N527MC

Part: SKIN — DELAMINATED (LT WING FOREFLAP) · airframe 97,559 hrs · 19,588 cycles

LEFT WING INBOARD T/E FOREFLAP HAS SIGNS OF DELAMINATION 15" FROM OUTBOARD EDGE. PERFORMED WING TRAILING EDGE REPAIR AS PER SRM 51-40-09 AND 51-40-06 AND XEO 57-110707.

Part: DRAIN VALVE — CORRODED (TOILET) · corrosion level 2 · airframe 90,961 hrs · 19,465 cycles

DURING SCHEDULED TIME REMOVAL OF THE TOILET SERVICE DRAIN VALVE FOUND HEAVY CORROSION ON THE BRACKET ABOVE THE PAN AND SERVICE DOOR INSTALLATION. REMOVED ALL BRACKET THAT HAD CORROSION DAMAGE. REPAIRED INTERNAL STRAPS PER SRM 53-30-03. REPAIRED INTERNAL SECTION USING FLAT PATTERN METHOD WITH SRM 51-20-01.

Part: FLAP TRACK — CRACKED (TE FLAPS) · airframe 90,961 hrs · 19,465 cycles

NR 1 MOVABLE FLAP TRACK FAIRING HAS SMALL CRACK LOWER SURFACE. REPAIRED PER SRM 51-40-09 AND 51-40-12.

Part: SKIN — CRACKED (ZONE 500) · airframe 90,961 hrs · 19,465 cycles

LEFT WING INBOARD FOREFLAP HAS 2" CRACK ON LEADING EDGE 12" FROM OUTBOARD EDGE. REPAIRED PER SRM 51-40-12 AND 51-40-08.

Part: SKIN — DAMAGED (LT WING LE FLAP) · airframe 90,961 hrs · 19,465 cycles

LEFT WING NR 7 VARIABLE CAMBER FLAP OUTER SKIN HAS LOWER EDGE RIVETS LOOSE AND UPPER EDGE FASTENER HEADS BROKEN. REMOVED LT WING NR 7 L/E FLAP TO FACILITATE ACCESS FOR SHEET METAL REPAIR. REPLACED RIVETS AND FASTENERS AS NECESSARY AS PER SRM 51-30-02. REINSTALLED FLAP IAW MM 27-81-02.

Part: STRUCTURE — DAMAGED (KRUGER FLAP) · airframe 96,924 hrs · 19,454 cycles

ON WALK AROUND FOUND NR 12 L/E KRUGER FLAP DAMAGED. PERFORMED INTERIM REPAIR IAW XEO 57-081307. PERM REPAIR TO BE ACCOMPLISHED AT NEXT "A' CHECK 20 AUG 07.

Part: ENGINE — FAILED (NR 3) · airframe 96,705 hrs · 19,406 cycles

NR 3 ENGINE SHUT DOWN DUE TO A LOUD BANG, N1 STARTED TO DECREASED, VISUAL INSPECTION SHOWED NO OPEN T/R BUT ENGINE WAS SWINGING EXCESSIVELY COMPARED TO NR 4 ENGINE WAS NOT SWINGING OR MOVING SMOOTH AIR SHUT DOWN IAW FHB SEC 3.

Part: INU — INOPERATIVE (NR 1) · airframe 95,773 hrs · 19,224 cycles

INFLIGHT, 7MINS AFTER T/O, NR 1 INS WENT TO WRN WITH NO DISPLAYS. NR 1 ATT FLAG AND NR 1 HDG FLAG APPEARED AND A/T WENT INOP. SWAPPED NR-1 INS NAV UNIT WING NR-3 INS NAV UNIT. TESTED NR-1 INS NAV UNIT PER AMM 34-41-03. CHECKED GOOD NO ACTION CODES.

Part: SKIN — CORRODED (BS 2360 S30-32R) · corrosion level 2 · airframe 95,660 hrs · 19,198 cycles

FUSELAGE STATION 2360 RT SIDE, BETWEEN STRINGERS 30R AND 32R HAS AN AREA OF 3.0 INCH LONG BY 11.0 INCHES WIDE OF CORROSION ON SKIN. ACCOMPLISHED PERMANENT REPAIR AS PER 747-200 SRM 53-30-03 FIG 1. AREA OF CORROSION WAS CUT-OUT AND HFEC WAS ACCOMPLISHED TO VERIFY ANY CRACKS AS PER 747 NDT MANUAL 51-00-00 FIG 23 PAR 6, DOUBLER AND FILLER WERE INSTALLED PER 747-200 SRM 53-30-03 FIG 1. ALSO, REFERENCE ATLAS AIR XEO 53-040207.

