N537MC

Part: ACOUSTIC PANEL — CRACKED (NR 2 NACELLE) · airframe 98,496 hrs · 19,325 cycles

DURING A CHECK INSPECTION, NR 2 ENGINE NOSE COWL, VISUALLY FOUND AFT INNER SKIN OF ACOUSTIC PANEL CRACKED THREE PLACES (AS VIEWED WITH COWL OPEN): 6 O'CLOCK/8 INCHES LONG; 06:45 O'CLOCK/11 INCHES LONG; 7 O'CLOCK/15 INCHES LONG. APPLIED INTERIM REPAIR IAW SRM 54-00-02,51-40-09 FIGURE 9 AND XEO 71-111707. VISUAL INSPECTION REQUIRED EVERY FLIGHT CYCLE UNTIL NOSE COWL REPLACED.

Part: NOSE COWL — CRACKED (NR 2 ENGINE) · airframe 98,517 hrs · 19,329 cycles

NR 2 ENGINE NOSE COWL HAS 3 EACH CRACKS. ONE CRACK AT 7 O'CLOCK POSITION IS 15" LONG. NEXT CRACK AT 6 O'CLOCK POSITION IN 6 INCH LONG AND THE NEXT CRACK AT 6.45 O'CLOCK POSITION IS 11 INCH LONG. REPAIRED NR 2 ENGINE NOSE COWL IAW SRM 51-43-01 AND XEO 71-111707.

Part: INU — MALFUNCTIONED (E/E BAY)

NR 2 INU BECAME COMPLETELY UNREADABLE AFTER ONE HOUR OF FLIGHT, IT HAD DEVIATED MORE THAN 10 MILES RIGHT OF TRACK. TWO HOURS INTO FLIGHT IT WAS MORE THAN 100 MILES OFF ACTUAL AIRCRAFT POSITION AS ESTABLISHED WITH VOR OVERHEAD. REMOVED AND REPLACED INU P/N 463001-6130-0413.OPS CHECKED GOOD, OK FOR CONTINUED SERVICE.

Part: SPAR CAP — DAMAGED (ZONE 300) · airframe 97,429 hrs · 19,113 cycles

HORIZONTAL STAB RT AFT CRACK INDICATION/HOLE DAMAGED AT RT HORIZ SPAR CAP INBD OF 43.5 INBD AFT HOLE. REAMED DAMAGED HOLE TO FIRST OVERSIZE (.450-.453) IAW SB 747-55A2050. NDT FINDS NO DEFECTS. BOLTS INSTALLED ON CARD 8010 / 8011.

Part: SPAR CAP — DAMAGED (ZONE 300) · airframe 97,429 hrs · 19,113 cycles

SEVERAL BOLT HOLES DAMAGED IN LEFT HORIZ STAB SPAR CAP IN THE AREA OF LBL 43.5. REF NON ROUTINES 18389-18392. REAMED DAMAGED HOLE TO FIRST OVERSIZE (.450-.453) IAW SB 747-55A2050. NDT FINDS NO DEFECTS. BOLTS INSTALLED ON CARD 8010 / 8011.

Part: SPAR CAP — DAMAGED (HORIZONTAL STAB) · airframe 97,429 hrs · 19,113 cycles

HORIZONTAL STAB RT UPPER AFT DAMAGED HOLE AT RT VERTICAL SPAR CAP. INBD OF RBL 43.5 INBD UPPER AND LOWER FASTENER HOLE (CENTER SECTION) WAS NOTED DURING OPEN HOLE HFEC INSPECTION (NDT). COULD NOT ACQUIRE GOOD HFEC INDICATION DUE TO HOLE DAMAGE. REAMED DAMAGED HOLES TO 2ND OVERSIZE (.403-.406) IAW SB 747-55A2050 NDT FINDS NO DEFECTS BOLTS INSTALLED ON CARD 8010 / 8011.

Part: SPAR CAP — DAMAGED (ZONE 300) · airframe 97,429 hrs · 19,113 cycles

HORIZONTAL STAB RT AFT CRACK INDICATION/HOLE DAMAGED AT RT HORIZ SPAR CAP INBD OF 43.5 O/B AFT HOLE. REAMED DAMAGED HOLE TO FIRST OVERSIZE (.450-.453) IAW SB 747-55A2050. NDT FINDS NO DEFECTS. BOLTS INSTALLED ON CARD 8010 / 8011.

Part: WEB — CRACKED · airframe 97,429 hrs · 19,113 cycles

.50 LENGTH HORIZONTAL CRACK RIGHT SIDE PANEL/WEB AT WL 170 STA 313 NOSE WHEEL WELL AREA. ACCOMPLISHED NOSE WHEEL WELL REPAIR AT WL 170 FROM STA 309 TO 317 IAW SRM 53-10-04.

Part: SPLICE PLATE — DAMAGED (ZONE 300) · airframe 97,429 hrs · 19,113 cycles

HORIZONTAL STAB UPPER AFT CRACK INDICATION HOLE/HOLE DAMAGE AT LT SPLICE PLATE UPPER PLATE UPPER INBOARD OF LBL 45.3. AFT OF T/E AFT OUTBOARD FASTENER HOLE (CENTER SECTION). WAS NOTED DURING OPEN HOLE HFEC (NDT) COULD NOT ACQUIRE GOOD HFEC INDICATION DUE TO DAMAGED HOLE. REAMED DAMAGED HOLE TO FIRST OVERSIZE (.388-.391) IAW SB 747-55A2050. NDT FINDS NO DEFECTS. BOLTS INSTALLED ON CARD 8010 / 8011.

Part: SKIN — CORRODED (BS 1250) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

CORROSION LEFT FWD UPPER CORNER CUTOUT INNER SURFACE MED NR 3L. REMOVED CORROSION ON INNER SURFACE OF L-3 DOOR CUTOUT IAW B747 SRM 51-10-01. FOUND TO BE OUT OF LIMITS IAW BOEING MSG SR-1384850927-4. FABRICATED REPLACEMENT TAB FROM .080 2024-T3 PER SAME BOEING MESSAGE. REPLACED SKIN WITH P/N 65B15410-603 IAW BOEING MESSAGE NUMBER SR-1-38450927-2.

Part: TRUNNION — CORRODED (BS 1480) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

LEFT BODY GEAR INBOARD TRUNNION FITTING HAS CORROSION AROUND THE UPPER FACE OF 3 BOLT HOLES (INBOARD FWD, OUTBOARD FWD, AND OUTBOARD AFT). LOCALLY BLENDED OUT ALL PITTING CORROSION AREAS. HFEC AND 10X VISUAL INSPECTION PLUS DYE PENETRANT INSPECTION ACCOMPLISHED. SPOT FACED WASHER BEARING SURFACE AREA. HFEC AND 10X VISUAL INSPECTION OF BOLT HOLES ACCOMPLISHED, FLAP PEENED REWORKED AREA. TREATED AND PRIMED AREA. AREA WITH IN LIMITS PER BOEING MESSAGE NR 1-381511269.

