCOMPLISHED ON THE SURROUNDING FASTENER HOLE LOCATIONS IN THE STRAP AND UNDERLYING FRAME STRUCTURE. THE SURROUNDING EDGE FRAME STRUCTURE HAS BEEN CONFIRMED TO BE CRACK/DAMAGE FREE IAW SB 747-53A2450 INSPECTION REQUIREMENTS. WITH THE REVEAL SECTION REMOVED AN HFEC INSPECTION OF THE FRAME STRAP BETWEEN S-17R AND S-18R IS ACCOMPLISHED IN LIEU OF THE SB SPECIFIED & NBSP; LFEC. THE DAMAGE WAS REPAIRED BY TRIMMING AND SPLICING THE FRAME STRAP, REPLACING THE REVEAL PANEL AND INSTALLING 2 DOUBLERS.
Part: TENSION TIE — DAMAGED (BS 920) · airframe 105,635 hrs · 21,872 cycles
DURING INSPECTION OF DATUM ACFT IAW EO 4753B328, ELONGATION FASTENER HOLE WAS FOUND ON AT BS 920 RT SIDE TENSION TIE AFT CHANNEL (FIG 1). THE DAMAGED TENSION TIE WAS REPAIRED IAW WORK STEP 29D OF PART 2 OF EO 4753B328. IAW WORK STEP 29D OF PART 2 OF THE EO, THE TENSION TIE DAMAGE THAT CANNOT BE REMOVED BY DOING THE OVERSIZE HOLE REPAIR, SHOULD BE REPAIRED AS GIVEN IN SRM 53-10-11, FIG 2.
Part: TENSION TIE — CRACKED (BS 940) · airframe 105,635 hrs · 21,872 cycles
THE PURPOSE OF THIS EO IS TO DOCUMENT A MAJOR REPAIR THAT WAS ACCOMPLISHED DURING C4/A6 CHECK. DURING INSPECTION OF DATUM ACFT IAW EO 4753B328, CRACK WAS FOUND ON AT BS 940 LT SIDE TENSION TIE STR - 8L AFT CHANNEL AT HOLE NR 20 (FIGURE 1) (CRACK LENGHT WAS 0.040" AND RUNNING UPWARD AT 11 O'CLOCK). (THE DAMAGED TENSION TIE WAS REPAIRED IAW WORK STEP 32D OF PART 1 OF EO 4753B328. IAW WORK STEP 32D OF PART 1 OF THE EO, THE TENSION TIE CRACKS THAT CANNOT BE REMOVED BY DOING THE OVERSIZE HOLE REPAIR, SHOULD BE REPAIRED AS GIVEN IN SRM 53-10-11, FIG 2.)
Part: TENSION TIE — CRACKED (BS 880 S9L) · airframe 105,635 hrs · 21,872 cycles
DURING INSPECTION OF DATUM ACFT IAW EO 4753B328, A CRACK WAS FOUND ON AT BS 880, LT SIDE TENSION TIE STR 9L, AFT CHANNEL AT HOLE NR 16 FIG 1 CRACK LENGTH WAS 0.040" AND RUNNING INBD AT 9 O'CLOCK. THE DAMAGED TENSION TIE WAS REPAIRED IAW WORK STEP 23D OF PART 1 OF EO 4753B328. THE SUBJECT DAMAGE WAS DOCUMENTED ON NRC 501948. THE DAMAGED TENSION TIE WAS REPAIRED IAW WORK STEP 23 D OF PART 1 OF EO 4753B328. AS PER WORK STEP 23 D OF PART 1 OF THE EO, THETENSION TIE CRACKS THAT CANNOT BE REMOVED BY DOING THE OVERSIZE HOLE REPAIR, SHOULD BE REPAIRED AS GIVEN IN SRM 53-10-11, FIG 2.
Part: TENSION TIE — CRACKED (BS 920) · airframe 105,635 hrs · 21,872 cycles
DURING INSPECTION OF DATUM ACFT IAW EO 4753B328, A CRACK WAS FOUND ON AT BS 920, RT SIDE TENSION TIE FWD CHANNEL AT HOLE NR 5 (FIGURE 1) CRACK LENGTH WAS 0.060" AND RUNNING INBD AT 3 O'CLOCK. THE DAMAGED TENSION TIE WAS REPAIRED IAW WORK STEP 29D OF PART 2 OF EO 4753B328.
Part: NOZZLE — CRACKED (NR 1 EXHAUST) · airframe 105,635 hrs · 21,872 cycles
DURING A 'C4/A4' CHECK OF ACFT, MX FOUND 2 CRACKS ON THE NR 1 ENGINE EXHAUST NOZZLE OUTER SKIN AT 12 O'CLOCK POSITION (REFER TO FIG 1 AND 2 ). (THE CRACKS CAN BE REPAIRED IAW THE ENGINE MANUAL (ESM) TASK 78-11-01-300-011. REPAIR 78-11-01 REPAIR 011. THIS REPAIR CALLS FOR REMOVAL OF THE EXHAUST NOZZLE, SEPARATING THE OUTER COWL AND PERFORMING A POST WELD HEAT TREATMENT. MX DOES NOT HAVE THE REQUIRED EQUIPMENT TO ACCOMPLISH THE POST WELD TREATMENT. DISPOSITION IS TO ACCOMPLISH THE ESM 78-11-01 REPAIR 011, WITHOUT DISASSEMBLY OF THE EXHAUST NOZZLE, EXCLUDE THE POST WELD HEAT TREATMENT AND ACCOMPLISH DVI OF THE REPAIR AREA AT EVERY 'A' CHECK. THE NOZZLE IS TO BE R & R AT THE NEXT 'C' CHECK.)
Part: FRAME — CRACKED (BS 488) · airframe 105,635 hrs · 21,872 cycles
DURING ACCOMPLISHMENT OF SB 747- 53A2414 (AD 99-07-03) IAW CEO 72530A, A CRACK WAS FOUND IN THE WEB OF THE LT 488 FRAME. THE CRACK WAS FOUND BELOW THE NR1 STOP FITTING. REPAIRED BY ACCOMPLISHING A DOUBLER REPAIR IAW SRM 53-10-04, FIG 92 AS INSTRUCTED BY SB 747-53A2414.
Part: INU — FAILED · airframe 105,563 hrs · 21,929 cycles
AFTER TAKEOFF, CAPTAINS FLIGHT INSTRUMENTS HAD ATT FLAG IN ADI, HSI. FLAG IN HSI FOLLOWING RED WARNING LIGHT ON INU NR1, CODE 591 IN INS, PLATFORM FAILURE. INS WAS SHUTDOWN, UNABLE TO RESTORE CAPTAINS HSI AND ADI. USING FHB PROCEDURE CIWS LIGHTS ON CAPTAINS SIDE WERE ATT( NR1 INU REPLACED, UPDATED SAME, REALIGNED ALL 3 INU'S ALL FUNCTIONS CHECKED NORMAL)
Part: ACCESS DOOR — CRACKED (THRUST REVERSER) · airframe 105,250 hrs · 21,790 cycles
DURING MX WALKAROUND, MX FOUND 1 EA CRACK ON THE NR 1 ENGINE THRUST REVERSER LWR ACCESS DOOR (PN: 9071M77G12). DAMAGE LOCATED AT 6 O'CLOCK POSITION. THE CRACK IS APPROX 2.0625 IN LONG. (IAW AMM 78-11-01 THE LENGTH OF THE CRACK IS OUT OF LIMITS. DISPOSITION IS TO STOP DRILL THE ENDS OF THE CRACK WITH A 0.098" - 0.125" DIAMETER HOLE (DRILL BIT); DVI EVERY 3 FLIGHT CYCLES; AND REMOVAL/REPLACEMENT OF THE PART PRIOR TO THE ACCUMULATION OF 1,000 FH (FLIGHT HOURS) AFTER PART 1.)