Part: START VALVE — FAULTY (NR 3 ENGINE) · airframe 95,146 hrs · 19,093 cycles

NR 3 ENGINE START VALVE OPEN LIGHT CAME ON DURING CRUISE, FOLLOWED FHB PROCEDURES AND SHUT DOWN THE ENGINE. TRANSFERRED TO DEFERRED ITEM M07-010, MEL 80-1-1. AS PER MCC REQUEST REMOVED AND REPLACED START VALVE. REMOVED AND REPLACED START VALVE AS REQUIRED.

Part: PANEL — DENTED (RT WING) · airframe 95,099 hrs · 19,082 cycles

RT WING INBOARD LEADING EDGE PANEL AT WBL 158.0 HAS A 2.0 INCH LONG BY 1.5 INCH WIDE BY .073 INCH DEEP DENT. ACCOMPLISHED PERMANENT REPAIR AS PER B747-200 SRM 51-40-09 FIG 18 SHEET 1 THRU 5. ALSO, REFERENCE ATLAS AIR EO NO. 4757A314.

Part: SKIN — CRACKED (LT WING) · airframe 95,099 hrs · 19,082 cycles

LT WING, UPPER SURFACE, TRAILING EDGE PANEL, AFT OF REAR SPAR, WBL 445 IS CRACKED AROUND FASTENER HOLE. ACCOMPLISHED PERMANENT REPAIR AS PER B747-200 SRM 51-40-09 FIG 2, SHEETS 1 THRU 5. REPAIR AREA IS 4.0 INCH BY 4.0 INCH ALSO, REFERENCE ATLAS AIR EO NR 4757A339.

Part: SKIN — CRACKED (NR 2 NACELLE) · airframe 93,948 hrs · 18,840 cycles

PYLON NR 2 ACCESS PANEL 462AL CUTOUT FOUND A CRACK NAC STA 220 0.75 INCH LONG. CARRIED OUT HFEC INSPECTION AS PER NTM PT 6 51-00-00 FIG 23 & 16. NIL CRACK INDICATION. CRACK ON SKIN WAS TRIMMED OUT & HFEC INSPECTED & REPAIR AS PER FAA FORM 8100-9.

Part: SKIN — DENTED (WING ROOT) · airframe 93,948 hrs · 18,840 cycles

RIGHT WING L/E CAP AT WING ROOT FOUND WITH A DENT. HFEC CARRIED OUT ON THE OUTER SKIN OF THE DENTED AREA. NIL CRACK. NTM PART 6 51-00-00 FIGURE 23. L/E CAP SKIN (INNER & OUTER SKIN), AND STRUCTURE INSPECTED FOUND NO DAMAGE OR DELAMINATION AERO DYNAMIC FILLER APPLIED PER SRM 51-40-01 IAW FAA FORM 8100-9.

Part: HINGE FITTING — CRACKED (HORIZONTAL STAB) · airframe 93,948 hrs · 18,840 cycles

HORIZONTAL STABILIZER CENTER SECTION ZONE-B, OPEN HOLE HFEC INSPECTION, FOUND RIGHT INBOARD VERTICAL HINGE FITTING AFT SIDE CRACK AT 6 O'CLOCK POSITION. LENGHT 15MM AND DEPTH 5MM THROUGH THE HINGE FITTING. CRACKED FITTING REMOVED & SENT TO WORKSHOP FOR FREEZE, PLUG REPAIR IAW, BOEING MSG 1-216184247-2 DTD 02 AUG 06. FITTING RE-INSTALLED BACK IAW DRG 65B03560. WORKSHOP JOB CARD SWJC, MS 130476044 & FAA 8100-9.

Part: SKIN — CRACKED (FUSELAGE) · airframe 93,948 hrs · 18,840 cycles

NOSE GEAR WHEEL WELL PRESSURE PAN CUT OUT AREA FOUND SKIN CRACKED AT STA 400 RT LOWER CORNER RBL 15. CRACKED PRESSURE PAN CUTOUT SKIN REPAIRED IAW BOEING MSG 1-215478617-2 DATED 02 AUG 06. REPAIR DOUBLERS USED 2 OFF 7075-T6, 0.080". CARRIED OUT EDDY CURRENT INSP AS PER MTM PART 6, 51-00-00, FIG 23 NIL CRACK INDICATION FOUND.