Part: SPAR CAP — DAMAGED (ZONE 300) · airframe 97,429 hrs · 19,113 cycles

HORIZONTAL STAB RT AFT CRACK INDICATION/HOLE DAMAGED AT RT HORIZ SPAR CAP RT SIDE OTBD OF 43.5 INBD FWD HOLE. REAMED DAMAGED HOLE TO FIRST OVERSIZE (.450-.453) IAW SB 747-55A2050. NDT FINDS NO DEFECTS. BOLTS INSTALLED ON CARD 8010 / 8011.

Part: FLOORBEAM — CRACKED (ZONE 200) · airframe 97,429 hrs · 19,113 cycles

CRACK INDICATION IN LEFT SIDE OF UPPER DECK FLOORBEAM FUSELAGE 6, 7 AND 8TH HOLES FROM OUTBOARD TOP ROW OF FASTENERS STRAP AREA OF UPPER CHORD REF S/B 747-53A24201 FIG 2 STEP 2. REMOVED CRACKED CHORD SECTION REMOVED CRACKED WEB SECTION FABRICATED AND INSTALLED NEW WEB SECTION AND REPAIR DOUBLER . FIT AND INSTALLED CHORD REPAIR KIT 141U0044-115 REINSTALLED PARTS REMOVED FOR REPAIR INCLUDING STIFFENERS ON FWD SIDE OF FLOORBEAMS COVERED BY BOEING MESSAGE 1-404648834-7 REF S/B 747-53A2429R1 AND DRAWING NR 141U0044 SHEET 4.

Part: THRESHOLD — CORRODED (ZONE 200) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

CORROSION ON RIGHT AFT LOWER CORNER CUTOUT INNER SURFACE MED NR 3. REMOVED CORROSION AND BLENDED AREA20:1 MIN REMAINING MATERIAL .222". REMOVED CORNER DOUBLER. INSTALLED NEW DOUBLER. INSTALLED NEW THRESHOLD IAW SRM 51-10-01, 51-30-02, 51-30-04 BOEING MESSAGE NR 1-383704990-2.

Part: THRESHOLD — CRACKED (ZONE 200) · airframe 97,429 hrs · 19,113 cycles

CRACK NOTED AT SKIN 1.75" IN LENGTH. CRACK NOTED IN BEARSTRAP AT SAME LOCATION 1.75" IN LENGTH. CRACK TERMINATES AT FASTENER HOLE. REMOVED EXISTING DOUBLER AT CRACK TERMINATION HOLE. REAMED HOLE .100 OVERSIZED. FABRICATED AND INSTALLED FREEZE PLUG DRILLED UP AND INSTALLED LARGE STEEL DOUBLER WHICH IS PART OF KIT NR 65B25848-9 ALONG WITH NEW STAINLESS STEEL THRESHOLD THEN REINSTALLED ALL PARTS IAW SB 747-53A2552.

Part: FLOORBEAM — CRACKED (BS 440) · airframe 97,429 hrs · 19,113 cycles

CRACK INDICATION IN RIGHT SIDE OF UPPER DECK FLOORBEAM FUSELAGE STA 440 3RD AND 4TH HOLES FROM THE OUTBOARD TOP ROW OF FASTENERS STRAP AREA OF UPPER CORD REF S/B 747-53A2449 FIG 2 STEP 2. DISASSEMBLED AREA AT STA 440 DISCOVERED CRACKS IN FRAME WEB AND CRACKED SPLICE DOUBLER. INSTALLED NEW SECTION IAW SRM 51-20-01 AND SRM 51-30-02.

Part: FLOORBEAM — CRACKED (ZONE 200) · airframe 97,429 hrs · 19,113 cycles

CRACK INDICATION IN LEFT SIDE OF UPPER DECK FLOORBEAM FUSELAGE STA 360 5TH AND 8TH HOLES FROM THE OUTBOARD STRAP AREA OF UPPER CORD REF S/B 747-53A24201 FIG 2 STEP 2. INSTALLED FRAME WEB REPAIR REPLACEMENT PARTS IAW SRM 53-10-04 FIG 103 DETAIL 2.

Part: STRINGER — CORRODED (BS 1220) · airframe 97,429 hrs · 19,113 cycles

CORROSION ON STRINGER S-15 RIGHT AT BS 1220 4 EACH RIVETS HEADS POPPED WITH CORROSION NOTED UNDER THE RIVET. PRIMER LOOSE AND FLAKING OFF THE STRINGER AT SAME AREA. REMOVED FASTENER AND STRAP IAW SRM 51-30-02. CLEANED STRINGER 15R AT BS 1220 IAW MM 20-11-14. TREATED AND PRIMED AREA AND INSTALLED NEW FASTENERS IAW SRM 51-30-02. NO CORROSION NOTED ON STRINGER.

Part: STRUCTURE — PUNCTURED (ZONE 600) · airframe 97,429 hrs · 19,113 cycles

PUNCTURE IN COMPOSITE ON RIGHT OUTBOARD T/E FLAP CARRIAGE NR 6 ON RT INBOARD FLAP. REMOVED DAMAGED FABRICATED DOUBLER OUT OF 2024 T3 IAW SRM 51-40-20.

Part: SKIN — PUNCTURED (TE FLAP) · airframe 97,429 hrs · 19,113 cycles

LT OUTBOARD MID FLAP HAS A PUNCTURE IN THE UPPER SURFACE 112" FROM INBOARD EDGE AND 8" FROM T/E. REPAIRED LT OUTBOARD MIDFLAP IAW SRM 51-40-15 PARA 4C. APPLIED CONDUCTIVE COATING IAW SRM 51-24-03 APPLIED PRIMER AND TOP COAT PER 51-21-02.

Part: SEAT TRACK — CORRODED (BS 480-520) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

CORROSION ON SEAT TRACK UPPER DECK GALLEY STA 480 TO 520 LBL 40. REMOVED UPPER DECK GALLEY SEAT TRACK STA 480-530 LBL 40. FABRICATED NEW SECTION OF SEAT TRACK FROM BAC1520-1567 7178-T6511 PO NR 1114517 IAW SRM 53-10-05. INSTALLED NEW SECTION OF SEAT TRACK FOD CHECKED AREA AS REQUIRED.

Part: STRUCTURE — DAMAGED (TE FLAP) · airframe 97,429 hrs · 19,113 cycles

NICK AND GOUGE DAMAGE TO COMPOSITE ON RT OUTBOARD MID FLAP. CLEANED AND PREPPED AREA. APPLIED REPAIR PER SRM 51-40-15PARA 4L.

Part: SUPPORT BRACKET — DELAMINATED (ZONE 600) · airframe 97,429 hrs · 19,113 cycles

RIGHT INBOARD MIDFLAP MOST OUTBOARD UNDERSIDE SUPPORT BRACKET AREA ON FLAP PREVIOUS REPAIR DISBONDED. REMOVED DISBONDED REPAIR AND INSTALLED NEW REPAIR ON RIGHT INBOARD MIDFLAP MOST OUTBOARD UNDERSIDE SUPPORT BRACKET AREA IAW SRM 51-40-12.