Part: SKIN — DENTED (NR 1 NACELLE) · airframe 105,248 hrs · 21,789 cycles
MX FOUND THE NR1 ENGINE INLET NOSE COWL - OUTER BARREL SKIN DENT, MEASURING: 12.0" X 9.0" AND THE DEPTH 0.250 (REF FIG 1), LOCATED APPROX AT 3 O'CLOCK POSITION. THE DAMAGE IS BEYOND THE ALLOWABLE DAMAGE LIMITS IAW SRM 54-31-01, FIG 1, IAW SRM 51-40-06, FIG 2. PERFORMED A DETAIL VISUAL INSP, PENETRATION OR ANY OTHER DEFECTS EXISTS IN THE VICINITY. REMOVE ANY MOSTURE OR CONTAMINATION FROM THE DAMAGED AEA. USE A VACUUM AND HEAT (MAX OF 125A (52AC)) TO REMOVE MOISTURE FROM THE DAMAGED AREA.3 . FILL IN THE DAMAGED AREA (REF FIG 1) WITH BMS 5-28 POTTY COMPOUND OR EQUIVALENT. PROTECT THE DAMAGE FROM ENTRANCE OF WATER, SUNLIGHT OR OTHER FOREIGN MATTER BY APPLYING 3 LAYERS OF ALUMINUM FOIL TAPE OVERLAPPING A MINIMUM OF 1.5 INCHES IAW LAYER. (SPEED TAPE) EXTENDING MINIMUM 2 INCHES OF THE SURROUNDING DAMAGED AREA ON ALL SIDES TO RESTORE OUTER SURFACE CONTOUR)
Part: CHECK VALVE — FAILED (NR 4 ENGINE) · airframe 104,582 hrs · 21,739 cycles
BLOCK TURN BACK DUE NR 4 ENGINE FAILED TO ACCELERATE PAST 40 PERCENT N1, WITH HIGH EGT AND 4 COMPRESSOR STALLS WERE EXPERIENCED. (REPLACED 8TH STAGE CHECK VALVE AND PERFORMED ENGINE RUNUP. ALL OPERATES NORMAL. DUE TO COMPRESSOR STALL, BOROSCOPE INSPECTION ACCOMPLISHED, OK.)
Earlier reports · 1999–2010 · 97 reports
2010
Part: PANEL — CRACKED (NLG WW) · airframe 103,932 hrs · 21,541 cycles
DURING A-CHECK INSP, CRACKS WERE FOUND ON LT AND RT SIDE PANELS IN THE NLG WW AREA OF LT PANEL: THE CRACK WAS LOCATED BETWEEN BS260 AND 280, WL 150, AND THE CRACK LENGTH WAS APPROX 2.0 INCHES (FIG 1). RT PANEL: THE CRACK WAS LOCATED BETWEEN BS300 AND 320, WL 150, AND THE CRACK LENGTH WAS APPROX 8.0 INCHES (FIG 2). (REPAIRS WERE ACCOMPLISHED IAW PROPOSAL REPAIR (HKA-TLS-10-0019-01C), SRM 53-10-04, FIG 116 AND SR 1-1769325648 (FIG 3 AND 4) AND THEY WERE APPROVED BY FAA 8100-9 DATED 29 DEC, 2010 (FIG 5). IAW FAA FORM 8100-9, REPAIRS ARE TIME LIMITED REPAIR, AND NEED PERMANENT REPAIR AT 22,000 TFC IAW PART 3 OF EO 4753A458RB (REF SB 53A2562R2).)
Part: PANEL — CRACKED (BS 318) · airframe 103,932 hrs · 21,541 cycles
DURING A-CHECK INSP, CRACK WAS FOUND AT BS 318 LBL 20 AREA. THE CRACK WAS LOCATED ON THE TOP PANEL ALONG THE EDGE OF THE STIFFENER (PN: 65B13797-50), THE CRACK RUN FROM FWD TO AFT AND THE LENGTH OF IT WAS APPROX 1.5 INCH (FIG 1). (REPAIR WAS ACCOMPLISHED IAW PROPOSAL REPAIR (HKA-TLS-10-0018-01C), SRM 53-10-04, FIG 119 AND SR 1-1769311396 (FIG 2) AND IT WAS APPROVED BY FAA 8100-9 DATED 29 DEC, 2010 (FIG 3). IAW FAA FORM 8100-9, THE REPAIR IS TIME LIMITED REPAIR, AND NEED PERMANENT REPAIR AT 22,000 TFC IAW PART 3 OF EO 4753A458RB (REF SB 747-53A2562R2).
Part: LENS — BROKEN (LANDING LIGHT) · airframe 102,803 hrs · 21,308 cycles
ON WALK AROUND, FOUND LT INBD LANDING LIGHT LENS SHATTERED. LT INBD LANDING LIGHT CONSIDERED INOP. (ACCOMPLISHED EO 4733A032, PART 1 AS REQUIRED. OPENED NON MEL 18697)
Part: SKIN — DENTED (FAN COWLING) · airframe 100,337 hrs · 20,810 cycles
DURING WALKAROUND INSPECTION IN HKG, MAINTENANCE FOUND DAMAGE TO THE NR 2 ENGINE RT FAN COWL DENT DAMAGE, BELOW THE SERVICE OIL DOOR (REF FIGURE 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 OR AT THE NEXT C CHECK AFTER PART 1.
Part: TRIM SYSTEM — MALFUNCTIONED · airframe 101,838 hrs · 21,124 cycles
MANUAL STAB TRIM LEVERS MORE THAN 1 KNOB SPLIT (AT CRUISE. (DIVERSION) ACCOMPLISHED STAB TRIM / ADJ TEST IAW 27-41-00. IN PITOT STATIC TEST SET IAW 34-11-00. BROUGHT L/E TO ORIGINAL AND 20000 FT. COULD NOT DUPLICATE. TESTED RIGGING TENSION IAW 27-41-00, FIG 502. ALL CHECKS NORMAL. OK FOR SERVICE
Part: INTERCOSTAL — DAMAGED (BS 260-280) · airframe 101,810 hrs · 21,118 cycles
DURING C-CHECK, DAMAGE WAS FOUND IN THE 65B07942-26 INTERCOSTAL ON THE NWW SIDEWALL WL 153 STIFFENER BETWEEN BS 260 AND 280.THE INTERCOSTAL WAS REPLACED USING A 141U1193-43 INTERCOSTAL WHICH IS PART OF THE MODIFICATION IAW SB 747-53A2562, REV 2. PART 1 OF THIS EO DOCUMENTS THE INTERCOSTAL REPAIR IAW NRC 270 AND MFG SR 1-1573014701. THE REPAIR CONSISTS OF THE INSTALLATION OF THE 141U1193-43 MODIFIED INTERCOSTAL. THE INSTALLATION OF THE MODIFIED INTERCOSTAL IS FAA APPROVED BY A MFG AR IAW THE FAA FORM 8100-9 DATED 30APR2010 INCLUDED IN SR 1-1573014701 (SEE FIG 3). THE FAA FORM 8100-9 DATED 30APR2010 REQUIRES CONTINUED INSP IAW AD 2006-22-15. THE REQUIRED INSPECTIONS ARE IAW EO 4753A459 AND MRI 5311001707, THEREFORE NO ADDITIONAL INSPECTIONS ARE REQUIRED IAW THIS EO.
Part: FRAME — DAMAGED (BS 2231) · airframe 101,810 hrs · 21,118 cycles
DURING C-CHECK AND INSPECTION IAW EO 4753A521, ADDITIONAL DAMAGE WAS FOUND IN THE BS 2231 FRAME INNER CHORD AT S-25R. THE DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 745 AND SRM 53-10-04, FIGURE 115 (SEE FIG 1, 2 AND 3). NOTE: THIS EO REPLACED EO 4753A521. TERMINATE INSPECTION IAW EO 4753A521 AND CONTINUE INSP AS REQUIRED BY THIS EO.
Part: SKIN — DAMAGED (BS 160-180 S45R) · airframe 101,810 hrs · 21,118 cycles
DURING C-CHECK, LIGHTNING STRIKE DAMAGE WAS FOUND IN THE 65B07658-1002 SKIN AT BS 160-180, S-45R. THE DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 094 AND SRM 53-30-03, FIGURE 26 (SEE FIGURES 1 AND 2).
Part: SKIN — DAMAGED (BS 1940) · airframe 101,810 hrs · 21,118 cycles
DURING C-CHECK, DAMAGE WAS FOUND IN THE 65B04141-2 SKIN AT BS 1940, S-40L TO -41L.THE DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 270 AND SRM 53-30-03, FIGURE 18 (SEE FIGURES 1 AND 2). THE 65B04141-2 SKIN IS MADE FROM 0.063 INCH THICK 2024-T3 CLAD ALUMINUM SHEET IAW QQ-A-250/5. THE REPAIR CONSISTS OF AN 0.071 INCH THICK DOUBLER THAT MEASURES 12.0 INCH BY 12.0 INCH AND AN 0.071 INCH THICK STRUCTURAL FILLER THAT MEASURES 14.0 INCH BY 10.0 INCH.
Part: CARGO TRACK — DAMAGED (BS 1780-1820) · airframe 101,810 hrs · 21,118 cycles
DURING C-CHECK, DAMAGE WAS FOUND IN THE AFT LOWER CARGO COMPARTMENT SEAT TRACK AT RBL 25 BETWEEN BS 1800 AND 1820. THE DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 476 AND SRM 53-10-05, FIG 5. THE TRACK IS MADE FROM BAC1520-1682 EXTRUSION MADE FROM 7178-T6511 ALUMINUM IAW SRM 53-10-23, FIGURE 5, DETAIL XI, ITEM 3. THE REPAIR CONSISTS OF (2) AND 10134-1601 ANGLES MADE FROM 7178-T6 ALUMINUM, (1) 0.090 INCH THICK STRAP MADE FROM 7075-T6 ALUMINUM, ALL 18 INCHES LONG, AND ONE BAC1520-1682 REPLACEMENT SEAT TRACK 26 INCH LONG. REPAIR PARTS WERE INSTALLED USING BACR15BB6D RIVETS AND BACB30FM8 HI-LOKS. PART 1 OF THIS EO DOCUMENTS THE TRACK REPAIR IAW NRC 476 AND SRM 53-10-05, FIG 5.
