N616US

Part: FRAME — CRACKED (FUSELAGE) · airframe 100,648 hrs · 24,943 cycles

DURING L-CHECK AND ACCOMPLISHMENT OF EM 5310-01357-01A FOUND CRACK IN TENSION TIE FRAME FASTENER HOLE AT BS 920 RT. REPAIRED PER EA 67-206256.

Part: FRAME — CRACKED (FUSELAGE) · airframe 101,648 hrs · 24,943 cycles

DURING L-CHECK FOUND CRACK IN FRAME CUTOUT AT BS 880 S9R. REPAIRED PER EA 67-206264.

Part: FRAME — CRACKED (FUSELAGE) · airframe 101,648 hrs · 24,943 cycles

DURING L-CHECK AND ACCOMPLISHMENT OF EM 5310-01357-01A FOUND CRACKS IN TENSION TIE FRAME FASTENER HOLES AT BS 860 LT. REPAIRED PER EA 67-206266.

Part: SKIN — CORRODED (RT WING) · airframe 101,648 hrs · 24,943 cycles

DURING L-CHECK FOUND CORROSION ON RT WING LOWER SKIN AT WS 1530. REPAIRED PER EA 67-206259.

Part: FRAME — CRACKED (FUSELAGE) · airframe 101,648 hrs · 24,943 cycles

DURING L-CHECK AND ACCOMPLISHMENT OF EM 5310-01357-01A FOUND CRACK IN TENSION TIE FRAME FASTENER HOLE AT BS 940 RT. REPAIRED PER EA 67-206260.

Part: FRAME — CRACKED (FUSELAGE) · airframe 101,648 hrs · 24,943 cycles

DURING L-CHECK AND ACCOMPLISHMENT OF MOD PER EM 5310-01319-02K FOUND CRACK IN UPPER DECK FRAME WEB CHORD AT BS 420 S12R. REPAIRED PER EA 67-206251.

Part: ACTUATOR — FAILED (RUDDER) · airframe 100,838 hrs · 24,774 cycles

AFTER TAKEOFF NR 3 HYDRAULIC SYSTEM QUANTITY WENT TO NEAR ZERO. AIRCRAFT DUMPED 150,000 LBS OF FUEL AND RETURNED TO ANC, AND LANDED WITHOUT INCIDENT. ANC MAINTENANCE REMOVED AND REPLACED RUDDER ACTUATOR, AND NR 3 ENG HYDRAULIC PUMP. OPERATIONAL CHECKED OK, AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — CRACKED · airframe 88,176 hrs · 22,250 cycles

During "L" check found crack in the fuselage skin and bonded doubler at aft cargo door cutout. Repaired per EA 67-189583.

Part: FRAME — CRACKED (FUSELAGE) · airframe 83,738 hrs · 21,351 cycles

DURING M-CHECK, FOUND CRACK AT LEFT SIDE INNER FRAME, AFT HOLE, STATION 2231, STR 25L. REPAIRED PER EA 67-165008.

Part: KEELBEAM — CORRODED (FUSELAGE) · corrosion level 2 · airframe 83,738 hrs · 21,351 cycles

DURING M-CHECK, FOUND CORROSION ON UPPER SURFACE OF KEEL BEAM LOWER STRUCTURE, STATION 1310 TO 1329. REPAIRED PER EA 67-165004.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 83,738 hrs · 21,351 cycles

DURING M-CHECK, FOUND CORROSION UNDER FORWARD LOWER SKIN AT LT OUTFLOW VALVE, STATION 2184, STR 45L. REPAIRED PER EA 67-165012.

Part: DETECTOR — MALFUNCTIONED (CARGO BAY) · airframe 81,056 hrs · 20,820 cycles

DURING CLIMB, THE NR 5 CARGO SMOKE DETECTOR LIGHT ILLUMINATED AND FIRE BELL ACTIVATED. AIRCRAFT RETURNED TO ANC AND LANDED WITHOUT INCIDENT. REPLACED NR 5 CARGO SMOKE DETECTOR, OPERATIONAL CHECK GOOD.