Part: FLOORBEAM — CRACKED (BS 330) · airframe 97,429 hrs · 19,113 cycles

CRACK ON FORWARD FACE OF FLOORBEAM WEB (UPPER DECK) STA 330 LEFT SIDE AT FRAME TO FLOORBEAM ATTACHMENT. REPAIRED CRACKED FLOORBEAM WEB AT STA 330 LEFT PER SB 747-53-2272 DRAWING NR 65B28068 SRM 51-30-02 AND SRM 51-10-01. AREA CHECKED FOR FOD.

Part: SEAT TRACK — CORRODED (ZONE 900) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

CORROSION ON SEAT TRACK UPPER DECK GALLEY STA 480 TO 520 LBL 60. REMOVED UPPER DECK GALLEY SEAT TRACK STA 480-590 LBL 60. FABRICATED NEW SECTION OF SEAT TRACK FROM BAC1520-1567 7178-T6511 PO NR 1114517 IAW SRM 53-10-05. INSTALLED NEW SECTION OF SEAT TRACK FOD CHECKED AREA AS REQUIRED.

Part: SKIN — PUNCTURED (TE FLAP) · airframe 97,429 hrs · 19,113 cycles

3 SMALL PUNCTURES IN UPPER SURFACE OF LEFT INBOARD MID FLAP. CAUSED BY DROPPED TOOL. CLEANED AREA OF DAMAGE PREPPED AREA FOR REPAIRS IAW 747 SRM 51-40-12 REPAIRS 4C AND 4D. APPLIED CONDUCTIVE COATING IAW 747AMM 51-24-03 PRIMED AND TOP COATED IAW AMM 51-24-03.

Part: FRAME — CORRODED (BS 1310) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

CORROSION ON RIGHT AFT UPPER AND LOWER CORNER INBOARD SIDE OF THE R3 DOOR CUT OUT. XEO-53-072007 ACCOMPLISHED TO REMOVE EXFOLIATION CORROSION. TO BE REINSPECTED EVERY 3000 FLIGHT CYCLES PER PART 2 OF XEO 53-072007. NDT AND VISUAL INSPECTION ACCOMPLISHED REF BOEING MESSAGE 1-383704990-2 AND SRM 53-30-03 FIG 44.

Part: SPAR CAP — CRACKED (HORIZONTAL STAB) · airframe 97,429 hrs · 19,113 cycles

HORIZONTAL STABILIZER UPPER AFT CRAFT INDICATION/HOLE DAMAGE AT LT HORIZONTAL SPAR CAP INBD OF LBL 43.5 INBD AFT HOLE. REAMED DAMAGED HOLE TO FIRST OVERSIZE (.450-.453) IAW SB 747-55A2050. NDT FINDS NO DEFECTS. BOLTS INSTALLED ON CARDS NR 8010/8011.

Part: TRUNNION — CORRODED (BS 1480) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

LT BODY GEAR OUTBOARD TRUNNION BEARING SUPPORT FITTING FACE HAS PITTING. BORE FACE AND SIDE FACES WERE MACHINED TO REMOVE DAMAGED AREAS ID= 10.826", IB SIDE FACE = 0.017 REMOVED. OB SIDE FACE = 0.025 REMOVED. REPAIR REF B747 SRM 53-10-08 FIG 2.

Part: TRUNNION — CORRODED (BS 1480) · corrosion level 2 · airframe 97,429 hrs · 19,113 cycles

LT BODY GEAR OUTBOARD TRUNNION FITTING HAS CORROSION AROUND THE UPPER FACE OF THE FWD BOLT HOLE. LOCALLY BLENDED CORROSION AREAS AND THEN SPOT FACING AROUND THE FORWARD BOLT HOLE REMOVE ALL BLEND OUTS WITHIN THE BEARING SURFACE. REF BOEING 8100-9.

Part: SPAR — GOUGED (HORIZONTAL STAB) · airframe 97,429 hrs · 19,113 cycles

RT HORIZ STAB AUX SPAR FWD FACE HAS 7 EACH GOUGES BETWEEN STAB STATIONS 210 - 240 ABOVE LOWER RIVET PATTERN. FOUND GOUGES OUT OF LIMITS, IAW 747 SRM 55-10-01. CUT OUT DAMAGE, FABRICATED FILLER AND DOUBLER IAW B747 SRM 51-10-02. INSTALLED FILLER AND DOUBLER IAW SRM 55-10-05.

Part: SKIN — PUNCTURED (TE FLAP) · airframe 97,429 hrs · 19,113 cycles

PUNCTURE ON LOWER AFT SURFACE OF RT INBOARD T/E FORE FLAP AT WBL 235.2. PUNCTURE ON LOWER AFT SURFACE OF RIGHT I/B T/E FOREFLAP AT WBL 235.2 CLEANED AND PREPPED AREA FOR REPAIR IAW SRM 51-40-12. APPLIED REPAIR IAW SRM 51-40-12 PARA 4A AND PAINTED IAW MM 51-40-12. REINSTALLED PHONOLIC RUB STRIP IAW 51-50-00 PARA 3.

Part: TRUNNION — CORRODED (BS 1480) · airframe 97,429 hrs · 19,113 cycles

CORROSION ON UPPER SURFACE OF RIGHT BODY GEAR OUTBOARD TRUNNION UPPER CAP AROUND THE FORWARD BOLT HOLE. LOCALLY BLENDED PITTING CORRODED AREA. HFEC AND 10X VISUAL INSPECTION PLUS DYE PENETRANT INSPECTED. SPOT FACED WASHER BEARING SURFACE AREA SHOT PEENED BLEND. REWORKED AREA. HFEC CHECKED BOLT HOLES. TREATED ,PRIMED AREA PER BOEING 8100-9.

Part: PANEL — GOUGED (HORIZONTAL STAB) · airframe 97,429 hrs · 19,113 cycles

PANEL 341BR RIGHT HORIZ STAB LEADING EDGE TOOLING MARKS AND GOUGES. REPAIRED TOOLING MARKS ON RIGHT LEADING EDGE OF HORIZ STAB IAW SRM 55-10-03.

Part: TRUNNION — DAMAGED (ZONE 700) · airframe 97,429 hrs · 19,113 cycles

NOSE GEAR LEFT TRUNNION BEARING LOWER CAP TOOLING DAMAGE ON BOTTOM MATING SURFACE. BLENDED OUT DAMAGE MIN .250"R , HFEC AND 10X VISUAL INSPECTION TREATED AND PRIMED. REF BOEING 8100-9 MESSAGE 1-384920112-1.

Part: SKIN — CRACKED (BS 1271.5) · airframe 97,429 hrs · 19,113 cycles

RIGHT SIDE STA 1271.5 WL 200 CRACK NOTED ON SKIN 1" IN LENGTH AND TERMINATES JUST AFT OF FASTENER HOLE. DOES NOT GO INTO HOLE. REMOVED EXISTING DOUBLER ACCOMPLISHED TRIM OUT ON SKIN AND BEAR STRAP. INSTALLED NEW DOUBLER AND FILLER FOR TRIMMED OUT AREA IAW SB 747-53A2512.