Part: SKIN — DAMAGED (RT WING) · airframe 101,810 hrs · 21,118 cycles
THIS EO DOCUMENTS A MAJOR REPAIR. DURING C-CHECK, CORROSION WAS DETECTED COMMON TO LST SIDE WING INTERSPAR SKIN (65B14451-3 WING UPPER SKIN PANEL NR 1) AFT OF REAR SPAR , WS 415 LOCATION - (REF FIGURE 1).THE CORROSION WAS BLENDED OUT IAW THE SRM 57-30-01 FIGURE 1; THE FLANGE WAS BLENDED TO MINIMUM THICKNESS. REMAINING MATERIAL THICKNESS MEASUREMENT WAS PERFORMED AND FOUND 0.176 INCH, WHILE THE NOMINAL MEASURED THICKNESS IS 0.235 INCH. (REF. FIGURE 2 {NDT REPORT}).THE BLENDOUT DESCRIBED IS STRUCTURALLY ACCEPTABLE WITHOUT ANY REINFORCEMENT IAW MFG MESSAGE: IAI-TLS-10-0021-01C (SR 1-1567652132) CORROSION BLEND-OUT (1" X .7500") ACCOMPLISHED IAW SRM 57-30-01 FIG 1 ON 65B14451-3 (WING UPPER SKIN PANEL NR 1) SKIN AFT OF REAR SPAR, WS 415, AT INTERFACE WITH 65B11616-* (UPPER FIXED T/E PANEL INSTL, WBL 198.6 TO WBL 163. T/E PANEL). A MINIMUM 0.176 INCH REMAINING THICKNESS WAS VERIFIED BY NDT INSP REPORTED (REF FIG 2 {NDT REPORT}). LEVEL 1 CORROSION.
Part: STRINGER — CRACKED (BS 370-390 S40L) · airframe 101,810 hrs · 21,118 cycles
THIS EO DOCUMENTS A MAJOR REPAIR. DURING C-CHECK, DAMAGE WAS FOUND IN THE BS 370 - 390, S40L STRINGER, CONSISTING OF A CRACK. THE DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 521 AND SRM 53-10-03, FIGURE 3 (SEE FIGURE 1). THE STRINGER 40L IS MADE FROM 0.040 INCH THICK 2024-T42 CLAD ALUMINUM IAW THE SRM 53-10-20 FIGURE 11, ITEM 3.
Part: SKIN — DENTED (RWS 420) · airframe 101,810 hrs · 21,118 cycles
DURING C-CHECK, A DENT WAS FOUND IN THE SKIN AT BS 420-440, S12AL-13L.THE DAMAGE WAS TRIMMED OUT AND REPAIRED IAW NRC 212 AND SRM 53-30-03, FIG 1. THE SKIN AT THE DENT LOCATION IS MADE FROM 0.063 INCH THICK 2024-T3 CLAD ALUMINUM SHEET IAW SRM 53-30-02, FIG 1, ITEM 3. THE REPAIR CONSISTS OF AN 0.071 INCH THICK DOUBLER THAT MEASURES 12.0 INCH BY 11 INCH MADE FROM 2024-T3 CLAD ALUMINUM SHEET INSTALLED USING BACR15CE6 AND BACR15BB8 RIVETS. THIS EO DOCUMENTS THE FUSELAGE SKIN REPAIR IAW NRC 212 AND SRM 53-30-03, FIGURE 1. EO 4753B286.
Part: SKIN — CORRODED (RT WING) · airframe 101,810 hrs · 21,118 cycles
THIS EO DOCUMENTS A MAJOR REPAIR. DURING C-CHECK, CORROSION WAS DETECTED COMMON TO RT WING LOWER SKIN WS1285 - WS1320 (REF FIG 1). THE CORROSION WAS BLENDED OUT IAW THE SRM 51-10-01/02 WITHIN LIMITS IAW SRM 57-30-01 FIGURE 2 (SHEET 7); THE FLANGE WAS BLENDED TO MINIMUM THICKNESS. REMAINING MATERIAL THICKNESS MEASUREMENT IAW (REF. FIGURE 1). NOTE: THIS REPAIR IS CLASSIFIED AS: LEVEL 1 CORROSION IAW GMM 5.8.1 (CPCP).PART 1 OF THIS EO ACCOMPLISHES A PERMANENT REPAIR OF THE RT WING LOWER SKIN WS1285 - WS1320 IAW IAI NRC264.
Part: SKIN — DAMAGED (BS 720 S40R) · airframe 101,810 hrs · 21,118 cycles
DURING C-CHECK, DAMAGE WAS FOUND IN THE 65B23675-1 SKIN AND 65B23678-2 DOUBLER AT BS 720, S-40R. THE DAMAGE WAS TRIMMED OUT AND REPAIRED IAW RFTA 00694-0004 AND REA MF00694R0004, EO 4753B287.
Part: RIB — CORRODED (STABILIZER) · airframe 101,810 hrs · 21,118 cycles
LT STABILIZER STA 281 RIB LOWER CORD SURFACE CORRODED. LEVEL 1. DAMAGED CHORD REMOVED NEW FABRICATED. PN 65B03680-29 IAW DWG 65B03680-28 AND NR A004088G002. USING WITH FASTENERS IAW SRM 51-30-02.
Part: ESCAPE HATCH — UNSECURE · airframe 101,386 hrs · 21,035 cycles
PASSING THROUGH 21,000' POPPING NOISE HEARD AND THEN LOUD NOISE OF RUSHING AIR FROM ESCAPE HATCH. RETURNED TO DEPARTURE. GROUND CHECKED REVEALED OVERHEAD ESCAPE HATCH NOT FULLY CLOSED. VISUALLY CHECKED AREA, ALL OK AND PERFORMED OPS CHECK AND DOOR CLOSED IAW MM 52-21-00, ALL NORMAL.
2009
Part: SKIN — DELAMINATED (LT WING) · airframe 100,708 hrs · 20,887 cycles
DURING LETTER "A" CHECK IN MIA, DELAMINATION WAS FOUND ON THE LEFT WING TRAILING EDGE AT WBL 208 UPPER EXTERNAL SKIN, RT LEADING EDGE ILES 760 UPPER EXTERNAL SKIN, AND RT LEADING EDGE ILES 672 GAP PANEL. ENGINEERING ORDER 4757A490 DATED 20 OCT 2009 WAS ISSUED TO PERFORM PERMANENT REPAIRS.
Part: ATTACH FITTING — CRACKED (ZONE 200) · airframe 99,985 hrs · 20,743 cycles
MAIN ENTRY DOOR NR 3 RT, FWD ATTACHMENT FOR SLIDE GIRT BAR, SUPPORT ATTACHMENT HAS A 0.625 INCH CRACK. INTERIM REPAIR WAS ACCOMPLISHED IAW SRM 51-10-01. REFERENCE EO4754A298 APPROVED VIA FAA 8110-3 FORM.
Part: SKIN — DELAMINATED (RT WING TE FLAP) · airframe 99,985 hrs · 20,743 cycles
RT WING INBD MID FLAP UPPER SURFACE AT WBL 347.78 AND 22.0 INCHES FROM T/E HAS AN AREA OF 1.0 BY 1.0 INCH OF DELAMINATION. PERMANENT REPAIR ACCOMPLISHED IAW SRM 51-40-09, FIG. 5, SHEETS 3 AND 8. REF: EO 4757A484.
Part: PANEL — CRACKED (NR 3 PYLON) · airframe 99,985 hrs · 20,743 cycles
RT WING NR 3 PYLON UPPER SURFACE GAP PANEL HAS 2 EA COMPOSITE CRACKS. STA ILES 666.22 CRACK IS 24.0 INCHES LONG AND AT ILES 670.22 CRACK IS 12.0 INCHES LONG. PERMANENT REPAIR ACCOMPLISHED IAW SRM 51-40-09, FIG 18, SHEETS 2 AND 5, 250 DEGREE CURE IAW SRM 51-40-12. EO 4757A483.
Part: SKIN — DELAMINATED (RT WING TE FLAP) · airframe 99,273 hrs · 20,605 cycles
RT INBD MID FLAP AT WBL 128.45 AND RT INBD AFT FLAP AT WBL 195.45 DAMAGED WITH DELAMINATION. INBD LOWER SURFACE DAMAGE MEASURES 4.0 IN X 4.0 IN. L/E LOWER SUFACE DAMAGE MEASURES 3.0 IN X 3.0 IN. "PERMANENT REPAIRS PERFORMED IAW THE SRM 51-41-09 FIG 6. TABLE I, IAW SRM 51-40-15".