Part: ROD — DAMAGED (LT MLG) · airframe 93,737 hrs · 18,792 cycles

AFTER T/O THE LEFT WING GEAR WOULD NOT RETRACT. R&R LT WING GEAR WHEEL WELL DOOR RADIUS ROD AS PER AMM 32-12-00. R&R FWD RADIUS ROD ASSY AS PER AMM 32-12-00. R&R FWD RADIUS ROD ASSY AS PER AMM 32-12-00. R&R FWD RADIUS ROD ASSY AS PER AMM 32-12-00. R&R SUPPORT, INSTL FWD RADIUS AS PER AMM 32-12-00. R&R ROD ASSY AS PER AMM 32-12-00. R&R BUMPER, INSTL AFT WHEEL WELL MLG TRUCK LT AS PER SRM 51-30-02.

Part: SKIN — DELAMINATED (LT WING LE) · airframe 93,178 hrs · 18,677 cycles

LEFT WING UPPER LEADING EDGE PANEL AT NR 2 ENGINE PYLON DELAMINATED AT PREVIOUS REPAIR JUST I/B OF L/E GAP PANEL. REMOVED DAMAGE LEADING EDGE PANEL IAW B-747-200 SRM 51-30-02.SENT TO OUTSIDE SERVICE AIRCRAFT CONNECTION INC. REPAIRED PER SRM 51-40-08 PAGE 1, SRM 51-40-09 FIG 1, SRM 51-40-12 PAGE 1 THRU 38 FIG 6 SHEET 1, REV 105. OK TO INSTALL. LOCATED INSTALLED AND SEALED IAW B-747-200 SRM 51-30-02 AND 51-10-06.

Part: FAN BLADE — BIRD STRIKE (NR 3 ENG INLET) · airframe 92,614 hrs · 18,566 cycles

ON WALKAROUND FOUND NR 3 ENGINE SUSTAINED BIRD STRIKE, FOUND FAN BLADE BENT. PERFORMED CHAPTER FIVE BIRD STRIKE INSPECTION, NO FINDINGS. REMOVED AND REPLACED FAN BLADE. BORESCOPED CORE ENGINE, NO FINDINGS. PERFORMED OPS RUNUPS WITH NO FINDINGS. RELEASED AIRCRAFT.

Part: SPAR — CORRODED (FLAP TRACK)

DURING SCHEDULE INSPECTION, CORROSION WAS FOUND ON THE REAR SPAR ATTACHMENT HOLES OF NR 5 TRAILING EDGE FLAP TRACK. OVERSIZED THE AFFECTED ATTACHMENT HOLES. MAGNETIC PARTICLE INSPECTED THE REWORKED AREA TO ENSURE CRACK AND DEFECT FREE CONDITION. THE REPAIRED HOLES WERE REPAIRED USING 17-4PH SLEEVE. DETAIL VISUAL INSPECT THE AFFECTED EXPOSED FLANGE EDGES FOR CRACKS FOR CORROSION EVERY C-CHECK INTERVAL NOT TO EXCEED 18 MONTHS. EO 4757A168 ISSUED TO ACCOMPLISH THE INSPECTION. (M)

Part: SKIN — DELAMINATED (RT OTBD FLAP)

DURING SCHEDULE INSPECTION, DELAMINATION WAS FOUND ON THE OUTBOARD TRAILING EDGE FLAP AFT FLAP LOWER SKIN PANEL. PANELS EXCEEDED 25 PERCENT DAMAGE OF THE TOTAL AREA. TRIMMED OUT THE DELAMINATED SKIN REGIONS. NDT INSPECTED TO ENSURE CRACK AND DEFECT FREE CONDITION. INSTALLED REPAIR FILLERS AT EACH TRIM LOCATION AND A SINGLE DOUBLER TO COVER THE PANEL SURFACE. REFINISHED THE PANEL TO DESIGN STANDARD. DETAIL VISUAL INSPECT THE REPAIR AREA FOR DELAMINATION, CRACKS OR LOOSE FASTENERS AT NEXT AIRPLANE A CHECK, 700 HOURS. THERE AFTER REPEAT INSPECTIONS AT 4 MONTH INTERVALS. REPLACE PANEL AT NEXT C-CHECK OR 18 MONTHS WHICHEVER IS EARLIER. ATLAS AIR EO 4757A166 ISSUED TO ACCOMPLISH THE INSPECTION. (M)

Part: MOUNT — CRACKED (NR 4 PYLON)