Part: PANEL — DENTED (LT WING) · airframe 97,116 hrs · 19,053 cycles

LT WING LEADING EDGE HAS A 6.5 INCH LONG BY 3.0 INCH WIDE DENT AT ILES 207.0. PERMANENT REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 18 SHEETS 1 THRU 5 AND B747-200 51-40-12. ALSO, REFERENCE ATLAS AIR EO NR 4757A357.

Part: PANEL — DELAMINATED (RT WING) · airframe 97,116 hrs · 19,053 cycles

RT WING UPPER L/E PANEL AT WS 440.0 HAS AN AREA OF 24.0 INCH LONG BY 12.0 INCH WIDE OF DELAMINATION. PERMANENT REPAIR WAS ACCOMPLISHED AS PER B747-200 SRM 51-40-09 FIG 18 SHEETS 1 THRU 5 AND 747-200 SRM 51-40-12. ALSO, REFERENCE ATLAS AIR EO NR 4757A358.

Part: WARNING HORN — FALSE ACTIVATION · airframe 97,061 hrs · 19,040 cycles

TAKEOFF WARNING HORN SOUNDED WITH ALL THROTTLES AT N-1 APPROX 104.9 JUST PRIOR TO 80 KNOTS. (RTO). TAKEOFF AURAL WARN TEST CARRIED OUT AS PER MM 31-26-00, NO FAULTS FOUND. AURAL WARN UNIT ELECT CONNECTION INSPECTED AND CHECKED OK. FLAPS, SPEED BRAKE AND STAB TRIM SYSTEM ALL EXERCISED.

Part: ACTUATOR VALVE — FAILED (MLG DOOR) · airframe 97,024 hrs · 19,035 cycles

DIVERSION TO JFK, AFTER T/O THE GEAR WAS RETRACTED RED GEAR LIGHT REMAINED ON APPROX 3 SECS LATER THE NOSE GEAR DOOR CAME OPEN AND THEN CLOSED. DOOR CYCLED 3 TIME WITH GEAR HANDLE IN THE UP POSITION. REMOVED AND REPLACED NOSE GEAR DOOR OPERATED SEQUENCE VALVE IAW MM 32-34-07. REMOVED AND REPLACED NOSE GEAR DOOR ACTUATOR IAW MM 32-34-14. DOOR CHECKED NORMAL IN PRIMARY AND ALTERNATE.

Part: SKIN PANEL — DELAMINATED (ZONE 500) · airframe 95,850 hrs · 18,763 cycles

LT WING UPPER L/E PANELS AT ILES 675.50 AND ILES 651.50 HAS AREA OF DELAMINATION. ACCOMPLISHED PERMANENT REPAIRS AT LT WING L/E UPPER PANELS AS PER BOEING 747 SRM 51-40-09 FIG 18, SHEET 5 AND 747 SRM 51-40-12. ILES 675.50 REPAIR AREA IS 7.0 INCH LONG BY 7.0 INCH WIDE. ILES 651.50 REPAIR AREA IS 13.0 INCH LONG BY 18.0 INCH WIDE. ALSO, REFERENCE ATLAS AIR EO NR 4757A331.

Part: SKIN PANEL — DELAMINATED (LT WING) · airframe 95,850 hrs · 18,763 cycles

LT WING UPPER FIXED TRAILING EDGE PANEL AT WBL 445.0 HAS A 2.O INCH CRACK. ACCOMPLISHED PERMANENT REPAIR AS PER BOEING 747 SRM 51-40-09 FIG. 2, SHEET 5 AND 747 SRM 51-40-12. REPAIR AREA IS 3.0 INCH LONG BY 4.0 INCH WIDE. ALSO, REFERENCE ATLAS AIR XEO NR 57-112906.

Part: TIRE — BLOWN (MLG) · airframe 95,219 hrs · 18,625 cycles

MLG WHEEL NR 14 BLOWN OUT DURING LANDING. REMOVED AND REPLACED 13 & 14 MLG WHEEL IAW AMM 32-45-01 SPIN AND LEAK CHECK OK. REMOVED AND REPLACED ANTI-SKID CONTROL BOX AND 14 FRONT OUTBOARD ANTI-SKID SERVO VALVE AS PER AMM 32-42-00. TEST & LEAK CHECK OK. ACCOMPLISHED BLOWN TIRE INSPECTION CHECK IAW AMM 05-51-25, NO ABNORMAL CONDITION FOUND.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FRAME WEB CRACKED AT STA 420 RT STR 12A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 107 AND EO NR 4753A817 AT BS 420 RT STR 12A FRAME WEB.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND M/D FRAME WEB CRACKED AT STA 340 RT STR 12A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 102 AND EO NR 4753A817.

Part: PANEL — CRACKED (CABIN) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION, REVEAL PANEL CRACKED AT STA 800 RT NR 2PAX DOOR FWD CUT-OUT STR-24R. REPAIR CRACK AS PER SRM 53-10-04 FIG 84 AND EN-EA 53-1069 AND FAA FORM 8100-9.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION FOUND INTERCOSTAL WEB CRACKED AT STA 1220. INTERCOSTAL WEB REPAIRED AS PER EN-NO EA 53-10-74 AND EO-NR 4753A814.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

FOUND BS 1220 LT MOST O/B INTERCOSTAL WEB FOUND CRACKED, BS1220 LT MOST O/B INTERCOSTAL WEB REPAIRED AS PER EN-EA 53-10-75 AND FAA FORM 8100-9.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION M/D BS 1180, LT MOST O/B INTERCOSTAL WEB FOUND CRACK. BS 1180 LT MOST O/B INTERCOSTAL WEB REPAIRED AS PER EN-EA 53-10-70 AND EO-NR 4753A814.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION REVEAL M/D FRAME WEB CRACKED AT STA-480 STR-16L. REPAIR FRAME WEB AS PER EN NR EA 53-10-73 AND FAA FORM 8100-9.

Part: WEB — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FRAME WEB CRACKED AT STA 520 RT STR 13. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 112 AND EO NR 4753A817.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION FOUND U/D COCKPIT STRINGER CUT-OUT AREA FRAME WEB CRACKED AT STA-380 STR-10R. REPAIR FRAME WEB AS PER EN NR EA 53-10-72 AND FAA FORM 8100-9.

Part: PANEL — CRACKED (CABIN) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION REVEAL PANEL CRACKED AT STA-800 LT NR 2 PAX DOOR FWD CUT-OUT LWR AREA STR 24L. REPAIR CRACKED AS PER SRM 53-10-04 FIG 84 AND EN-EA 53-10-69 AND EO NR 4753A813.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FRAME WEB CRACKED AT STA 440 LT STR 12A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 110 AND EO NR 4753A817.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION FOUND FRAME WEB CRACKED AT STA 440 RT STR 12A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 110 AND EO NR 4753A817.