Part: DETECTOR — FALSE INDICATION (CARGO BAY) · airframe 81,056 hrs · 20,820 cycles

DURING DESCENT, THE NR 5 CARGO SMOKE DETECTOR LIGHT ILLUMINATED AND FIRE BELL ACTIVATED. VISUALLY CONFIRMED NO CARGO SMOKE OR FIRE. AIRCRAFT CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. REPLACED THE NR 5B CARGO SMOKE DETECTOR, OPERATIONAL CHECK GOOD.

Part: SUPPORT — CORRODED (BS 600)

DURING P-CHECK, FOUND CORROSION UNDER NUT PLATE UPPER CHORD OF FLOOR SUPPORT. REPAIRED PER EA 67-166746 (P/N 65B01723-328).

Part: FLAPS — VIBRATING (NR 1 LE FLAPS)

DURING CLIMB, THE AIRCRAFT EXPERIENCED VIBRATIONS AND THE NR 1 LEADING EDGE FLAP NEEDED TO BE RAISED ELECTRICALLY. AIRCRAFT RETURNED TO NRT AND LANDED WITHOUT INCIDENT. REPLACED THE NR 1 LEADING EDGE FLAP POWER DRIVE UNIT. OPERATIONAL CHECK GOOD. SPECIFIC PART CAUSING FAULT TO BE DETERMINED.

Part: START VALVE — FAILED (NR 3 ENGINE)

DURING CLIMB, THE NR 3 START VALVE LIGHT ILLUMINATED. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT RETURNED TO NRT. MAINTENANCE CHANGED THE START VALVE AND THE START PRESSURE SWITCH. ALL INDICATIONS WERE NORMAL AND THE AIRCRAFT RETURNED TO SERVICE. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: BREATHER TUBE — LEAKING (NR 4 ENGINE)

DURING CRUISE, THE OIL QUANTITY INDICATED FOR THE NR 4 ENGINE DROPPED TO ZERO. THE ENGINE WAS SHUT DOWN AND THE FLIGHT DIVERTED TO MNL. MAINTENANCE FOUND THE UPPER RIGHT MAIN ENGINE BREATHER TUBE LEAKING. THE TUBE WAS REPLACED AND NO LEAKS WERE NOTED DURING ENGINE RUN.

Part: LOGIC CARD — LOOSE (FIRE DET SYST)

DURING TAKEOFF, THE MASTER CAUTION FIRE LIGHT ILLUMINATED AND THE AURAL WARNING SOUNDED. AIRCRAFT ABORTED TAKEOFF AND RETURNED TO GATE. RESEATED FIRE DETECTOR LOGIC CARDS AND SECOND OFFICER'S MASTER CANCEL SWITCH. OPERATIONAL CHECKS GOOD.

Part: BRACKET — CORRODED (BS 1404)

DURING ARMAR, FOUND CORROSION ON RIGHT BODY GEAR WHEEL WELL PRESSURE DECK LOWER SURFACE AT FS 1404, RBL 109 - 119. REPAIRED PER EA 67-150441.

Part: PRESSURE DECK — CORRODED (BS 1360)

DURING ARMAR, FOUND CORROSION ON RIGHT BODY GEAR WHEEL WELL PRESSURE DECK LOWER SURFACE AT FS 1360, RBL 63. REPAIRED PER EA 67-150399.

Part: PRESSURE DECK — CORRODED (BS 1440)

DURING ARMAR, FOUND CORROSION ON PRESSURE DECK UPPER SURFACE AT FS 1440, LBL 33. REPAIRED PER EA 67-150118.

Part: FRAME — CRACKED (BS 434)

DURING ARMAR, FOUND A CRACK IN FRAME WEB FS 434 BELOW STR 26L. REPAIRED PER EA 67-150127.

Part: FRAME — CRACKED (BS 488)

DURING ARMAR, FOUND CRACKED FRAME WEB FS 488, STR 25L. REPAIRED PER EA 67-150371.

Part: FLOORBEAM — CRACKED (BS 380)

DURING ARMAR, FOUND CRACK IN FLOORBEAM WEB FS 380, STR 13R. REPAIRED PER EA 67-150380.

Part: FLOORBEAM — CRACKED (BS 380)

DURING ARMAR, FOUND CRACK IN UPPER DECK LEFT FLOORBEAM WEB FS 380. REPAIRED PER EA 67-150379.