DURING SCHEDULED INSPECTION, NR 4 PYLON, BULKHEAD UPPER CHORD CRACKED AT STATION 270. STOP DRILLED THE CRACK PER 747 SRM 51-10-01. NDT INSPECTED THE REPAIR AREA, INCLUDING HFEC INSPECTION OF ALL TRIMMED FLANGE EDGES AND STOP DRILLED HOLES TO ENSURE CRACK REMOVAL OR CONTAINMENT. INSTALLED ALUMINUM FILLERS, ANGLES AND STRAPS COMMON TO THE UPPER AND AFT CHORDS. DETAIL VISUALLY INSPECT THE AFFECTED CHORD AREA FOR CRACKS, CORROSION AND/OR LOOSE FASTENERS EVERY C-CHECK OR 18 MONTHS, WHICHEVER OCCURS EARLIER. ATLAS AIR EO 4754A131 ISSUED TO ACCOMPLISH THE INSPECTION. (M)

Part: BULKHEAD — CRACKED (NR 1 PYLON)

DURING SCHEDULED INSPECTION, NR 1 PYLON, THE BULKHEAD UPPER LEFT SIDE FORWARD AND AFT CHORD ANGLES WERE FOUND CRACKED. TRIMMED AND STOP DRILLED THE CRACK PER 747 SRM 51-10-01 NDT INSPECTED THE REPAIRED AREA, INCLUDING HFEC INSPECTION OF ALL TRIMMED FLANGE EDGES AND STOP DRILL HOLES TO ENSURE CRACK REMOVAL OR CONTAINMENT. INSTALLED ALUMINUM, REPAIR ANGLES AND STRAPS COMMON TO THE UPPER AND FORWARD AND AFT CHORDS. DETAIL VISUALLY INSPECT THE AFFECTED CHORD AREA FOR CRACKS, CORROSION AND/OR LOOSE FASTENERS EVERY C CHECK OR 18 MONTHS, WHICHEVER COMES FIRST. ATLAS AIR EO 4754A129 ISSUED TO ACCOMPLISH THE INSPECTION. (M)

Part: SKIN — DENTED (NR 2 PYLON)

DURING INSPECTION, FOUND DENT (SKIN WRINKLE) NR 2 NACELLE STRUT INBOARD SKIN BETWEEN NACELLE STATION 286 TO 300.1. CONFIRMED THAT THE AFFECTED WAS FREE FROM DISCOLORATION. NDT CONDUCTIVITY MEASURED READING ACCOMPLISHED. HFEC INSPECTED AND WAS FOUND TO BE DAMAGE FREE. AREA IS STRUCTURALLY SATISFACTORY PER BOEING MESSAGE 1-141MMN SERVICE REQUEST ID-67130304. CONDUCT REPEAT DETAILED INSPECTIONS OF THE AFFECTED AREA EVERY C-CHECK, NOT TO EXCEED 18 MONTHS, LOOKING FOR CRACKS AND OR LOOSE/MISSING FASTENERS. ATLAS AIR EO 4754A134 ISSUED TO ACCOMPLISH THE INSPECTION. (M)

Part: BULKHEAD — CRACKED (NR 3 PYLON)

DURING SCHEDULED INSPECTION, NR 3 PYLON, THE BULKHEAD UPPER LEFT AND RIGHT SIDE FORWARD CHORD ANGLES WERE FOUND CRACKED. STOP DRILLED THE CRACK PER 747 SRM 51-10-01. NDT INSPECTED THE REPAIR AREA, INCLUDING HFEC INSPECTION OF ALL TRIMMED FLANGE EDGES AND STOP DRILLED HOLES TO ENSURE CRACK REMOVEAL OR CONTAINMENT. INSTALLED ALUMINUM ANGLES COMMON TO THE UPPER FORWARD AND AFT LT AND RT CHORDS. DETAIL VISUALLY INSPECT THE AFFECTED CHORD AREA FOR CRACKS, CORROSION AND/OR LOOSE FASTENERS EVERY C-CHECK OR 18 MONTHS, WHICHEVER COMES FIRST. ATLAS AIR EO 4754A130 ISSUED TO ACCOMPLISH THE INSPECTION. (M)

Part: BULKHEAD — CRACKED (NR 2 PYLON)

DURING SCHEDULE MAINTENANCE, THE BULKHEAD UPPER LEFT AND RIGHT SIDE FORWARD CHORD ANGLES WERE FOUND CRACKED, NR 2 PYLON. STOPPED DRILLED THE CRACK END AND NDT INSPECTED TO ENSURE CRACK CONTAINMENT. INSTALLED ALUMINUM REPAIR ANGLES COMMON TO THE UPPER FORWARD AND AFT LEFT AND RIGHT CHORDS. DETAIL VISUALLY INSPECT THE AFFECTED CHORD AREAS FOR CRACKS, CORROSION AND/OR LOOSE FASTENERS EVERY C-CHECK OR 18 MONTHS, WHICHEVER OCCURS EARLIER.