2008
Part: CONNECTOR — DEFECTIVE (TEMP SENSOR) · airframe 98,573 hrs · 20,464 cycles
AIR TURN BACK. NR 1 ENGINE OIL TEMP OFF SCALE HIGH FOR AT LEAST 10 MINUETS . ENGINE SHUT DOWN. WIRING CHECKS ACCOMPLISHED AND FOUND NR 1 OIL TEMP SENSOR CONNECTOR DEFECTIVE . CONNECTOR REPLACED AND ALL OPERATIONS NORMAL. ENGINE RUN UP NORMAL. NR 1 ENGINE OIL TEMP SENSOR REPLACED AS PRECAUTION AND ENGINE RUNUP. LEAK CHECKED NORMAL.
Part: SKIN — CRACKED (PAX DOOR)
RT NR 3 MAIN ENTRY DOOR FWD LOWER CORNER SKIN & STRAP FASTENER HOLE CRACKED. REPAIRED IAW BOEING SERVICE REQUEST 1-917061347 APPROVED BY FAA FORM 8100-9 DATED 13 AUGUST 2008, DETAILS OF WORK KEPT AT ATLAS ENGINEERING ORDER EO4753B181. (S)
Part: DOOR FRAME — CRACKED (FUSELAGE)
LEFT NR 1 MAIN ENTRY DOOR FORWARD FRAME UPPER HINGE CUTOUT AREA CRACKED. REPAIRED IAW BOEING SERVICE REQUEST 1912258448 APPROVED BY FAA FORM 8100-9 DATED 6 AUG 2008, DETAILS OF WORK KEPT AT ATLAS ENGINEERING ORDER EO 4752A146. (S)
Part: FRAME — CRACKED (BS 380)
BS 380 FRAME WEB AT STRINGER 17L & 17R CRACKED. REPAIRED IAW SERVICE REQUEST 1911068869 APPROVED BY FAA FORM 8100-9 DATED 6 AUG 2008, DETAILS OF WORK KEPT AT ENGINEERING ORDER EO 4753B184. (S)
Part: DOOR FRAME — CRACKED (R4 DOOR)
RT NR 4 MAIN ENTRY DOOR FWD FRAME LOWER HINGE CUTOUT AREA CRACKED. REPAIRED IAW BOEING SERVICE REQUEST 1912258253 APPROVED BY FAA FORM 8100-9 DATED 07 AUGUST 2008, DETAILS OF WORK KEPT AT ATLAS ENGINEERING ORDER EO-4752A148. (S)
Part: SKIN — CRACKED (LT MLG DOOR)
LT WING LANDING GEAR INBOARD STRUT DOOR EXTERIOR SURFACE AND EXISTING DOUBLER CRACKED. REPAIRED IAW SRM 51-40-24 FIGURE 1&2, DETAILS OF WORK KEPT AT ATLAS ENGINEERING ORDER EO4752A149. (S)
Part: FRAME — CRACKED (BS 360)
BS 360 FRAME WEB NEAR STRINGER 14L CRACKED. REPAIRED IAW BOEING SERVICE REQUEST 1911055155 APPROVED BY FAA FORM 8100-9 DATED 6 AUG 2008, DETAILS OF WORK KEPT AT ATLAS ENGINEERING ORDER EO4753B183. (S)
Part: INTERCOSTAL — CRACKED (BS 1200)
BS 1200 RBL 110 FLOORBEAM INTERCOSTAL WEB CRACKED. REPAIRED IAW BOEING SERVICE REQUEST 1912291334 APPROVED BY FAA FORM 8100-9 DATED 04 AUGUST 2008, DETAILS OF WORK KEPT AT ATLAS ENGINEERING ORDER EO-4753B190. (S)
Part: PRESSURE PANEL — CRACKED (NOSE WHEEL WELL)
NOSE WHEEL WELL TOP PANEL WEB FOUND WITH A CRACK AT BS 304 AT RBL11. CRACK LENGTH IS 2.250 INCHES. INTERIM REPAIR ACCOMPLISHED IAW SRM 53-10-04, FIG 116, SHEETS 1 AND 6 AND FIG 117, SHEETS 1 THRU 10. REQUIRES INITIAL INTERNAL DETAIL VISUAL INSPECTION PRIOR TO 15,000 FC. REF EO. (K)
Part: PRESSURE PANEL — CRACKED (NOSE WHEEL WELL)
NOSE WHEEL WELL TOP PANEL WEB FOUND WITH A CRACK AT BS 310 AT LBL 10. CRACK LENGTH IS 1.125 INCHES. INTERIM REPAIR ACCOMPLISHED IAW SRM 53-10-04, FIG 116. SHEETS 1 AND 6 AND FIG 117 SHEETS 1 THRU 10. REQUIRES INITIAL INTERNAL DETAIL VISUAL INSPECTION PRIOR TO 15,000 FC. (K)
Part: FAIRING — DAMAGED (LT WING)
LT IB FLAP NR 3, MOVEABLE FLAP TRACK FAIRING HAS A HOLE AT WBL 353.0 HOLE SIZE IS 4.0 INCHES X 7.0 INCHES. PERMANENT REPAIR ACCOMPLISHED IAW B747200, SRM 51-40-09, FIG 6 SHEET 1 THRU 3, 250 DEGREES F CURE IAW SRM 51-40-12. ALSO, REFERENCE EO 4757A449. (K)
Part: ENGINE — DAMAGED
SHORTLY AFTER TAKING OFF, HEARD AND FELT 2 LOUD BANGS (18 SECONDS AFTER TAKEOFF) EGT WENT TO 962 FOR 3 SECONDS ACCOMPLISHED ENGINE FAILURE AND SEVERE DAMAGE CHECKS. ENGINE WAS LOCKED AND PERFORMED 3 ENGINE FERRY. ENGINE WAS REPLACED. (K)
Part: DOOR — OPEN (MAIN CARGO) · airframe 97,582 hrs · 20,323 cycles
AFTER TAKEOFF UNABLE TO PRESSURIZE AIRCRAFT. CABIN WAS CLIMBING AT 2000 FPM EVEN WITH 3 PACKS TURNED. ALL DOOR WARNING LIGHTS ON F/E PANEL AND CARGO DOOR LIGHTS ON PILOTS MCP WERE OUT. INSPECTION OF THE MAIN DECK REVEALED LOUD NOISE COMING FROM BULK CARGO DOOR AREA. A/C WAS DEPRESSURIZED IAW WITH FHB AND LANDED AT NEAREST AIRPORT. ON WALK AROUND, FOUND BULK CARGO DOOR OPEN. CLOSED DOOR AND PRESSURE CHECKED GOOD IAW MM 52-63-01 601 AND 21-31-00. OPENED A DMI FOR THE BULK CARGO DOOR WARNING LIGHT INOP.
Part: INU — FAILED (NR 1) · airframe 97,535 hrs · 20,313 cycles
AIR TURN BACK: NR 1 INU RED WARNING LIGHT ILLUMINATED AFTER TAKEOFF, CDU SCREEN BLANKED, CAPTAINS HEADING AND ATTITUDE FLAGS IN VIEW. F/O ADI ATT FLAG CAME INTO VIEW BUT F/O ADI WORKED PROPERLY. F/O FLAG RETRACTED AFTER 5 MIN. REPLACED NR 1 INU PER AMM 34-41-03 AND UPDATE NAV DATA BASE OPS CHECKED OK.
Part: SEAT TRACK — BROKEN (BS 1689) · airframe 97,172 hrs · 20,165 cycles
MAIN DECK CARGO SEAT TRACK AT BS 1689, RBL 11 HAS DAMAGE CROWN LUGS. ACCOMPLISHED PERMANENT REPAIR AS PER B747-200 SRM 53-10-05 FIG 14.
Part: STRUCTURE — DAMAGED (LT WING LE FLAP) · airframe 97,172 hrs · 20,165 cycles
LT WING DAMAGED FROM BIRD STRIKE ON L/E OF INBOARD MID FLAP, WBL 391.50. AREA OF DAMAGE IS 3.250 INCHES LONG BY 3.0 INCHES WIDE. ACCOMPLISHED PERMANENT REPAIR AS PER B747-200 SRM 51-40-09 FIG 5, SHEETS 3 AND 8, 250 DEGREES F PER SRM 51-40-12. REFERENCE ATLAS AIR EO NR 4757A424.
Part: WINDSHIELD — CRACKED (COCKPIT) · airframe 97,123 hrs · 20,154 cycles
AIR TURN BACK ON CLIMB TO FL 320 AT FL 250 THE FIRST OFFICERS WINDSHIELD STARTED ARCING, CAUGHT FIRE AND CRACKED. FOLLOWED FHB PROCEDURES. REPLACED R1 WINDSHIELD IAW AMM 56-11-01.