Part: PANEL — CRACKED (CABIN) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION REVEAL PANEL CRACKED AT STA 800 RT NR 2 PAX DOOR FWD CUT-OUT STR 24. REPAIRED CRACKED AS PER SRM 53-10-04 FIG 84 AND EN-EA 53-10-69 AND EO-NR 4753A813.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING VISUAL INSPECTION FOUND U/D COCKPIT STRINGER CUT-OUT AREA WEB CRACKED AT STA 380 STR 10R. FRAME WEB REPAIR AS PER EN NR EA 53-10-72, AND FAA FORM 8100-9.

Part: PANEL — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND CLOSEOUT PANEL CRACK AT STA 1240 RBL 75-98. REPAIRED CLOSEOUT PANEL AS PER DWG 65B07992.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND M/D FRAME WEB CRACKED AT STA 500 LT STR 13A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 111 AND EO NR 4753A817.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FRAME WEB CRACKED AT STA 380 LT STR 12A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 106 AND EO NR 4753A817.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FRAME WEB CRACKED AT STA 420 LT STR 12A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 107 AND EO NR 4753A817.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FRAME WEB CRACKED AT STA 500 RT STR 13. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 111 AND EO NR 4753A817.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FLOORBEAM WEB CRACKED AT STA 360 RT STR 12A. FLOORBEAM WEB REPAIRED AS PER SRM 53-10-09 FIG 11 AND EO NR 4753A818.

Part: FRAME — CRACKED (FUSELAGE) · airframe 95,152 hrs · 18,609 cycles

DURING INSPECTION FOUND FRAME WEB CRACKED AT STA 360 RT STR 12A. FRAME WEB REPAIRED AS PER SRM 53-10-04 FIG 103 AND EO NR 4753A817.

Part: WINDOW — DELAMINATED (COCKPIT) · airframe 95,070 hrs · 18,594 cycles

R-2 COCKPIT WINDOW DELAMINATED ON LOWER CORNERS. R-3 COCKPIT WINDOW DELAMINATED ON UPPER AND LOWER CORNERS. R-3 WINDOW- AFT LWR CORNER HAS .5 INCH CRACK INTO FASTENERS AREA MARKED.ACCOMPLISHED TIME LIMITED REPAIR IAW XEO 53-080206 TO R-3 WINDOW FRAME CRACK. REMOVED AND REPLACED R-2 AND R-3 WINDOWS IAW MM 56-11-00. RII PERFORMED ON BOTH WINDOWS AND R-3 WINDOW FRAME.

Part: TIRE — FAILED (LANDING GEAR) · airframe 94,769 hrs · 18,533 cycles

TAKEOFF REJECTED AT APPROX 90 KTS, LOUD POPPING NOISE AND ACFT SWERVED SLIGHTLY TO THE RIGHT. GROSS WEIGHT 353.4KGS. ALL 4 RIGHT BODY BRAKE TEMPS IN RED NR 9, NR 10, NR 11, NR 12 MAIN WHEEL THERMAL FUSES MELTED AFTER RTB. BOROSCOPE INSPECTED NR 3 ENGINE, NO DEFECTS NOTED PER MM 72-00-00. PER TEST 4, MPA, NO DEFECT NOTED, BORO PLUGS INSPECTED. SPECIAL INSPECTION C/O PER MM 5-51-10, NO DEFECT NOTED. REMOVED AND REPLACED NR 9, 10, 11 AND 12 MWA PER MM 32-45-01. NO LEAKS NOTED.

Part: WEB — CRACKED (NR 5 SPOILER) · airframe 94,679 hrs · 18,511 cycles

NR 5 SPOILER -H- FITTING ATTACH WEB FOUND CRACKED AFT FITTING REMOVED. LEFT WING NR 5 SPOILER -H- FITTING ATTACH WEB CRACKED, AREA REPAIRED AS PER SRM 51-40-02 FIG 1 AT LEFT WING WBL 373 TO WBL 395.

Part: COMPUTER — UNSERVICEABLE (AUTOPILOT) · airframe 94,354 hrs · 18,447 cycles

(AIR TURN BACK) AUTOPILOT WOULD NOT ENGAGE. TROUBLESHOT TO "B" AUTOPILOT ROLL COMPUTER FAULTY. SWAPPED B AND C ROLL COMPUTERS REF 22-13-01, AUTOPILOT B ENGAGEMENT CHECKS SATIS REF 22-10-00. A/C STILL CAT II RESTRICTED.

Part: PANEL — CRACKED (RT WING TE FLAP) · airframe 94,074 hrs · 18,388 cycles

RT WING O/B MID FLAP COVE PANEL CRACKED AT SUPPORT ARM APPROX 8" AT W/S 1084. REPAIRED IAW SRM 747-51-40-12. ATLAS AIR EO4757A278 ISSUED.

Part: WIRE HARNESS — SHORTED (ELECTRICAL BUSS)

DAILY CHECK, IB PICKUP ITEM BY MAINTENANCE. UNABLE TO POWER CGO HANDLING BUSSES. REMOVED AND REPLACED BPCU NR 1 AND NR 2. ALSO, FOUND WIRE HARNESS W124, 12 WIRES SHORTED OUT. REPAIRED IAW SWPM ACCOMPLISHED, CARGO HANDLING SYSTEM CHECKS NORMAL. (K)

Part: BRAKE — LEAKING (LT MLG)

AFTER TAKEOFF, NR 4 HYD LOW QUANTITY LIGHT CAME ON. NR 4 SYSTEM WAS 1.5 GAL. SYSTEM WAS SHUTDOWN AND USED ONLY FOR LANDING. FOUND NR 8 BRAKE ASSY BLANKING PLATE MISSING AND LEAKING BAD. REMOVED AND REPLACED NR 8 BRAKE ASSY IAW MM. LEAK CHECK, OK. REPLACED NR 8 WHEEL ASSY DUE CONTAMINATED WITH HYD FLUID. (K)

Part: COMPUTER — INOPERATIVE (AUTOPILOT)

AUTOPILOT WILL NOT ENGAGE. AUTOPILOT PUT AIRPLANE IN A 45 DEGREE BANK LT AND RT. DISENGAGED AUTOPILOT, STABILIZED AIRCRAFT AND RE-ENGAGED AUTOPILOT, AIRCRAFT STARTED ROLLING AGAIN. THE AIRCRAFT DIVERTED. RE-RACKED THE AUTOPILOT ROLL COMPUTER IAW MM, AUTOPILOTS CHECK GOOD NOW. SWAPPED AND AUTOPILOT ROLL COMPUTERS FOR TROUBLESHOOTING IAW MM. PN AND SN RECORDED ON LOG PAGE. (K)

Part: PANEL — CRACKED (BULKHEAD)

