N534MC

Part: ODOR — DETECTED (COCKPIT) · airframe 91,375 hrs · 19,484 cycles

DURING DESCENT HAD STRONG ELECTRICAL SMELL IN COCKPIT. PERFORMED INSPECTION OF COCKPIT, UNABLE TO FIND SOURCE OF ELECTRICAL SMELL.

Part: TIRE — BLOWN (LANDING GEAR) · airframe 91,065 hrs · 19,426 cycles

ON TAKEOFF ROLL, CREW HEARD 2 LOUD BANGS AND LOST NR1 HYDRAULIC SYSTEM. FOUND 8 BLOWN TIRES, REPLACED 12 TIRES AND 3 BRAKES IAW MM 32-45-01 AND 32-45-15, ACCOMPLISHED CONDITIONAL INSPECTIONS IAW MM 05-51-10 AND 05-51-09.

Part: ACTUATOR — ACTIVATED (RT MLG DOOR)

FLT 8867 - WRI-JFK- AFTER TAKEOFF, GEAR RETRACTED WITH NO PROBLEM. THEN DURING CLIMB TO 5,000 FEET THE RED DOOR LIGHT ILLUMINATED WITH PRIMARY AND SECONDARY LIGHT ON ENGINEERS PANEL. USED FHB SECTION 3 TO BRING GEAR UP, RIGHT WING GEAR. VIBRATION WAS ALSO EVIDENT UNTIL GEAR WAS RETRACTED. REMOVED AND REPLACED RIGHT WING GEAR DOOR ACTUATOR PER 32-12-00. OPS AND LEAK CHECK OK S/N OFF 4079. (M)

Part: SERVO VALVE — LEAKING (NR 2 HYD SYSTEM)

DURING CRUISE, NR 2 HYD QUANTITY WENT FROM 6.1 TO 2.2, 5 HOURS INTO FLIGHT. SUSPECT HYD LEAK. RAN PROCEDURES TO SHUTDOWN HYD SYSTEM NR 2 IAW FLIGHT HAND BOOK. REPLACED LOWER RUDDER POWER PACKAGE SERVO VALVE IAW MM. PRESSURIZED HYD SYSTEM IAW MM. LEAD CHECK OK, SN OFF 1895 (K)

Part: SWITCH — DIRTY (RT WING GEAR)

ON TAKEOFF, WHEN GEAR RETRACTED, RED GEAR WARNING LIGHT CAME ON. F/E PANEL RT WING DOOR OPEN LIGHT WAS ON, BOTH PRIMARY AND ALT POSITIONS. DID FHB CHAPTER 3, GEAR HANDLE UP, LIGHT WHEN OUT. GEAR HANDLE OFF, LIGHTS ON AGAIN. LT HANDLE UP. INSPECTED AND FOUND ABNORMAL AMOUNT OF DIRT AND GRIT IN RT WING GEAR ROLLER AND UPLOCK ROLLER INTERFACE. ALSO, FOUND DIRT AND GRIT AT DOOR INDICATOR MAG SWITCHES. CLEANED ALL AFFECTED AREAS AND CYCLED WING GEAR DOOR FOLLOW UP DOOR. OPS CHECK GOOD IAW MM. NO DEFECTS NOTED.

Part: PRECOOLER — CRACKED (NR 4 ENGINE)

EK9971 ICN/ANC (ATB) FIRE WARNING: NR 4 ENGINE FIRE LIGHT CAME ON IN-FLIGHT NACELLE INDICATOR WAS ABOUT 3 TO 3.5 EGT APPROX 900 DEGREE HIGH STAGE BLEED LIGHT CAME ON JUST BEFORE FIRE LIGHT AND BELL. FIRE LIGHT CAME ON ABOUT FL 24.2 ENGINE S/D A/WITH FHB. INSPECTION FOUND NR 4 ENGINE PRECOOLER HAS CIRCUMFERENTIAL CRACK ON INLET FLANGE APPROX FROM 5 OCLOCK TO 10 OCLOCK. REPLACED PRECOOLER ASSY. LEAK CHECK NORMAL IAW MM 36-12-01.

