N535MC

Part: WINDOW — CRACKED (COCKPIT)

RIGHT FORWARD NR 1 WINDOW HAS DELAMINATION AND POSSIBLE CRACK. INSPECTED WINDOW, AND FOUND ACCEPTABLE FOR FLIGHT IAW MEL 56-1-1, NR 1 WINDOW OUTER GLASS PLY CRACKED ONLY, AND VISIBILITY THROUGH ASSOCIATED WINDSHIELD IS ACCEPTABLE, AND VISION IS NOT IMPAIRED ON REMAINING WINDSHIELD. AIRPLANE TO BE OPERATED FOR ONE TAKEOFF ONLY TO AN AIRPORT WHERE REPLACEMENT CAN BE MADE. REMOVED AND REPLACED WINDOW, AND RETURNED TO SERVICE.

Part: COMPUTER — MALFUNCTIONED (COMPASS)

AIR TURNBACK, AT APPROXIMATELY 80-85 KNOTS ON TAKEOFF ROLL, HEADING FLAG ON CAPTAIN'S HSI AND FO'S RMI WITH FILGHT DIRECTOR WARNING LIGHT ON CAPTAINS SIDE. FLAG REMAINED IN FIEW ENTIRE FLIGHT. APPROXIMATELY 5 DEGREES DIFFERENCE IN NR 1 COMPASS VS NR 2 COMPASS AIRCRAFT RRETURNED TO AMS, 24,000 KGS OF FUEL DUMPED. FOUND WIRE SHORTED TO GROUND W153-1F263-22. REPLACED WIRE FROM D1166P TO TX214H26 AND REPLACED COMPAS COUPLER IAW MM 34-12-00 SATISFACTORY. ALSO, REPLACED INU NR 1 AND NR 3 ACC MM 34-41-03 P/N 7886580-011. REPLACED CIWS COMPUTER ACC MM 34-44-01 P/N 777-1826-004. REPLACED CAPTAINS HSI ACC MM 34-41-06 P/N 2592639-901. ALL OPERATIONAL CHECKS SATISFACTORY. (M)

Part: COUPLER — FAILED (COMPASS)

DURING TAKEOFF ROLL, HEADING FLAG ON CAPTAIN'S HSI AND FO'S RMI. AIRCRAFT DIVERTED TO AMS, 23,000 KGS OF FUEL DUMPED. INSTALLED TEMP SPAR WIRE FROM D2206P TO DB105, WING TIP TO WIG DISC, AND REPLACED BOTH COMPASS COUPLER NR 1 AND FO'S RMI IAW MM 34-12-00, RMI P/N 2594661-801. (M)

Part: FLAP TRACK — CORRODED (NR 6)

DURING CURRENT "C" CHECK, FOUND NR 6 FLAP OUTBOARD BUSHING OF PIVOT FITTING LOOSE. DISASSEMBLY REVEALED CORROSION ON THE LEFT SIDE TO SIDE LOAD FITTING ON CONTACT AREAS, (NO CORROSION LEVEL DECLARED). REMOVED TRACK, ROUTED TO SHOP. MACHINED FLAP TRACK FLANGES TO REMOVE CORROSION. NDI INSPECTED TO ENSURE CORROSION REMOVAL. NO FINDINGS. SHOT PEENED AND REFINISHED REWORK AREA. FABRICATED REPLACEMENT BEARING PLATES TO COMPENSATE FOR REMOVED MATERIAL IAW STANDARD OVERHAUL PRACTICE. TRACK OVERHAULED AND RESTORED TO ORIGINAL STANDARDS IAW MM. REINSTALLED FLAP TRACK.

Part: STRINGER — CORRODED (FUSELAGE)

DURING CURRENT C-CHECK FOUND BS 2179 STRINGER 45L CORRODED ON OUTBOARD FLANGE. CUT AWAY CORRODED AREA. MANUFACTURED REPAIR FILLER, SHIMS AND REPAIR DOUBLERS SIMILAR TO SRM 53-10-03 FIG 1. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING CURRENT C-CHECK, FOUND CRACKS EMANATING FROM THE LOWER OUTBOARD CORNER OF THE FRAME ACCESS HOLE CUTOUT AT BS 2040, 2080, 2100, 2120, 2160 AT LBL 16 WL 137. EACH FRAME CRACKED AT THE SAME LOCATION. CRACKS STOP DRILLED OR CUT AWAY AS REQUIRED. REPAIR DOUBLERS, FILLERS AND OR TAPERED SHIMS FABRICATED IAW SRM 53-10-04 FIG 43. REPAIR DOUBLERS LENGTHENED AS NECESSARY. INSTALLED RELATED REPAIR PARTS PER STANDARD SRM PRACTICES. (M)

Part: MEC — INOPERATIVE (NR 4 ENGINE)

WHILE CLIMBING THROUGH 13,500 FEET AND ACCELERATING THROUGH 310 KTS, NR 4 ENGINE ROLLED BACK TO IDLE ACCOMPANIED BY A NOTICEABLE YAW. INSTRUMENTS CONFIRMED NR4 ENGINE HAD INDEED ROLLED BACK. AUTO THROTTLES WERE ENGAGED AT TIME. USING CLIMB POWER BUT NO THROTTLE INDUCEMENT OCCURRED ON ANY THROTTLE. SHORTLY AFTER ROLL BACK, ENGINE RESUMED ITS CLIMB POWER REVOLUTIONS. ALL OTHER INDICATIONS WERE NORMAL. C/A: PERFORMED VISUAL INSPECTION AT LINKAGE, FOUND OK. CHECKED SPECIFIC GRAVITY READING 0.76. REPLACED MEC IAW MM. STATIC RIG CHECK ACCOMPLISHED. WET MOTORING PERFORMED OK. ACCOMPLISHED TEST NR 4 MAX POWER ASSURANCE TESTED, TEST SATISFACTORY. VSV TRACKING CHECK ON NR 4 ENGINE TO BE DONE, LATER CHECK.

Part: FRAME — CRACKED (FUSELAGE)

DURING THE CURRENT A-CHECK, LOWER LOBE FORWARD CARGO DOOR FRAME BS 560 AT STRINGER 38R WAS FOUND CRACKED. CUTOUT SECTION OF CRACKED AREA FROM S37 AND S39. MANUFACTURED FILLER, REPAIR ANGLES, DOUBLERS AND ASSOCIATED FILLERS. INSTALLED IAW ATLAS EO 4753A125. (M)

Part: ACM — FAILED (NR 3 A/C PACK)

FLT 56 - UIO-GYE - PRIOR TO DEPARTURE, NR 3 ACM FAILED ALLOWING SMOKE TO ENTER THE MAIN CARGO DECK AND THE FLIGHT DECK. AIRCONDITIONING SYSTEM WAS DEFERRED PER THE DDPG. ON 10/18/2000 MIA MAINTENANCE REPLAED ACM, OPERATIONAL CHECK SATISFACTORY. (M)

Part: VALVE — STUCK (NR 2 ENGINE)

FLT GT57 - NR 2 ENGINE FIRE WARNING ILLUMINATED AFTER TAKEOFF. IT OCCURRED DURING CLIMB WITH CLIMB POWER SET. BOTH NACELLE TEMPS WERE 8.5. ENGINE SECURE DIAW FHB. DECLARE EMERGENCY AND JETTISONED 14 KGS OF FUEL. LANDING WAS UNEVENTFUL. FOUND NR 2 ENGINE PRESSURE RELIEF VALVE STUCK OPEN. REPLACED VALVE. ENGINE RUN UP NORMAL. (M)