D-CHECK, DURING SCHEDULED INSPECTION, CRACKS WERE FOUND AT THE LOWER CORNERS OF STA 400 BULKHEAD WEB PRESSURE PANEL CUTOUT. ANOTHER CRACK WAS FOUND ON THE LOWER IB SIDE OF THE PRESSURE PANEL ASSY. THE CRACKS ON THE STA 400 WERE TRIMMED OUT. REPAIRED DOUBLERS WERE INSTALLED AT EACH CORNER OF THE CUTOUT, AND A REPAIR STRAP WAS INSTALLED ACROSS THE BOTTOM OF THE CUTOUT. THE CRACKED PRESSURE PANEL ASSY WAS REMOVED AND PREFABRICATED IAW ORIGINAL DWG SPECS. HFEC INSPECTION PERFORMED OF THE TRIM LINE TO COMFIRM NO ADDITIONAL CRACK EXISTS AND OF ALL EXISTING FASTENER HOLES IN THE REPAIR AREA. (K)

Part: SKIN — CRACKED (NR 1 NACELLE)

D-CHECK, DURING SCHEDULE INSPECTION, CRACK DAMAGE WAS FOUND IN THE SKIN ASSY AND THE ADJACENT NR 3 STIFFENER AT PRE-COOLER EXHAUST CUTOUT LOWER EDGE NEAR THE AFT CORNER AT STA 248 ON THE RT SIDE. THE NR 3 STIFFENER LOWER FLANGE WAS TRIMMED TO REMOVE CRACKS. THE CRACK IN SKIN ASSY WAS CONTAINED WITH 1.0 INCH HOLE AT THE CRACK TIP. THE NR 3 STIFFENER WAS REINFORCED WITH A NEW STEEL LOWER REPAIR ANGLE FROM NAC STA 235 TO 254. THE RIB INSTALLATIONS AT NAC STA 248 WAS MODIFIED TO ACCOMMODATE THE NEW STEEL LOWER REPAIR ANGLE. NDT INSPECTED EACH REPAIR AREA, INCLUDING HFEC INSPECTION OF ALL REPAIR FASTENER LOCATIONS AND TRIMMED EDGES TO ENSURE ABSENCE OF CRACKS, CORROSION AND ANY OTHER DAMAGE. (K)

Part: BEAM — CRACKED (FUSELAGE)

D-CHECK, DURING SCHEDULED INSPECTION, CRACKS WERE FOUND AT THE NOSE GEAR WELL ON THE VERTICAL BEAM WEBS AT LHS BS 280L, 300L, 320L AND 320R. DAMAGED PORTION OF THE VERTICAL BEAM WEB WAS TRIMMED OUT AND A NEW SECTION OF THE WEB WAS SPLICED IN. NOTE: THESE REPAIRS ARE SUBJECT TO CONTINUED INSP IAW SB. (K)

Part: SKIN — CRACKED (NR 3 PYLON)

D-CHECK, DURING SCHEDULE INSPECTION, NR 3 PYLON, A 2.25 INCH CRACK WAS FOUND AT THE TOP EDGE OF SKIN ASSY AT NAC WL147.8, JUST FORWARD OF THE NAC STA 286. CRACK IN THE SKIN ASSY WAS CONTAINED WITH A 1.0 INCH DIAMETER HOLE AT THE CRACK TIP. REPAIR AREA WAS NDT INSP, INCLUDING HFEC INSPECTION OF THE SKIN ASSY TRIMMED EDGES AND ALL REPAIR FASTENER HOLES. SKIN ASSY WAS REINFORCED AT THE CRACK LOCATION WITH 2 LAYERS IF STAGGERED EXTERIOR ALUMINUM REPAIR DOUBLERS. REPAIR AREA IS TO BE GIVE A DETAILED VISUAL EVERY C-CHECK OR 18 MONTHS, TO ENSURE ABSENCE OF LOOSE FASTENERS, CRACKS, CORROSION AND ANY OTHER DAMAGE. EO ISSUED TO ACCOMPLISH INSPECTION. (K)

Part: SKIN — CRACKED (NR 4 NACELLE)

D-CHECK, DURING SCHEDULE INSPECTION. THE STRUT SKIN ASSY EDGE ADJACENT TO THE PRECOOLER EXHAUST CUTOUT WAS FOUND CRACKED. SKIN ASSY INSPECTION CONFIRMED THAT CRACKS TERMINATED IN EXISTING FASTENER HOLES. NR3 STIFFENER WAS REINFORCED WITH A STEEL LOWER REPAIR ANGLE FROM STA 237 TO STA 254. EXISTING REINFORCED RIB INSTALLED AT NAC STA 248 WAS MODIFIED TO ACCOMMODATE REPAIR ANGLE INSTALLED NO NR 3 STIFFENER. DETAIL VISUAL INSPECT ALUMINUM SKIN ASSY INNER SURFACE AREA, BELOW NR3 STIFFENER FLANGE, FOR ABSENCE OF ANY CRACKS AND LOOSE FASTENERS EVERY C-CHECK, NOT TO EXCEED 18 MONTHS. EO ISSUED TO ACCOMPLISH THE INSPECTION. (K)

Part: DRIVE UNIT — UNSERVICEABLE (SLATS)

DURING CLIMB LT L/E NR 2 AMBER LIGHT REMAINED ILLUMINATED. ALTERNATE PROCEDURES ACCOMPLISHED TO NO AVAIL. WITH NR 2 L/E DIRECTIONAL SW TO (UP), ALTERNATE L/E FLAP DRIVE C/B ON P6 TRIPS. 27000 KG FUEL DUMPED IAW FUEL JETTISON CHECKLIST AT FL140 TO MAX LANDING 295000 KG. REMOVED AND REPLACED L/E DRIVE UNIT IAW MM 27-81-03. FUNCTIONAL CHECK ACCOMPLISHED, ALL NORMAL.

Part: CHANNEL — CRACKED (NR 7 LE FLAP)

CENTER CHANNEL CRACKED BEYOND PRIVOUS REPAIR IB HINGE ON NR 7 LE FLAP. FOUND DURING VISUAL INSPECTION. CAUSE IS UNKNOWN. LOCATION IS WING STA 944.5. CORRECTIVE ACTION REPLACED LE FLAP ASSY IAW MM.

Part: DOOR — MISSING (NR 1 ACM)

BIRD STRIKE: VIBRATION OF ENTIRE AIRFRAME ON CLIMB OUT. SUDDEN VIBRATION AT APPROXIMATELY 16,000 FT AND 300K IAS. PERFORMED BIRD STRIKE INSP MM. FOUND DAMAGE TO THE FORWARD NR 1 ACM INLET LEFT SIDE AREA AND NR 1 ACM DOOR MISSING. REPAIRED DAMAGED AREA IAW SRM PROCEDURES AND REPLACED MISSING DOOR.