Part: LATCH — LOOSE (INSTRUMENT PANEL)

GROUND ABORT F/O'S FORWARD INSTRUMENT PANEL CAME OUT ON TAKEOFF ROLL. ABORTED AT 60 KNOTS. RESECURED F/O'S FORWARD INSTRUMENT PANEL IAW MM 31-10-00. ALL INSTRUMENT, OPS CHECK GOOD. (M)

Part: ENGINE — MALFUNCTIONED (NR 2) · airframe 86,986 hrs · 18,640 cycles

DURING T/O AFTER ROTATION NR 2 ENG TEMP ROSE INTO THE YELLOW BAND & THE NACELLE TEMP WAS RISING RAPIDLY, THE THROTTLE WAS RETARDED & TEMP CAME DOWN. ENG FAILURE CHECK ACCOMPLISHED. NR 2 ENGINE REMOVED & REPLACED.

Part: RELIEF VALVE — MALFUNCTIONED (NR 2 ENGINE) · airframe 86,970 hrs · 18,636 cycles

NR 2 ENG INDICATE A FIRE AT 13:50- 6 MINUTES AFTER TAKEOFF. NACELLE TEMP IN THE FIRE ZONE. ENGINE FIRE PROCEDURE WAS ACCOMPLISHED, PULLED FIRE HANDLE, DID NOT DISCHARGE FIRE BOTTLES. OIL PRESSURE NORMAL. REMOVED AND REPLACED NR 2 ENG PRESSURE RELIEF VALVE PER AMM 36-11-03. OPERATIONAL & LEAK CHECK NORMAL & PERFORMED SHUT OFF VALVE, OPS CHECKS ALL NORMAL.

Part: SEAL — LEAKING (NR 1 GENERATOR) · airframe 86,525 hrs · 18,529 cycles

NR 1 ENGINE OIL QTY DROPPED FROM 5.3 GALLONS AFTER TAKEOFF, QTY DROPPED TO 1.25 GALLONS, OIL PRESSURE CLIMBED FROM 50 PSI TO 75 PSI & TEMP 110C. REMOVED AND REPLACED NR 1 ENGINE GENERATOR & GENERATOR SEAL, ALSO REPLACED NR 1 ENGINE CSD SEAL. OPS CHECK OK IAW AMM 24-11-01.

Part: MANIFOLD — RUPTURED (NR 4 ENGINE) · airframe 86,323 hrs · 18,488 cycles

NR 4 ENGINE 14TH STAGE MANIFOLD RUPTURE AT LEFT HAND SIDE CDP AIR SWIVEL JOINT. REPLACED 14TH STAGE MANIFOLD & CLAMP AS PER AMM 75-23-00. OPS CHECK & LEAK CHECK ACCOMPLISH AS PER AMM 71-00-00.

Part: SPEAKER — FAILED (COCKPIT) · airframe 85,895 hrs · 18,402 cycles

TCAS FAILED IN FLIGHT. REPLACED TCAS SPEAKER, OPS CHECK OK MM 34-45-00.

Part: CONNECTOR — DAMAGED (EGT INDICATOR) · airframe 85,864 hrs · 18,395 cycles

AFTER PUSH BACK ON ENGINE START, NR 2 ENGINE EGT GAUGE HAD FLAG IN VIEW. T/S FOUND BROKEN PIN IN CONNECTOR, REPLACED, ALL INDICATIONS NORMAL.

Part: WIRE HARNESS — DAMAGED (NR 2 ENGINE) · airframe 85,890 hrs · 18,401 cycles

DURING ENGINE NR 2 START AT GATE, CREW REPORT THAT ENGINE NR 2 EGT NO INDICATION & FLAG IN VIEW. TROUBLE SHOT, FOUND RT UPPER HARNESS AT FAULT. REMOVED AND REPLACE ENGINE HARNESS, ENGINE RUN OPS CHECK OK.