Part: PANEL — DELAMINATED (RT WING) · airframe 96,817 hrs · 20,081 cycles
RT WING FIXED UPPER L/E PANEL DIRECTLY ABOVE NR 3 GROUP L/E PDU HAS AREA OF 23.5 BY 19.0 INCHES OF DELAMINATION. INTERIM REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-16 FIG 1, SRM 51-70-06, SRM 51-30-02, ATLAS AIR EO NR 4757A417 AND FAA FORM 8110-3. REQUIRES DETAILED VISUAL INSPECTION AT EVERY A-CHECK UNTIL PERMANENT REPAIR IS ACCOMPLISHED AT C-CHECK.
2007
Part: PUSHROD — BROKEN (TE FLAP) · airframe 96,164 hrs · 19,945 cycles
AIRCRAFT EXPERIENCED HARD LANDING. PERFORMED HARD LANDING PHASE I INSPECTION. NOTED DEFECTS LISTED ON FOLLOWING LOG PAGES PER AMM 5-51-05, FOUND LEFT INBOARD FLAP NR 4 PUSH ROD BROKEN. REPLACED AND ADJUST PUSH ROD ASSY. ACCOMPLISHED PARTS OF PHASE II INSPECTION AND DEFERRED REMAINDER OF THE PHASE II AFTER SPECIAL MAINTENANCE FERRY FLIGHT TO PIK TO COMPLETE THE PHASE II INSPECTION.
Part: SKIN — CRACKED (NR 4 NACELLE) · airframe 95,909 hrs · 19,894 cycles
NR 4 PYLON LT SKIN WAS FOUND A CRACK AT THE 483 AL ACCESS PANEL CUTOUT LOWER AFT CORNER. DEFECTIVE CRACK AREA INTERIM REPAIRED AS PER BOEING MESSAGE NR 1-656345659-3 AND ATLAS XEO NR 54-102307.
Part: LINK — BROKEN (RT MLG) · airframe 95,563 hrs · 19,822 cycles
ON LANDING INTO DOV, HEAVY SPARKS REPORTED DOWN RUNWAY. MX FOUND RIGHT BODY GEAR, FWD BRAKE TORSION LINK AT NR 10 BRAKE GAVE WAY, CAUSING DAMAGE (GROOVE) TO RUNWAY. BOTH THE NR 10 AND NR 12 BRAKES WERE REMOVED PER DDPG 32-5, AND THE AIRCRAFT WAS MADE READY FOR A MAINTENANCE FERRY FLIGHT WITH GEAR DOWN TO JFK.
Part: VALVE — SHUTDOWN (FUEL PUMP) · airframe 95,067 hrs · 19,714 cycles
AT CRUISE ALT 38000 AFTER APPROX 50 MIN INTO THE TRIP NR 2 ENGINE SLOWLY ROLLED BACK THEN SHUTDOWN ALL OTHER INDICATIONS NORMAL. OIL PRESS TEMP OIL QTY AND FUEL FLOW IND WERE NORMAL. AFTER ENGINE NR 2 SHUTDOWN ENGINE INDICATED APPROX 1000 KGS BURN PER HOUR. NO FUEL LEAK NOTED WAS DETERMINED. ACCOMPLISHED THE APPROP FWB CHECKLIST. CHECKED ENGINE INLET/EXHAUST, MASTER CHIP DETECTOR, CDP LINE, VSV FEEDBACK CABLE, FUEL FILTER, FUEL S/O ACTUATOR, SPAR VALVE. NO DEFECTS NOTED. REMOVED AND REPLACED MEC IAW MM 73-2101. REMOVED AND REPLACED ENG FUEL PUMP IAW MM 73-11-01. CARRIED OUT ENG NR 2 RUN AFTER MEC AND FUEL PUMP REPLACEMENT AS PER MM 71-00-00. TEST 5 AND SATISFIED.
Part: PRESSURE VALVE — UNRESPONSIVE (ENGINE) · airframe 94,748 hrs · 19,652 cycles
NR 3 ENGINE ON CLIMB-OUT, ENGINE NACELLE FAULT LIGHT ON NR 3 ENGINE A LOOP READ 8.5- B LOOP READ 4.5. AS SOON AS THROTTLE PULLED BACK THE B LOOP TEMP DROPPED DOWN TO 3.0. NR 3 THROTTLE PULLED TO IDLE TO GET A LOOP TO DROP DOWN TO 3.0. ON GROUND AT IDLE NACELLE TEMPS READ 2.8, ENGINE BLOW OUT DOORS OPEN ON GROUND. NR 3 ENGINE PRESS CHECK FOR AIR LEAKS OK. REPLACED PRESSURE RELIEF VALVE AS PER BOEING MM 36-11-03. REPLACED PRESSURE REGULATING VALVE AS PER BOEING MM 36-11-19. ENGINE RUN AT HIGH POWER TO CHECK VALVES, RUN OK.
Part: SELECTOR VALVE — LEAKING (MLG) · airframe 94,647 hrs · 19,629 cycles
AIR TURN BACK NR 4 HYDRAULIC SYSTEM LOST JUST ABOVE V1 ON TAKEOFF. SYSTEM WENT TO ZERO PRESSURE AND QUANTITY. EDP WAS PLACED TO SUPPLY OFF. FOUND WING GEAR SELECTOR VALVE IN RT WHEEL WELL LEAKING. REMOVED AND REPLACED VALVE PER 32-31-03, OPS AND LEAK CHECKED OK. HYD PUMP AND FILTERS REPLACED ALSO SEE LOG PAGE 193806.
Part: SKIN — CRACKED (NR 1 PYLON) · airframe 93,958 hrs · 19,481 cycles
NR 1 PYLON PRECOOLER EXHAUST CUT-OUT SKIN ASSEMBLY AND DOUBLER FOUND CRACKED. SKIN ASSEMBLY TRIMMED OFF FILLER FABRICATED AND INSTALLED AS PER BOEING MESSAGE 1-289015678-4 AND REMOVED FASTENERS INSTALLED AS PER BOEING MESSAGE 1-289015678-8 AND FAA FORM 8100-9.
Part: SKIN — CRACKED (`NR 4 NACELLE) · airframe 93,958 hrs · 19,481 cycles
NR 4 PYLON PRECOOLER EXHAUST CUT-OUT SKIN ASSEMBLY AND DOUBLERS CRACKED. PYLON REPAIRED AS PER BOEING MESSAGE 1-289015678-8.
Part: WINDOW FRAME — CRACKED (BS 340 S8L) · airframe 93,958 hrs · 19,481 cycles
NR 3L WINDOW FRAME FOUND CRACK AT STATION 340 STR 8L SKIN LOWER CORNER. SKIN REPAIRED AS PER BOEING MESSAGE 1-289012478-7 AND 12 AND 8100-9.
Part: SHEAR TIE — CRACKED (BS 860) · airframe 93,958 hrs · 19,481 cycles
BS 860L TENSION TIE ATTACHMENT FOUND ONE HOLE CRACKED. TENSION TIE REPAIRED AS PER BOEING MESSAGE DRAWING 1-283852979-4.
Part: LONGERON SPLICE — CRACKED (BS 2598 L11R) · airframe 93,958 hrs · 19,481 cycles
BS 2598 OUTER CHORD STR 11R FWD AND AFT LOWER LONGERON SPLICE FITTING FOUND BOLT HOLE CORROSION CRACK. FORWARD AND AFT SPLICE FITTING REPLACED PER SRM 51-10-01 PAGE 9 AND SB 74753A2410.
Part: FRAME — CRACKED (BS 840) · airframe 93,958 hrs · 19,481 cycles
FOUND BS 840 FRAME TO TENSION TIE CONNECTION FOUND 1 HOLE CRACKED. REPAIR ACCOMPLISHED PER BOEING DRAWING ON MESSAGE 1-283852403-4.
Part: FLOORBEAM — CRACKED (BS 340) · airframe 93,958 hrs · 19,481 cycles
BS 340 U/D FLOORBEAM UPPER CHORD FWD AND AFT FLANGE FROM RBL 13-44 FOUND 4 HOLES CRACKED. REPAIRED AS PER SB 747-53A2431 PART 3 FIGURE 9.
Part: BEAR STRAP — CRACKED (FUSELAGE) · airframe 93,958 hrs · 19,481 cycles
FOUND CRACK IN BEARSTRAP HOLE FORWARD CARGO DOOR FORWARD UPPER CORNER. REAMED HOLE COMMON TO SKIN AND BEARSTRAP TO REMOVE CRACK INDICATION AND INSTALLING FREEZE PLUG AND OVERSIZED FASTENER AS PER BOEING MESSAGE 1-285675404-1 AND 8100-9.