Part: LINK — MIGRATED (NR 4 FLAP TRACK)

DURING SCHEDULE MAINTENANCE, NR 4 T/E FLAP TRACK FAIL/SAFE LINK TOP END BEARING ON THE 'T' CHORD FOUND MIGRATED. THE LEFT FIXED TRAILING EDGE UPPER CHORD HOLE HAS ELONGATED DAMAGED. OVERSIZED HOUSING BORE TO A MAXIMUM OF .8930 INCH DIAMTER. NDT INSPECTED THE REWORKED AREA TO ENSURE DEFECT FREE CONDITION. INSTALLED CRES SPLIT SLEEVE BUSHING WITH SHRINK FIT METHOD AN CHAMFERS TO MATCH DRAWING REQUIREMENT FOR NEW BEARING INSTALLATION. DETAIL VISUAL INSPECT THE REPAIR AREA AT C-CHECK INTERVALS NOT TO EXCEED 18 MONTHS. ATLAS AIR EO 4757A169 ISSUED TO ACCOMPLISH THE INSPECTION. (M)

Part: BULKHEAD — CRACKED (FUSELAGE)

DURING INSPECTION, .5 INCH CRACK FOUND ON RT WHEEL WELL SLOPING PRESSURE DECK AT STATION 1240, RBL 35. THE CRACK ORIGINATED FROM THE WATER LINE CONNECTOR HOLE AND EXTENDS UPWARDS. THE CRACKED SLOPING PRESSURE DECK WEB WAS TRIMMED OUT AND REPAIRED WITH DOUBLERS AND FILLERS. (M)

Part: SPAR — CRACKED (NR 3 PYLON)

DURING SCHEDULED MAINTENANCE, NR 3 PYLON INBOARD MIDSPAR CHORD WAS FOUND CRACKED ON THE VERTICAL FLANGE. THE AFFECTED SECTION OF CHORD WAS TRIMMED OUT. NDT INSPECTION WAS PERFORMED AT TRIMMED EDGES AND AT AL AFFECTED FASTENERS LOCATION TO ENDURE A CRACK AND DAMAGE FREE CONDITION. A NEW SECTION OF CHORD REPLACEMENT WAS INSTALLED USING REPAIR SPLICE STRIPS AND FILLERS. THE REPAIR ASSEMBLY CONFORMS TO DESIGN REQUIREMENTS. (M)

Part: SKIN — CRACKED (KRUEGER FLAP)

DURING INSPECTION, NR 16 KRUEGER FLAP, FOUND CRACK AT PANEL ATTACH FASTENER HOLE. TRIMMED OUT AFFECTED SPAR SEGMENT. NDT INSPECTED TO ENSURE CRACK AND DEFECT FREE CONDIION. INSTALLED REPAIR FILLER AND ALUMINUM REPAIR ANGLE WITH ADDITIONAL FASTENERS. REFINISHED SPAR TO DESIGN STANDARD. (M)

Part: FRAME — CHAFED (BULKHEAD)

D-CHECK AT SINGAPORE, DURING INSPECTION GOUGES WERE FOUND ON THE STATION 2460 BULKHEAD INNER T-CHORD TOP SURFACE AT LBL 30, AND WL 235. BLENDED OUT THE DAMAGED AREA AND INSTALLED A REPAIR STRAP OF .0710 INCH THICK CLAD 2040-T3 MATERIAL. (M)

Part: FITTING — ELONGATED (CARGO DOOR)

DURING INSPECTION, REPORTED ELONGATED HOLES IN THE TEN LATCH FITTING OF THE MAIN DECK SIDE CARGO DOOR. THE TEN LATCH FITTING WERE REWORKED WITHIN ALLOWABLE REWORK LIMITS. (M)

Part: LINK — GOUGED (TE FLAP)

DURING D-CHECK, DEEP GOUGE FOUND ON THE EDGE OF THE INBOARD LINK ON THE NR 18 VARIABLE CAMBER FLAP. BLENDED OUT DAMAGE FROM SURFACE OF LINK. NDT INSPECTED TO ENSURE CRACK AND DEFECT CONDITION. SHOP PREENED PER SOPM 20-10-03, INTENSITY .006A2. REFINISHED LINK TO DESIGN STANDARD. (M)