Part: SEAT TRACK — CRACKED (FUSELAGE)

FORWARD CARGO COMPARTMENT SEAT TRACK CRACKED AT BS 576, APPROX RBL 48. REMOVED DAMAGED SEAT TRACK AS PER 747 SRM 51-30-01. INSTALLED SECTION OF SEAT TRACK IN FORWARD CARGO COMPARTMENT AT BS 576 RBL 48 P/N 65B601176-54. P/O NR 5075 LOT NR 01511488 REF 53-10-05 FIG 5. (M)

Part: BULKHEAD — CRACKED (FUSELAGE)

DURING CURRENT C-CHECK AT SIAEC INSPECTION OF BS 2484 UPPER BULKHEAD STRUCTURE DISCOVERED THE WEB CRACKED AT STRINGER 15L LBL 45 WL 287.03. REMOVED STIFFENER 65B02571-153. TRIMMED OUT CRACK IN WEB AREA. DYE CHECKED AREA. NO FINDINGS. FABRICATED REPAIR DOUBLER, FILLERS AND REPLACEMENT STIFFENER (65B02571-153) FROM DRAWING 65B02571. INSTALLED PER STANDARD SRM 51-30 PRACTICES. (M)

Part: FITTING — CORRODED (BULKHEAD)

DURING CURRENT C-CHECK AT SIAEC WHILE PRFORMING INSPECTION AND REWORK OF THE RIGHT BS 1480 LONGERON AREA PER SB 747-53A2390 FOUND NR 5 HOLE CORRODED AT BS 1480 RIGHT UPPER LONGERON BULKHEAD FITTING. REAMED HOLE TO .750 INCLUDING INSURANCE CUT. FABRICATED REPLACEMENT BUSHING. INSTALLED BUSHING AND FASTENERS PER ABOVE SB. POST MODIFICATION INSPECTION INTERVAL REDUCED TO 10,000 CYCLES AND REPEAT INSPECTION INTERVALS AT 2700 CYCLES THEREAFTER. AMOC ISSUED FOR REPAIR ON FORM 8110-3. (M)

Part: SPAR — CRACKED (RT WING)

DURING CURRENT C-CHECK AT SIAC INSPECTION OF THE RT L/E NR 15 KRUEGER FLAP, A CRACK WAS DISCOVERED IN THE FRONT SPAR INBOARD END OF THE DEVICE (65B39252-2). (M)

Part: ATTACH FITTING — SCORED (NR 4 PYLON)

DURING CURRENT C-CHECK AT SIAEC WHILE PERFORMING TERMINATING ACTION PER ATLAS AIR EO 4757A082, NR 4 PYLON LOWER WING DIAGONAL BRACE ATTACH FITTING, TAPER LOCATION INSTALLATION ' FOUND THE LAST THREE FASTENER HOLES SCORED. POSITIONS ARE ONE EACH AT INBOARD 2ND FROM NED, 1 EACH AT INBOARD AFT AND 1 EACH AT OUTBOARD AFT. REAMED HOLES TO .500. PERFORMED OPEN HOLE HFEC INSPECTION. NO FINDINGS. INSTALLED BACB30US8K32 FASTENERS IN LIEU OF TAPER LOCKS PER SRM 51-30. AMOC ISSUED TO SATISFY REQUIREMENTS PER AD 2001-13-06 ON FORM 8110-3. (M)

Part: WIRE — SHORTED (FIRE LOOP)

ON TAKEOFF ROLL, FIRE DETECTION MASTER CAUTION LIGHT FLICKERED. NR 2A FIRE LOOP NACELLE JUMPED FROM 1-5. ACCOMPLISHED PNEUMATIC LEAK CHECK. NO LEAKS FOUND. NR 2 ENGINE FIRE DETECTION LOOP 'A' FAILED OPERATIONAL TEST. WIRE NR W3296-2W10-18R FOUND SHORTED TO GROUND ON THE BACK OF CONNECTOR DX202A. WIRING REPLACED AS PER SWPM 20-10-11. LOOP 'A' OPERATIONAL TESTED OK PER MM 26-11-00. (M)

Part: SKIN PANEL — DAMAGED (WING)