Part: BEAR STRAP — CRACKED (FUSELAGE) · airframe 93,958 hrs · 19,481 cycles
NR 3L DOOR CUT-OUT FORWARD LOWER BEAR STRAP CRACKED. NR 3L DOOR CUT-OUT FORWARD LOWER BEAR STRAP CRACK REPAIRED AS PER EO4753A751 OPTION 2. INSTALLED WITH LARGE DOUBLER.
Part: FRAME — CRACKED (BS 360) · airframe 93,958 hrs · 19,481 cycles
CRACK FOUND IN THE FRAME WEB AT STATION 360 STR 14ER CUTOUT. THE CRACK IN THE FRAME WEB WERE INSPECTED AND A .063" DOUBLER WAS INSTALLED AS PER BOEING MESSAGE 1-28580146-3/5 AND 8100-9.
Part: SKIN — CORRODED (BS 1240) · airframe 93,958 hrs · 19,481 cycles
FOUND BS 1240 LBL 99 WING CENTER SECTION SKIN CORRODED. CORROSION REMOVED PER SRM 51-10-01. AREA HFEC INSPECTED AND FLAT PEENED. REPAIR DOUBLER WERE FABRICATED AND INSTALLED PER 8100-9.
Part: REVEAL — CRACKED (R4 DOORWAY) · airframe 93,958 hrs · 19,481 cycles
FOUND R4 DOOR CUTOUT UPPER FORWARD REVEAL CRACKED: CRACK WAS STOPPED DRILLED AND DOUBLER ADDED AS PER BOEING MESSAGE 1-294125025-3 AND 8100-9.
Part: DOUBLER — CRACKED (BS 800) · airframe 93,958 hrs · 19,481 cycles
BS 800 STR 19R DOOR CUTOUT DOUBLER FOUND CRACKED. REPAIRED PER BOEING MESSAGE 1-285788451-4. TRIMMED AND REMOVED DAMAGED FRAME STRAP NDT AREA. FABRICATED REPAIR STRAP AND DOUBLER. ALODINED AND COATED WITH BMS 5-95 BETWEEN MATING SURFACE. INSTALLED HI LOCKS WET WITH BMS 5-95.
Part: FLOORBEAM — CRACKED (BS 420) · airframe 93,958 hrs · 19,481 cycles
FOUND UPPER DECK FLOORBEAM AT BS 420R ONE FASTENER HOLE CRACK AT FRAME WEB. THE CRACK WAS TRIMMED OUT AND REPAIRED PER BOEING MESSAGE AND SRM 53-10-04 FIG 107.
Part: FLOORBEAM — CRACKED (BS 340) · airframe 93,958 hrs · 19,481 cycles
UPPER DECK FLOORBEAM AT BS 340L ONE FASTENER HOLE CRACK AT FRAME WEB. THE CRACK WAS TRIMMED OUT AND REPAIRED PER BOEING MESSAGE AND SRM 53-10-04 FIG 102.
2006
Part: VALVE — CRACKED (NLG STEERING) · airframe 93,033 hrs · 19,312 cycles
WHEN TAXING ON TO RUNWAY NOSE WHEEL STEERING BECAME IMPOSSIBLE NR 1 HYD SYSTEM FELL TO 4 GALLONS. NO SYSTEM PRESSURE WITH ADP ON. ENG PUMP OPERATING. ENGINE PUMP DEPRESSURIZED-SUPPLY OFF. QTY DROPPED TO 2 GALLONS. A/C TOWED OFF RUNWAY. FOUND BODY GEAR SELECTOR VALVE IN LT BODY GEAR WELL LEAKING AND VALVE BODY CRACKED. LT WHEEL WELL BODY GEAR SELECTOR VALVE REPLACED IAW AMM 32-31-03. HYD SYSTEM 1 REPLENISHED FUNCTION AND LEAK CHECK FOUND SATIS.
Part: FAIRING — DEPARTED (RT WING) · airframe 92,138 hrs · 19,135 cycles
DURING WALK AROUND, FOUND 1-EACH FILLET FAIRING DAMAGED ON RIGHT WING (OVERWING). REMOVED AND REPLACED FILLET FAIRING AS PER MM 53-51-01.
Part: SKIN — DAMAGED (T/E FLAP) · airframe 92,129 hrs · 19,133 cycles
RT INBOARD AFT FLAP HAS A .250 INCH DIAMETER HOLE AT BOTTOM SKIN. ACCOMPLISHED 250 DEGREES F. PREPREG PERMANENT REPAIR AS PER 747 SRM 51-40-09 FIG 5 AND SRM 51-40-12.
Part: SKIN — DAMAGED (T/E FLAP) · airframe 92,129 hrs · 19,133 cycles
LT INBOARD AFT FLAP HAS A .375 INCH DIAMETER HOLE AT BOTTOM SKIN. ACCOMPLISHED 250 DEGREES F. PREPREG PERMANENT REPAIR AS PER 747 SRM 51-40-09 FIG 5 AND 51-40-12.
Part: SKIN PANEL — DAMAGED (FUSELAGE) · airframe 91,875 hrs · 19,079 cycles
LWR FUSELAGE PANEL 191QL HAS IMPACT DAMAGE AT AFT END ~ 1" LONG. CLEANED UP DAMAGED AREA POTTED AND APPLIED FIBER GLASS OVERLAY AS PER SRM 51-40-09 AND RESTORED FINISH AS PER MM 51-24-11 IAW EO#4753A796.
Part: BRACE — CHAFED (NR 3 PYLON) · airframe 91,477 hrs · 18,996 cycles
PYLON NR 3 DIAGONAL BRACE OUTBOARD SIDE ON ZONE 4 HAS TWO CHAFED AREAS. BLENDED OUT 2 AREAS, ACCOMPLISHED HFEC PER NDT MANUAL D6-7170, PART6 RT4 NO DEFECTS NOTED. ROTO PEEN AREAS, TREATED AND PRIMED AS PER BOEING SB 747-54-2198. REQUIRES REPETATIVE INSPECTION AT INTERVALS OF 150 TO 300 FLIGHTS-CYCLES AS PER BOEING SB 747-54-2198 AND XEO 54-042806.
Part: SKIN — CRACKED (FUSELAGE) · airframe 91,477 hrs · 18,996 cycles
L-1 DOOR EXTERIOR SKIN, UPPER HINGE CUT OUT AREA OF THE DOOR, PREVIOUS DOUBLER ON THE LOWER EDGE APPEARS TO HAVE A HAIR LINE CRACK INDICATION VISUAL INSPECTION. REMOVED CRACKED DOUBLER, FOUND DOOR SKIN WITH 1/2" CRACK AT UPPER HINGE CUT OUT LOWER AFT CORNER, STOP DRILLED CRACK DEBUR AND POLISHED AREA. FABRICATED NEW DOUBLER FROM 2024-T3 0.63, COUNTER DRILLED, TRIMMED, COUNTER SUNK AND BORED NEW DOUBLER IAW BOEING DRAWING NR 65B07563 AND 747 SRM 51-10-01.
Part: SEAT TRACK — DAMAGED (BS 1975) · airframe 91,477 hrs · 18,996 cycles
MAIN CARGO COMPARTMENT SEAT TRACK HAT SECTION AT BS 1975- RBL 76" WITH A HOLE. REMOVED FLOOR PANEL TO GET ACCESS IAW SRM 51-30-02. CUT OUT DAMAGE SECTION IAW 51-40-04. FABRICATE PARTS PER SAMPLE IAW SRM 51-40-04. ALODINE + PRIMER NEW PARTS IAW SRM 51-10-02. OK TO INSTALL. INSTALLED REPAIR PARTS, 48" HAT SECTION AT MAIN DECK BS 1975 RBL 76" IAW SRM 51-40-04. OK TO INSTALL FLOORBOARD AND CARGO RESTRAINING SYSTEM, INSTALLED FLOOR BOARD AT MAIN DECK BS 1975 IAW MM 53-21-02. INSTALLED CARGO RESTRAINING SYSTEM AT MAIN DECK BS1975 IAW MM 25-58-00 AND 25-58-01.
Part: UNION — WORN (HYD SYSTEM) · airframe 91,194 hrs · 18,938 cycles
ATB:LOSS NR 4 HYD SYSTEM AFTER GEAR UP. SYSTEM LEAKING. FOUND UNION ON HYD RETURN LINE WORN, REPLACED OPS AND LEAK CHECKED NORMAL AS PER MM 29-00-00.