Part: ENGINE — SHUTDOWN (NR 2)

INFLIGHT ENGINE SHUTDOWN IN CRUISE NR 2 ENGINE N1 SPOOLED DOWN FROM 102 PERCENT TO 55 PERCENT. ALL OTHER INDICATIONS NORMAL. ENGINE WOULD NOT RESPOND TO THRUST LEVER MOVEMENT. ENGINE SHUTDOWN AS PRECAUTION AT 07:55 UTC. C/A: FOUND DEBRIS IN EXHAUST. BOROSCOPED HPC/LPC IAW FIM 71-00-42 PAGE 105 ITEM 2. ALL ROTOR BLADES DAMAGED FROM HPC STAGE NR1 THRU NR 2 NIL DAMAGE FOUND. REMOVED AND REPLACED NR 2 ENGINE IAW MM 71-00-02 AND FORM 01-AA-45. SN ON 530257.(K)

Part: FITTING — DAMAGED (NR 1 PYLON)

DURING C-CHECK, NR 1 PYLON OB SPRING BEAM SHEAR TRANSFER FITTINGS FOUND DAMAGED DUE TO CONTACT WITH SPRING BEAM. CONTRACT RESULTED FROM MISLOCATION OF FITTINGS. SUBJECT FITTINGS WERE TRIMMED TO REMOVED DAMAGE, NDT INSPECTED, & RESTORED PER DRAWING. FITTINGS OTHERWISE MET DRAWING REQUIREMENTS. CRACK FOUND ON FITTING 69B941204, .47 INCH LONG. ACCOMPLISH A VISUAL INSP NR 4 PYLON. PROBLEM DID NOT OCCUR AT PYLON NR 4. DAMAGE FOUND FITTING 69B94120-3. DAMAGE TRIMMED. REPAIRS STRUCTURALLY ACCEPTABLE & SUFFICIENT CLEARANCE PROVIDED. CONDUCT A DETAIL VISUAL INSPECTION OF FITTING & INSTALLATION EVERY 6 MONTHS TO CONFIRM NO OTHER FURTHER CRACKING OR DAMAGE TO THE FITTING, REPLACE FITTING WITHIN 18 MONTHS. (M)

Part: FRAME — CRACKED (FUSELAGE)

DURING C-CHECK AT AMS, FOUND CRACK IN STATION 500 FRAME WEB OUTER FLANGE BETWEEN RT STRINGERS S-10 AND S10A. TRIM CRACK AND SURFACE HFEC INSPECT TRIM LINE TO INSURE CRACK FREE CONDITION. INSTALLED TWO FILLERS, A REPAIR ANGLE, AND A REPAIR DOUBLER PER REF A OPEN HOLE HFEC INSPECT FASTENER HOLES COMMON TO REPAIR PARTS TO INSURE CRACK FREE CONDITION. CONTINUED INSPECTIONS ARE REQUIRED PER REF C SB 747-53A2265. REINSPECT AT REPEAT INTERVALS NOT TO EXCEED 3,000 FLIGHT CYCLES UNTIL THE AIRPLANE ACCUMULATES 20,000 FLIGHT CYCLES. THE REPAIR HAS BEEN APPROVED AS AN ALTERNATIVE METHOD OF COMPLIANCE TO PARAGRAHP B OF AD 91-11-01 AND HAS BEEN FOUND TO MEET THE TYPE CERT BASIS OF THIS AIRPLANE AS REQUIRED. (M)

Part: SPLICE — DAMAGED (RT WING)

DURING C-CHECK, AT AMS WHILE PERFORMING SB 747-53A 2309 KLM ACCIDENTALLY DAMAGED THE AFT INBOARD FASTENE HOLE OF THE OUTBOARD FLANGE OF THE LOWER SPLICE PLATE. REPAIR HOLE H IN THE LOWER SPLICE PLATE ON THE RT WING WAS OVERSIZED TO 1.0030 INCHES. AL-N1-BR BUSHING WAS INSTALLED. (M)

Part: FITTING — CRACKED (NR 1 PYLON)

DURING C-CHECK, AT AMS NR 1 PYLON OUTBOARD SPRING BEAM SHEAR TRANSFER FITTINGS FOUND CRACKED DUE TO CONTACT WITH SPRING BEAM. CONTRACT RESULTED FROM MIS-LOCATION OF FITTINGS. SUBJECT FITTING WERE TRIMMED TO REMOVE CRACK & DAMAGE, NDT INSPECTED, & RESTORED PER DRAWING. FITTINGS. CRACK FOUND ON FITTING .47 INCH LONG. ACCOMPLISH A VISUAL INSP NR 4 PYLON. PROBLEM DID NOT OCCUR AT PYLON NR 4. DAMAGE FOUND ON FITTING 69B94120-3. DAMAGED AREA WAS TRIMMED. THE REPAIRS ARE STRUCTURALLY ACCEPTABLE AND SUFFICIENT CLEARANCE IS PROVIDED. CONDUCT A DETAIL VISUAL INSPECTION OF THE FITTING & INSTALLATION EVERY 6 MONTHS TO CONFORM NO FURTHER CRACKING OR DAMAGE TO THE FITTINGS. REPLACE THE FITTING WITHIN 18 MONTHS. (M)

Part: FLAP TRACK — CORRODED (WING)

DURING C-CHECK AT AMS, IB FLAP TRACK POS NR 4 CORROSION AT FORWARD BOLT HOLES. OVERSIZE AFFECTED HOLES TO REMOVED DAMAGE. NDT INSPECT TO ENSURE CRACK AND DEFECT FREE CONDITION. INCORPORATE INSURANCE CUT TO HOLES. RE-FINISH FLAP TRACK AND FAIL/SAFE BAR. INSTALLED SLEEVED OR OVERSIZE FASTENERS AS APPLICABLE. ALL IAW REF 1 THRU 4, WHICH DEALS WITH LETTERS (E-MAILS) REQUESTING STRUCTURALLY ACCEPTABLE REPAIR TO THE BOLT HOLES IB FLAP TRACK POS NR 4. REF 5 THRU 7, REF 8 DETAIL VISUAL AND ULTRASONIC INSPECT AT THE INSTALLED FASTENER LOCATIONS (8 HOLES PER TRACK) AT INTERVALS NOT TO EXCEED 18 MONTHS OR 1200 CYCLES, WHICHEVER IS EARLIER. (M)

Part: WARNING SYSTEM — FALSE ACTIVATION (APU FIRE)

AFTER 3 HOURS IN CRUISE, FULL APU FIRE WARNING LIGHTS AND BELL ON. APU FIRE HANDLE PULLED AND BOTTLE DISCHARGED. LIGHT WENT OUT WHEN BOTTLE DISCHARGED. AREA INSPECTED. NO EVIDENCE OF FIRE OR PNEUMATIC DUCT DAMAGE. APU DEFERRED INOPERATIVE PER MEL 49-01 AND APU FIRE EXTINGUISHING SYSTEM DEFERRED PER MEL 26-8. DMI'S M03-023 AND M03-024. REMOVED AND REPLACED A5 FIRE WARNING CARD PER MM 26-45-01. FUNCTION CHECK SATISFACTORY. REMOVED AND REPLACED A12 FIRE WARNING CARD PER MM 26-15-01. FUNCTION CHECK SATISFACTORY. ALSO, FOUND A/T CONNECTORS ON FIRE WARNING LOOP APU DOOR IN BAD CONDITION. R & R BOTH CONNECTORS PER MM 20-62-16. FROM DMI M03-023, REPLACED APU FIRE BOTTLE PER MM 26-22-01 P/N 34504901P. (M)