DURING INSPECTION OF LOWER WING SKIN, SKIN FOUND DAMAGED AT STRINGER S-3C AND STRINGER S-40C BETWEEN LBL 40 AND LBL 50. SKIN DAMAGED BLENDED OUT, MEASURED, HOLES E/C CHECKED, SKIN FLAT PEENDED AND ALODINED. A 2024-T3 REINFORCEMENT DOUBLER INSTALLED. PER ATLAS TELEX AND BOEING REPAIR DATA. (M)

Part: BLANKET — BURNED (FUSELAGE)

DURING THE INSPECTION OF STRUCTURE BETWEEN STATION 2220 THROUGH 2360, THE INSULATION BLANKETS ON THE APU PNEUMATIC SUPPLY DUCT WERE FOUND WITH BURNED HOLES. THE P/N OF THE DAMAGED BLANKETS WERE CHECKED FOR CORRECT APPLICATION. THE CORRECT P/N WAS INSTALLED. ALL INSULATION BLANKETS WERE REPLACED. OPS CHECK AND LEAK CHECK PERFORMED. ALL OK. (M)

Part: DUCT — SEPARATED (NR 1 ENGINE)

FLT 7150 - GYE - ON TAKEOFF AT 400 AGL, NR 1 ENGINE EXPLODED AND HAD AIRCRAFT VIBRATION. LEVELED AIRCRAFT AT 817 FEET. ADVISED TOWER HAD AN ENGINE FIRE AND DECLARED AN EMERGENCY. DUMPED 30K FUEL AND RETURNED TO GYE. ON ARRIVAL, DETERMINED THAT NR 1 ENGINE HAD AN UNCONTAINED FAILURE. ANALYSIS OF FAILURE INDICATED AIRDUCT FAILURE IN AREA OF SEVENTH STIFFENER. AIRDUCT MACHINED INTO FAN MID-SHAFT. FAN MID-SHAFT SEPARATED, RESULTING IN UNCONTAINED ENGINE FAILURE AND STAGE 4 DISK AND RELATED HARDWARE DEPARTED THE ENGINE/AIRCRAFT. ENGINE REPLACED WITH S/N 517655. (M)

Part: LINE — CRACKED (NR 2 ENGINE)

FLT 51 - NR 2 ENGINE FIRE WARNING LIGHT AND BELL AT 3500 FEET. ACCOMPLISHED ENGINE FIRE CHECKLIST, SHUTDOWN ENGINE. LIGHT IN FIRE HANDLE WENT OUT IMMEDIATELY. DID NOT DISCHARGE FIRE BOTTLES AND DID NOT DUMP FUEL. LANDING WAS UNEVENTFUL. FOUND CRACKED/LEAKING MUSCLE LINE TO THE HIGH STAGE VALVE. PERFORMED DETAILED INSPECTION OF ENGINE AND WINDMILL INSPECTION, ALL OK. REPLACED TWO LINES AND ALL OPERATIONAL CHECKS WERE NORMAL. (M)

Part: BUILKHEAD SPLICE — CRACKED (PRESS BULKHEAD)

CRACKS FOUND ON WEB SPLICE PLATE HOLES NR 11 LEFT AND NR 21 LEFT. HOLES NR 11 LEFT, INSTALLED SEPARATE BUSHINGS IN EACH PART PER SB 747-53A2390 FIG 14. HOLE NR 21 LEFT, REPAIRED OVERSIZE HOLE IN BULKHEAD. CHORD AND WEB PER BUSHING REPAIR PER SB 747-53A2390 FIG 14. (X)

Part: BULKHEAD SPLICE — CRACKED (PRESS BULKHEAD)

CRACKS FOUND ON WEB SPLICE PLATE HOLES NR 11 RIGHT AND NR 23 RIGHT. HOLE NR 11 RIGHT, INSTALLED SEPRATE BUSHINGS IN EACH PART PER SB 747-53A2390 FIG 14. HOLE NR 23 RIGHT, REPAIRED OVERSIZE HOLE IN WEB SPLICE PLATE BULKHEAD. CHORD AND WEB PER BUSHING REPAIR PER SB 747-53A2390 FIG 14. (X)