2005
Part: SKIN — DAMAGED (NR 2 PYLON)
DURING D-CHECK FOUND NR 2 PYLON HAS CRACK DAMAGE IN THE SKIN ASSEMBLY AND THE ADJACENT NR 3 STIFFENER, AT PRE-COOLER EXHAUST CUTOUT LOWER EDGE NEAR THE AFT CORNER AT STATION 248. THE NR 3 STIFFENER LOWER FLANGE WAS TRIMMED TO REMOVED CRACKS. THE CRACK IN THE SKIN ASSEMBLY WAS CONTAINED WITH 1 INCH DIAMETER OLE AT THE CRACK TIP. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NS 235-254. THE RIB INSTALLATION AT NC 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL LOWER REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)
Part: SKIN — CRACKED (STA 248)
DURING D-CHECK, FOUND NR 3 PYLON, CRACKED DAMAGE WAS FOUND IN THE SKIN ASSEMBLY AND THE ADJACENT NR 3 STIFFENER, AT PRECOOLER EXHAUST CUTOUT LOWER EDGE NEAR THE AFT CORNER AT STATION 248. THE NR 3 STIFFENER LOWER FLANGE WAS TRIMMED TO REMOVE CRACKS. THE CRACK IN THE SKIN ASSEMBLY WAS CONTAINED WITH 1 INCH DIAMETER HOLE AT THE CRACK TIP. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NS 235-254. THE RIB INSTALLATION AT NS 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL LOWER REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)
Part: SKIN — CRACKED (STA 248)
DURING D-CHECK, NR 1 PYLON HAD CRACK DAMAGE IN THE SKIN ASSEMBLY AND THE ADJACENT NR 3 STIFFENER, AT PRECOOLER EXHAUST CUTOUT LOWER EDGE NEAR THE AFT CORNER AT STATION 248. THE NR 3 STIFFENER LOWER FLANGE WAS TRIMMED TO REMOVE CRACKS. THE CRACK IN THE SKIN ASSEMBLY WAS CONTAINED WITH 1 INCH DIAMETER HOLE AT THE CRACK TIP. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NAC STATION 235 TO 254. THE RIB INSTALLATION AT NACELLE STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL LOWER REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)
Part: SKIN — DAMAGED (NR 4 PYLON)
DURING D-CHECK, NR 4 PYLON HAD CRACK DAMAGE IN THE SKIN ASSEMBLY AND THE ADJACENT NR 3 STIFFENER, AT PRECOOLER EXHAUST CUTOUT LOWER EDGE NEAR THE AFT CORNER AT STATION 248. THE NR 3 STIFFENER LOWER FLANGE WAS TRIMMED TO REMOVE CRACKS. THE CRACK IN THE SKIN ASSEMBLY WAS CONTAINED WITH 1 INCH DIAMETER HOLE AT THE CRACK TIP. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NACELLE STATION 235 TO STATION 254. THE RIB INSTALLATION AT NACELLE STATION 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL LOWER REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)
Part: SUPPORT — CRACKED (NR 2 PYLON)
D-CHECK, NR 2 PYLON, RT LWR AFT SKIRT FAIRING LOWER STIFFENER CRACKED. STOPPED DRILLED THE CRACK. NDT AND HFEC INSPECTED ALL AFFECTED FASTENER HOLES AND REPAIR AREA TO ENSURE CRACKS AND DAMAGE FREE CONDITION. FABRICATED AND INSTALLED 0.050 INCH THICK REPAIR CHANNEL. EO ISSUED TO ACCOMPLISHED A DETAIL VISUAL INSPECTION OF THE REPAIR AREA EVERY C-CHECK OR 18 MONTHS WHICHEVER IS EARLIER FOR DEGRADATION OF THE REPAIR INCLUDING CRACKS OR LOOSE FASTENERS. (K)
Part: SKIN — CHAFED (NR 2 PYLON)
D-CHECK, DURING MAINTENANCE INSPECTION, THE NR 2 STRUT RT SIDE SKIN ASSEMBLY INTERNAL BONDED DOUBLER WAS FOUND CHAFED AT THE 463AR ACCESS PANEL CUTOUT. THE INTERNAL DOUBLER AND SKIN WERE TRIMMED BACK PAST THE EXISTING CUTOUT IN THE OUTER SKIN. THE REPAIR AREA WAS HFEC INSPECTED FOR CRACKS OR OTHER DAMAGE. REPAIR DOUBLERS WERE FABRICATED TO COVER THE ENTIRE ACCESS CUTOUT AND TO REPLICATE THE ACCESS DOOR LAND ATTACHMENT DETAILS. THE REPAIR DOUBLERS WERE INSTALLED BY BONDING TOGETHER WITH HI-LOCK FASTENERS. EO TO ACCOMPLISH REPEAT DETAIL VISUAL INSPECTION OF THE REPAIR AREA EVERY C-CHECK OR 18 MONTHS, WHICHEVER OCCURS EARLIER FOR CRACKS AND LOOSE OR MISSING FASTENERS. (K)
Part: PRESSURE PANEL — CRACKED (BS 1241)
D-CHECK, FUSELAGE STA 1241 SLOPING PRESSURE DECK WEB WAS FOUND WITH CRACK AT DUCT CUTOUT. THE CRACKED AREA REPAIRED BY CUTTING EXISTING WEB SECTIONS BETWEEN UPPER EDGE OF THE SLOPING DECK AND REAR SPAR AND FROM BL 0 TO TRIM LINE. HFEC INSPECTED THE EDGE OF THE WEB TRIM. A NEW REPAIR WEB SECTION WAS INSTALLED. (K)
Part: ANGLE — OUT OF LIMITS (NR 4 PYLON)
D-CHECK, NR 4 PYLON SIDE COWL HINGE SUPPORT ANGLE BRACE, ONE HOLE EXCEEDING LIMITS. THE HOLE WAS OVERSIZED TO 0.484 INCHES DIAMETER INCLUDING A .0312 DIAMETER INSURANCE CUT. THE HOLE WAS NDT INSPECTED TO ENSURE A CRACK AND DAMAGE FREE CONDITION. A REPAIR STEEL STRAP WAS INSTALLED ONT HE AFT SIDE OF THE ANGLE. A FREEZE PLUG WAS INSTALLED AND A .3750 INCHE DIAMETER FASTENER WAS INSTALLED THRU THE FREEZE PLUG, TO INSTALL A NEW ANGLE WITHIN 18 MONTHS. (K)
Part: TRUNNION — CHAFED (MLG)
D-CHECK, RECESSED MARK ON RT BODY GEAR IB TRUNNION SUPPORT FITTING. THE RECESSED MARK WAS BLENDED OUT WITH A MINIMUM 63 RHR SURFACE FINISH. 10X VISUALLY AND HFEC INSPECTED TO ENSURE CRACK AND CORROSION FREE CONDITION. ALODINED AND REINSTATED THE FINISH. FILLED THE VOID WITH SEALANT. (K)
Part: ACTUATOR — FAILED (NR 2 CROSSFEED)
DURING CRUISE, NR 2 CROSSFEED VALVE DOES NOT OPEN. TRANSITION BLUE LIGHT STAYS ON. REMOVED AND REPLACED NR 2 CROSSFEED VALVE ACTUATOR IAW MM 28-22-02. OPS CHECK SATISFACTORILY S/N OFF 90060. (M)
2004
Part: COMPUTER — FAILED (NR 2)
MIA/LAX - EN ROUTE AFTER LEAVING MIAMI THE F/O PRESSURE ALTIMETER FLUCTUATING UNCONTROLLABLE AND MACH INDICATOR FLAP ALTERNATELY COMING IN VIEW. WITH A DIFFERENCE IN MACH SPEED OF 6.5, CAPTAIN 79 MACH. F/O .19 MACH INDICATED. SUSPECT F/O CADS. REMOVED AND REPLACED CADC NR 2. OPS CHECK OK IAW REF MM 34-12-01. (M)
Part: PANEL — DELAMINATED (LT WING)
DURING FA12 A-CHECK ACCOMPLISHING ROUTINE WORK CARD 11M15002 INSPECTION OF LEFT WING UPPER SURFACE, FOUND LEFT LEADING EDGE INBOARD OF NR 1 PYLON PANEL VOIDED UPPER SURFACE WING STATION 1116 PANEL. T64R (M)
Part: SEAT TRACK — CRACKED (FUSELAGE)
DURING FA12 A-CHECK ACCOMPLISHING ROUTINE WORK CARD 02EM15002 INSPECTION OF MAIN CABIN FOUND MAIN CARGO DECK LEFT OUTBOARD FLOOR TRACK BROKEN OUT AT FUSELAGE STATION 1820. (M) T64R
Part: THERMAL SWITCH — FAILED (RT WING)
SHORTLY AFTER LEVEL OFF AT FL30.0 RIGHT WING OVERHEAT LIGHT ILLUMINATED. CHECK LIST PERFORMED, LIGHT EXTINGUISHED BEFORE 5 MINUTES CONTINUED AGAIN, COMPLETED CHECKLIST LIGHT STAYED ON NR 3 AND NR 4 BLEED VALVES CLOSED, RIGHT ISOLATION VALVE CLOSED ZERO AIR PRESSURE NR 3 A/C PACK OPEN. CHECK RIGHT WING PYLON NR 3 AND NR 4 FOR LEAKAGE. FOUND LEAKAGE AT LEADING EDGE DRIVE UNIT NR 2 RIGHT DUCT. RIGHT WING AND LEAKAGE OF SEAL OUTBOARD OF L/E NR 2 RIGHT END MANIFOLD. REPLACED SEALS P/N 820-1-200 AND SEAL P/N 600-600 CHECK FOR LEAKAGE. ALL SATISFACTORY IAW 36-11-00. MEASURE WIRING FROM D4644 TO SWITCHES WITH ISOL TESTER ALL SATISFACTORY. CHECKED BLEED VALVE FOR LEAKAGE FOUND NORMAL. MEASURE WIRING WITH LIGHT
Part: BRAKE — DAMAGED (LT MLG)
GT9813/24 RME/JFK BRAKE TEMPERATURE OVERHEAT LIGHT: BRAKE TEMPERATURE OVERHEAT LIGHT ILLUMINATED DURING TAXI-IN. LEFT BODY, LEFT REAR BRAKE TEMPERATURE APPROXIMATELY INDICATING 7.40. FOUND NR 7 BRAKE DAMAGED, REMOVED AND REPLACED SAME IAW MM, LEAK CHECKS GOOD. ACCOMPLISHED INSPECTION , ALL NORMAL.