Part: WIRE HARNESS — WORN (COCKPIT SEAT)

IN CRUISE MXP/JFK, F/E SEAT ELECTRICAL CHORD SPARKED WHEN SEAT WAS MOVED BACK MANUALLY. OPENED C/B. ODOR OF SMOKE WAS IN THE COCKPIT FOR ABOUT ONE MINUTE. INSPECTED F/E'S SEAT AND FOUND ELECTRICAL CHORD BROKEN. PULLED C/B AND REMOVED CHORD. NO OTHER DEFECTS FOUND. TRANSFERRED TO DI PAGE 03877, ITEM M02-013 PER DDPG 25-12-1 "D". (M)

Part: INTERCOSTAL — CRACKED (FUSELAGE)

DURING TVCI PER AD 90-06-14 REF SB 747-53-2293 AREA, FOUND VERTICAL CRACK IN INTERCOSTAL, STATION 290, APPROX LBL 26, UPPER NOSE WHEEL WELL BOX, INTERIOR. REMOVED INTERCOSTAL AT STATION 290. REPLACED INTERCOSTAL WITH P/N 654U6075-594 PER B747 SRM 51-30-02 PAGE 5. REMOVED AND REINSTALLED TWO INTERCOSTALS TO GAIN ACCESS PER SRM 51-30-02. (M)

Part: LINE — DISCONNECTED (FUSELAGE)

DURING ROUTINE INSPECTION, FOUND MAIN DECK CARGO COMPT SMOKE DETECTOR SYSTEM NOT CONNECTED TO FLEX LINE AT STATION 540 LEFT BEHIND SIDE WALL AT MAIN DECK LEVEL. RECONNECTED LINE AND CLAMPED. SYTEM OPS CHECKED OK PER AMM. (M)

Part: MOUNT — CHAFED (NR 1 & 2 ENGINE)

DURING ROUTINE INSPECTION, FOUND R/S ENGINE HANGER ASSEMBLY 65B94343-1 ON ENGINE POSITIONS NR 1 AND NR 2 CHAFED BY PDU SENSE LINE UNION. CHAFED AREA BLENDED PER SOPM 20-30-03, IAW BOEING TELEX. HFEC ACCOMPLISHED. PART REFINISHED. ADJUSTED TUBING TO PROVIDE CLEARANCE. (M)

Part: WARNING SYSTEM — ACTIVATED (NR 3 ENGINE)

FLT GT051 - ATB - DURING CLIMB-OUT AT APPROX 5500 FT, NR 3 ENGINE A AND B FIRE WARNING LOOPS PEGGED HIGH. LEVEL OUT AND REDUCED POWER AND FIRE WARNING INDICATION WENT OUT. ACCOMPLISHED ENGINE FIRE CHECKLIST AND SHUTDOWN ENGINE. DID NOT DISCHARGE FIRE BOTTLES DUE NO FURHTER FIRE INDICATION. DUMPED FUEL AND LANDING UNEVENTFUL. REPLACED NR 3 ENGINE, S/N ON 5171792. ENGINE RUNUP CHECKS NORMAL.

Part: VALVE — FAILED (NR 3 ENGINE)

FLT GT723 - ATB - AT APPROXIMATELY 1500 FT, NR 3 ENGINE FIRE WARNING CAME ON. BOTH LOOPS PEGGED HIGH. FOLLOWING FHB, SHUTDOWN ENGINE AND PERFORMED FIRE CHECKLIST. LIGHTS WENT OUT AND TEMPERATURE RETURNED TO NORMAL. FIRE BOTTLES WERE NOT DISCHARGED. REPLACED PRESSURE RELIEF VALVE AND HIGH STAGE VALVE. ACCOMPLISHED INSPECTION IAW 72-00-00, PAGE 680K, 71-00-42, PAGE 110, 36-11-01, PAGE 601. ALSO, PERFORMED MPA PER 71-00-00 AND ENGINE NOW OK FOR SERVICE. (M)

Part: SUPPORT — CRACKED (BS 1920)

CRACK MAIN DECK RIGHT SIDE SUPPORT POST FRAME AT BS 1920 LENGTH 140 MM. REPAIRED BOEING TLS BKK 99-0075TE. REF: SRM 53-10-07, FIG 7. (X)

Part: FRAME — CRACKED (BS 281)

CRACKED PORTAL FRAME BS 281. WL 331.75, RBL 45 NOSE CARGO DOOR. INSTALLED DOUBLER. REF: SRM 53-10-04, FIG 97. FOUND DURING ACCOMPLISHMENT OF SB B747-53A2265. (X)

Part: FRAME — CRACKED (BS 1700)

CRACKED FRAME BS 1680 BETWEEN STR 12/13 RS BS 1700 BETWEEN STR 10/11 RS. REPAIRED PER BOEING TELEX TLS-BKK-99-0082RE, 0079TE. (X)

Part: SKIN — DENTED (BS 433)

DENT IN FUSELAGE SKIN BS 433 BETWEEN STR 46L, 47L. DENT AT BS 520 STR 44L, 47L. INSTALLED DOUBLER PER BOEING TELEX TLS BKK 99-0077RE, 0071TE, 0053TE, 0057RE. 8130-3 ISSUED. (X)

Part: SKIN — DENTED (BS 800)

DENT IN FUSELAGE SKIN STA 800 BETWEEN STR 13L, STR 14L. DAMAGED AREA 4 INCHES BY 2.8 INCHES. NO FRAME DAMAGE. BOEING: TLS BKK 99-072TE, 0070RE, 0064TE, 0068RE, 0063TE, 0065RE, 0061TE, 8130-3 ISSUED. (X)

Part: SKIN — CRACKED (PYLON)

PYLON SKIN CRACKED NAC 235 R/S. EDGE OF PRE-COOLER EXHAUST DUCT OPENING EDGE. STIFFENER NR 3 RT SIDE. REPAIRED PER TLS BKK-99-0069RE, 99-0064RE, 99-0063RE. 8130-3 ISSUED. (X)

Part: SKIN — DENTED (BS 2252/2259)

SCRATCHES, DENTS FUSELAGE SKIN BS 2252 TO BS 2259 STR 49R. REPAIRED PER BOEING TLS BKK 99-0095RE, 0088TE, 8130-3 ISSUED. (X)

Part: CHORD — CRACKED (BS 1265)

CRACKED CHORD BS 1265 L/S. SPLICED FRAME BS 1265 L/S IAW DRW 14400053-317. REF: BOEING TLX TLS 99-0071RE, 0056TE, 0053RE, 0051TE, 0052RE 0048T3. 8130-3 ISSUED. (X)

Part: SPLICE — CRACKED (BS 1241)

CRACK IN SPLICE PLATE STRAP BS 1241 L/S. REPLACED SPLICE PLATE AT STA 1241 L/S IAW SB 747 53-2283. (X)