Part: SKIN — CRACKED (NR 2 PYLON)

DURING INSPECTION, NR 2 PYLON, CRACK DAMAGE WAS FOUND AT PRE-COOLER EXHAUST CUTOUT LOWER AFT CORNER AT NACELLE STATION 248. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NS 235 TO STA 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 — CRACKED (NR 3 PYLON)

DURING INSPECTION, NR 3 PYLON, CRACK DAMAGE WAS FOUND AT PRE-COOLER EXHAUST CUTOUT LOWER AFT CORNER AT NACELLE STATION 248. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NACELLE 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: CAP — CHAFED (STRUT)

DURING SCHEDULED MAINTENANCE, CHAFING MARK WAS FOUND ON THE LEFT SIDE OF THE SKIN ASSEMBLY AT NACELLE STATION 270. AFFECTED FASTENERS WERE REMOVED AND FASTENER HOLES WERE HFEC INSPECTED TO ENSURE CRACK AND DAMAGE FREE CONDITION. THE CHAFING DAMAGE WAS REMOVED BY BLENDING TO A SMOOTH CONTOUR. ENSURED MINIMUM MATERIAL REMOVED. THE BLENDED SURFACE WAS REFINISHED AND DESIGN TYPE OVERSIZE FASTENERS WERE INSTALLED PER SRM REQUIREMENTS. THE REPAIR CONFORMS TO DESIGN REQUIREMENTS. (M)

Part: SKIN — CRACKED (NR 4 PYLON)

DURING INSPECTION, NR 4 PYLON, CRACK DAMAGE WAS FOUND AT PRE-COOLER EXHAUST CUTOUT LOWER AFT CORNER AT NACELLE STATION 248. 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 ACCOMODATE THE NEW STEEL LOWER REPAIR ANGLE INSTALLATION ON THE NR 3 STIFFENER. (M)

Part: DOOR — CRACKED (R-4)

R-4 DOOR LOWER AFT CORNER HAS 2 CRACKS, ONE CRACK IS 4 INCHES AND THE OTHER CRACK IS 3 INCHES, STA 1715, W/L 199.8. CAUSE OF DAMAGE UNKNOWN. CRACKS FOUND DURING VISUAL INSPECTION. INSTALLED DOUBLER REPAIR IAW SRM.

Part: TRANSMITTER — LOOSE (T/E FLAP)

TLV - ACCEPTANCE FLIGHT FROM C-CHECK AIR TURNBACK, AFTER TAKEOFF DURING FLAP RETRACTION INBOARD FLAPS STOPPED AT 19 DEGREES INDICATES FLAP ASYMMETRY. AIRCRAFT RETURNED TO TLV. NO FUEL DUMPED. FOUND RIGHT OUTBOARD FLAP TRANSMITTER LOOSE. TIGHTENED TRANSMITTER LOOSE. TIGHTENED TRANSMITTER AND ADJUSTED THE SYSTEM PER MM 27-50-00. CHECKED ALL SYSTEMS ON GROUND PER MM 27-58-00. FOUND OK. (M)

Part: SENSOR — MALFUNCTIONED (NLG DOOR)

NOSE GEAR DOOR LIGHT (RED) AND GEAR LIGHT REMAINED ON AFTER GEAR LEVER WAS RAISED. ATTEMPTED TO CORRECT PER FHB PROCEDURES TO NO AVAIL. AIR TURN BACK REQUIRED. JETTISONED APPROXIMATELY 70,000 KGS OF FUEL. LIFTED THE AIRCRAFT AND TROUBLESHOT PER MM. ALL GEAR VISUAL INSPECTIONS AND OPS NORMAL. TROUBLESHOT LANDING GEAR WARNING LOGIC CARD AND SENSOR PER MM AND CLEANED SAME. INSPECTED AND ADJUSTED NOSE GEAR DOOR WARNING SENSOR PER MM. LUBRICATED NOSE GEAR AS REQUIRED. SWING CHECK OPS AND INDICATION NORMAL.

Part: CONTROL UNIT — FAILED (NR 3 GENERATOR)

ON CLIMBOUT, NR 3 AND NR 4 BUS TIES OPENED. SPLIT BUS SYSTEM OPEN. NR 3 GENERATOR WAS DISCONNECTED. NR 4 GENERATOR CHECKED GOOD VOLTS/ FREQ. NR 3 BUS LOST POWER AND COULD NOT REPOWER. DUMPED 17.0 KGS OF FUEL PRIOR TO LANDING. REMOVED AND REPLACED RIGHT BUS PROTECTION UNIT IAW MM. ALL OPS OK DURING ENGINE RUNS AND APU GENERATORS.