2003
Part: ENGINE — LEAKING (NR 3)
DOV-RMS - NR 3 ENGINE SHUTDOWN DUE TO ZERO OIL QUANTITY AND PERSSUER BELOW 10 PSI WITH LOW OIL PRESSURE LIGHT ON AT 1509Z. AFTER SHUTDOWN OIL PRESSURE WENT TO ZERO WHILE WINDMILLING. AIRCRAFT DIVERTED TO AMS. REMOVED AND REPLACED ENGINE NR 3 ACCORDING TO MM 71-00-02 AND ATLAS AIR FORM 01-AA-45 PAGE 1 TO 68. ACCOMPLISHED ENGINE RUN, ALL PARAMETERS CHECK NORMAL. (M)
Part: WARNING SYSTEM — MALFUNCTIONED (TE FLAPS)
DURING TAKEOFF AT APPROXIMATELY 75 KNOTS, PILOTS LEADING EDGE FLAP INDICATED UNSAFE WITH F/E LT WING PANEL LEADING EDGE FLAP INDICATORS ALSO INDICATING UNSAFE. NO WARNING HORN WAS HEARD AT ANY TIME DURING TAKEOFF. VISUALLY AND MANUALLY CHECKED ALL LEFT WING PDU`S AND CONNECTORS. OPERATIONALLY CHECKED FLAPS IN PRIMARY AND ALTERNATE MODES IAW MM 27-81-03. ALL INDICATIONS AND FUNCTIONS NORMAL.
2001
Part: FRAME — DENTED (FUSELAGE)
DURING ROUTINE INSPECTION, FOUND BS 1780 FRAME DENTED AND DEFORMED AT STRINGER 15R. TRIMMED AWAY DAMAGED AREA. FABRICATED FILLER, NEW SHEAR TIE, REPAIR DOUBLE AND SPLICES. INSTALLED PER STANDARD PRACTICES. (M)
Part: SKIN — CRACKED (FUSELAGE)
DURING ROUTINE HFEC INSPECTION, FOUND SKIN CRACKED .33 INCH AT RADIUS CUT OUT, UPPER FORWARD CORNER OF LOWER LOBE AFT CARGO COMPARTMENT DOOR FRAME, BS 1815, AT STRINGER 15R. TRIMMED AWAY CRACK AREA FABRICATED FILLER AND REPAIR DOUBLERS PER SRM 53-30-03 FIG 60 TYPE 2 AS REPAIR REFERENCE SCHEME. INSTALLED PER STANDARD PRACTICES. (M)
Part: PANEL — DELAMINATED (LT WING)
DURING ROUTINE INSPECTION, FOUND LEFT SIDE UNDER WING VAPOR BARRIER PANEL DELAMINATED IN SEVERAL AREAS FROM LBL 29.98 TO 103.95. DELAMINATED AREAS SANDWICHED WITH ALUMINUM PLATES AND THROUGH BOLTED. REPAIR AREA TO BE REINSPECTED FOR STRUCTURAL INTERGRITY AND SECURITY AT EVERY 2A CHECK. PANEL REPLACEMENT NOT TO EXCEED 18 MONTHS FROM 3/26/01. (M)
2000
Part: TIRE — FAILED (MLG)
FLT 8612 - FRA/JFK - ATB - CREW REPORTED EXCESSIVE VIBRATION AFTER V1. UPON INSPECTION OF RUNWAY, FRA AIRPORT AUTHORITIES FOUND PIECES OF HONEYCOMB PANEL, FLAP PANEL AND TIRES. AIRCRAFT RETURNED TO FRA. LANDING WAS UNEVENTFUL. UPON ARRIVAL ON THE RAMP AT FRA, MAINTENANCE FOUND NR 11 AND NR 12 TIRES BLOWN AND DAMAGE TO SEVERAL SKIN PANELS LOCATED AROUND BS 1500. TWO FRAME SHEAR TIES WERE CRACKED AND STRINGER 37R AND 38R WERE DEFORMED. AIRCRAFT STILL UNDER REPAIR. ALL STRUCTURAL REPAIRS ACCOMPLISHED PER SRM OR EO 4753A101. REPLACED NR 11 AND NR 12 BRAKE AND WHEEL ASSEMBLIES AND ALSO REPLACED RT BODY GEAR ELECTRICAL HARNESS. OPERATIONAL CHECK OF ALL GEAR SYSTEMS/COMPONENT SUCCESSFULLY ACCOMPLISHED. (M)
Part: SKIN — CORRODED (WING)
DURING INSPECTION OF LEFT WING LEADING EDGE INTERIOR BAY, THE LOWER WING SKIN WAS FOUND CORRODED BOTH SIDES OF FSSO 1381.5. CORRODED AREA OF LEFT WING SKIN WAS CUT OUT, AREA TREATED, ECI CHECKED, FLAT PEENED. FILLER AND DOUBLER MANUFACTURED. INSTALLED IAW ATLAS AIR EO 4757A073. FORM 8110-3 ISSUED. (X)
1999
Part: FITTING — CRACKED (NR 6 SPOILER)
NR 6 SPOILER SUPPORT FITTING CRACKED AT LOWER LEFT SIDE ATTACHING FLANGE APPROXIMATELY 2 INCHES BETWEEN AND OUT OF SECOND AND THIRD RIVET HOLE. FITTING ATTACHED TO THE AFT SIDE OF WING GEAR AFT SUPPORT BEAM. FITTING REPLACED DURNIG CURRENT C-CHECK AT KLM. (M)
Part: BOLT — FAILED (RT WING)
RT WING GEAR FORWARD TRUNNION OUTBOARD SIDE SUPPORT FITTING HAS SHEARED BOLT ON OUTBOARD UPPER ATTACHMENT. INSPECTED AREA, FOUND NO DAMAGE. REPLACED BOLT PER DRAWING 65B010222 FR 2 10-2480. REPLACED SHEARED BOLT WITH P/N BACB30US7K20. (M)
Part: BOLT — FAILED (BS 1241)
BOLTS SHEARED AT BODY STATION 1241 LBL 110 AND LBL 118. INSPECTED AREA, FOUND NO DEFECTS. PERFORMED HFEC INSPECTION PER D6-7170 51-00-00 PART 6, FOUND NO CRACKS. REPLACED BOLTS. TORQUED BOLTS PER 20-51-00. (M)
Part: BOLT — FAILED (BS 2360)
AFT PRESSURE BULKHEAD HAS SHEARED BOLT AT STRINGER 14 RT SIDE. INSPECTED AREA FOUND ON DEFECTS. REPLACED BOLT. TORQUED PER MM 20-51-00. (M)
Part: DUCT — CRACKED (NR 1 ENGINE)
JFK/MIA - FLT GT870 - NR ENGINE FLAME-OUT AT TOP OF DESCENT. UNABLE TO RE-LIGHT. MAINTENANCE CHECKED THE FOLLOWING AND NO DISCREPANIES NOTED (INLET AND EXHAUST, VISUAL CHECK UNDER COWL, BLEW OUT CDP LINE. CHECKED CHIP DETECTORS, FUEL FILTER FOUND CLEAN, SUMPED NR 1 MAIN AND NR 1 RES TANKS AND NO CONTAMINATION FOUND, CONDITION MOTOR AND LINKAGE OK, DRY AND WET MOTOR OF ENGINE OK, FUEL PRESSURE AND FUEL FLOW OK). RE-RIGGED VSV/VBV. FURTHER TROUBLESHOOTING IDENTIFIED CRACK IN FLANGE OF 8TH STAGE DUCT. REPLACED DUCT ENGINE. RUN-UP SATISFACTORY. (X)