Part: PANEL — SEPARATED (GAP PANEL)

TURN BACK DUE TO ENGINE NR 1 AND ENGINE NR 4 GAP PANELS SEPARATED FROM AIRCRAFT ON TAKE OFF ROLL. INSTALLED NR 1 ENGINE GAP PANEL ISW SRM. REPAIRED NR 4 GAP PANEL PER SRM. REINSTALLED GAP PANEL ON NR 4 ENGINE IAW MM. CHAPTER 5 INSPECTION NOT REQUIRED. ACCOMPLISHED A GENERAL THROUGH VISUAL INSPECTION OF THE FUSELAGE, TAIL, WINGS, GEARS AND ENGINES. NO DISCREPANCIES FOUND.

Part: STRUCTURE — CRACKED (FUSELAGE)

DURING CURRENT C-CHECK AT KLM/AMS WHILE PERFORMING SB 747-53A2450, IAW AD 2001-16-02 AND HFEC OPEN HOLE INSPECTION REVEALED CRACKS EMINATING FROM THE AFT STRAP ROW AT BS 2231, STRINGER 24R AND 25R. CUT OUT BLENDED CRACKS IN STRAP. HFEC INSPECTED ROUTED AREAS AND ALL OPEN HOLES PER SRM 53-10-04 FIG 115. NO ADDITIONAL CRACKS FOUND. FILLERS AND REPAIR ALUMINUM STRAPS FABRICATED AND INSTALLED IAW ABOVE SRM TEXT. REPAIR IS A TIME LIMITED REPAIR AND REQUIRES A REPETITIVE 3000 CYCLE INSPECTION. AD REQUIREMENTS NEVER TERMINATE. (M)

Part: SPAR — CORRODED (WING)

DURING CURRENT C-CHECK AT KLM/AMS, FOUND LEVEL 1 CORROSION ON THE L/W VERTICAL FLANGE OF THE LOWER FRONT SPAR CHORD BETWEEN ILES 630.72 AND 638 (INBOARD OF NR 2 PYLON). TAPER LOCK FASTENERS IN THE AFFECTED AREA WERE REMOVED. CORROSION BLENDED AND FASTENER HOLES WERE REAMED AND SPOT FACED TO ENSURE A STRAIGHT HOLE AND FLAT CONTACT AREA. MATERIAL LOSS MEASURED AT .150 INCH. AN OPEN HOLE HFEC, DYE CHECK AND SURFACE HFEC INSPECTION WAS PERFORMED TO INSURE NO CRACKS/CORROSION REMAINED. NO FINDINGS. AREA FLAP PEENED, ALODINED AND PRIME PAINTED. OVER-SIZED HI-LOCK FASTENERS INSTALLED WET WITH BMS 5-26 SEALANT. TANK SEALED. (M)

Part: STRUCTURE — CRACKED (FUSELAGE)

DURING CURRENT C-CHECK AT KLM/AMS WHILE PERFORMING SB 747-53A2450, IAW AD 2001-16-02 AND HFEC OPEN HOLE INSPECTION REVEALED CRACKS EMINATING FROM THE AFT STRAP ROW AT BS 2231, STRINGER 25L. CUT OUT BLENDED CRACK IN STRAP. HFEC INSPECTED ROUTED AREA AND ALL OPEN HOLES PER SRM 53-10-04 FIG 115. NO ADDITIONAL CRACKS FOUND. FILLER AND REPAIR ALUMINUM STRAPS FABRICATED AND INSTALLED IAW ABOVE SRM TEXT. REPAIR IS A TIME LIMITED REPAIR AND REQUIRES A REPETITIVE 3000 CYCLE INSPECTION. AD REQUIREMENTS NEVER TERMINATE. (M)

Part: DOOR ACTUATOR — FAILED (NR 2 PACK)

NR 2 AIR CONDITIONING PACK OVERHEATED WITH A DOOR OUT OF SEQUENCE INDICATION. CAUSED FUMES IN AIR CONDITIONING SYSTEM. MANUALLY POSITIONED NR 2 PACK INLET DOOR CLOSED. REPLACED INLET DOOR ACTUATOR. (M)

Part: DISPLAY — FAILED (COCKPIT)

DURING CRUISE FLIGHT, RIGHT ENGINE INSTRUMENT DISPLAY FAILED, NR 2 EGT SPIKED UP AND FLIGHT CREW REPORTED SMOKE IN COCKPIT AND ELECTRICAL BURNING ODOR. SMOKE CLEARED AND FLIGHT CONTINUED TO DESTINATION. REMOVED AND REPLACED RIGHT ENGINE INSTRUMENT DISPLAY SCREEN. (M)

Part: FRAME — CRACKED (FUSELAGE)

FOUND AFTER HFEC INSPECTION, CRACK FROM FRAME WEB AT STATION 1265 LEFT WL 199 HOLE A. REMOVED INTERIM REPAIR. STOP DRILLED CRACK, INSTALLED A FRAME WEB DOUBLER, INTERCOSTAL DOUBLER AND ATTACH ANGLE PER AMOC TO PARAGRAPH A AND C OF AD2000-02-01. (M)

Part: SKIN — CRACKED (FUSELAGE)

NOSE GEAR CUTOUT CORNER CRACKED AT STATION 240 STRINGER 40R. FOUND NO SECONDARY CRACKS. REPAIRED BY INSTALLING DOUBLER PER SB 747-53-2272. (M)

Part: FITTING — MISDRILLED (FUSELAGE)

FOUND STATION 1480 STRINGER 39R FOUND TWO HOLES INSTALLED IN THE RADIUS. REMOVED CORNER FITTING, REDRILLED AND SLEEVED HOLES, REINSTALLED FITTING. INSTALLED FASTENERS PER SB 747-53A2390. (M)

Part: FRAME — CRACKED (FUSELAGE)

FOUND CRACK FROM FRAME WEB AT STATION 1265 RIGHT WL 199 CRITICAL HOLE FASTENER. STOP DRILLED CRACK, INSTALLED A STEEL FRAME WEB DOUBLER, INTERCOSTAL DOUBLER AND ATTACH ANGLE PER AMOC TO PARAGRAPH A AND C OF AD2000-02-01. (M)

Part: FIRE WARNING — ACTIVATED (APU)

FLT GT394 - CTS-ANC - DURING CRUISE, APU 'A' LOOP FIRE WARNING ILLUMINATED INTERMITTENTLY, WARNIGN HORN DID NOT SOUND. APU FIRE WARNING WAS SELECTED TO THE BOTH POSITION. SYSTEM CHECK WAS PERFORMED AND 'B' LOOP FAILED TEST. 'A' LOOP WAS SELECTED AND TESTED OK, HOWEVER, LATER THE APU FIRE WARNING ONCE AGAIN SOUNDED VERY BRIEFLY. CREW PERFORMED APU FIRE CHECKLIST AND DISCHARGED APU FIRE BOTTLE. ATC NOTIFIED. NO FIRE HAD ACTUALLY OCCURRED. ANC MAINTENANCE WAS UNABLE TO DUPLICATE DISCREPANCY. APU FUEL VALVE LOCKED CLOSED AND ITEM DEFERRED AS MEL ITEM 49-1 AND 26-08. REPLACED FIRE EXTINGUISHER BOTTLE AND SQUIB AND RESEATED FIRE WARNING CARD. REACTIVATED FUEL VALVE. APU AND APUF FIRE WARNIGN SYSTEM OPERATI

Part: GCU — INOPERATIVE (NR 2 ENGINE)

TPE/ANC - FLT GT386 - AFTER TAKEOFF, NR 2 GENERATOR FIELD AND MAIN BREAKER TRIPPED FOLLOWED BY NR 2 BUS TIE BREAKER TRIP. ONE MINUTE LATER, NR 1 GENERATOR FIELD AND MAIN GEN BREAKER TRIPPED. COULD NOT RESTORE EITHER GENERATOR. RESET NR 2 BTB AND THE NR 1 BTB TRIPPED AND COULD NOT BE RESTORED. 20 MINUTES LATER, NR 3 BTB TRIPPED, DUMPED FUEL RETURNED TO TPE. APPROACH AND LANDING UNEVENTFUL. DURING T/S, TPE MAINT FOUND NR'S 1, 2, AND 3 GENERATOR CONTROL UNITS DEFECTIVE. REPLACED 3 GCU'S ALL ENG RUN-UP AND NR'S 1 AND 2 GENERATOR CHKS NORMAL. NR 2 GEN INOP, DEFERRED MEL ITEM 24-1. MAINT REPLACED NR 2 GEN AND NR 2 GCU AGAIN. OPER NORMAL. (X)