Part: FLOORBEAM — CRACKED (BS 380)

DURING ARMAR, FOUND CRACK IN FLOORBEAM CHORD FS 380, STR 13R. REPAIRED PER EA 67-150380.

Part: SPAR WEB — CORRODED (WS 930)

DURING PERIODIC CHECK, FOUND CORROSION ON LEFT WING FORWARD SPAR WEB AT FSS 930. REPAIRED PER EA 67-106389.

Part: SPAR WEB — CORRODED (WS 895)

DURING PERIODIC CHECK, FOUND CORROSION ON LEFT WING FORWARD SPAR WEB AT FSS 895. REPAIRED PER EA 67-106389.

Part: SPAR WEB — CRACKED (WS 382-411)

DURING PERIODIC CHECK, FOUND CRACK IN LEFT WING MID SPAR WEB BETWEEN WS 382 AND 411. REPAIRED PER EA 67-106387.

Part: TRANSDUCER — MALFUNCTIONED (CREW OXY SYST)

DURING CRUISE, THE FLIGHT CREW OXYGEN GAUGE INDICATED ZERO. AIRCRAFT RETURNED TO SFO AND LANDED WITHOUT INCIDENT. REPLACED THE OXYGEN PRESSURE TRANSDUCER, OPERATIONAL CHECK GOOD.

Part: EGT WIRE — FAILED (NR 1 ENGINE)

DURING TAKEOFF ROLLOUT, THE NR 1 ENGINE EGT GAUGE INDICATED APPROXIMATELY 400 DEGREES WHILE OTHERS INDICATED 750 DEGREES. THE TAKEOFF WAS ABORTED AND THE AIRCRAFT RETURNED TO THE GATE WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND A PREVIOUSLY REPAIRED WIRE FORWARD OF A JUNCTION BOX MELTED. REPAIRED THE WIRE AND AIRCRAFT RETURNED TO SERVICE.

Part: DETECTOR — MALFUNCTIONED (CARGO COMPART)

DURING CRUISE, THE NR 2 MAIN DECK CARGO SMOKE DETECTOR ACTIVATED. AIRCRAFT DIVERTED TO YEG AND LANDED WITHOUT INCIDENT. REPLACED DETECTOR, OPERATIONAL CHECK GOOD.

Part: FUEL CONTROL — MALFUNCTIONED (NR 2 ENGINE)

DURING TAKEOFF, THE NR 2 ENGINE FAILED TO REACH TAKEOFF POWER. CREW ABORTED TAKEOFF AT 60 KNOTS AND RETURNED TO THE GATE. FOUND HYDRAULIC STAGE PRESSURE TO BE ZERO. REPLACED FUEL CONTROL AND FUEL PUMP. THE NR 2 ENGINE HIGH POWER RUNUP CHECK WAS NORMAL AND THE AIRCRAFT RETURNED TO SERVICE.

Part: ACTUATOR — MALFUNCTIONED (NR 1 LE FLAP)

SFO-ANC - EN ROUTE, THE NR 1 LEADING EDGE DEVICE IN TRANSIT LIGHT ILLUMINATED. CREW FOLLOWED COCKPIT OPERATING PROCEDURE AND DIVERTED TO SEA. MAINTENANCE REPLACED THE LEADING EDGE FLAP DEVICE ACTUATOR AND PERFORMED FUNCTIONAL CHECK. CHECK WAS NORMAL AND AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — DELAMINATED (RT ELEVATOR)

DURING PERIODIC CHECK, FOUND PREVIOUS FIBERGLASS REPAIR DELAMINATED ON THE RIGHT OUTBOARD ELEVATOR, 8 FORWARD OF THE TRAILING EDGE. REPAIRED PER SRM 51-40-12.

Part: SKIN — DELAMINATED (RT AILERON)

DURING PERIODIC CHECK, FOUND DELAMINATION ON RIGHT OUTBOARD AILERON UPPER SURFACE WS 1508. REPAIRED PER SRM 51-40-14, PART 4, FIG. 9.

Part: SUPPORT — CRACKED (CARGO DOOR LATCH)

DURING PERIODIC CHECK, THE LEFT AND RIGHT NOSE CARGO DOOR PORTAL LATCH NR 4 SUPPORT FITTING AT LBL 70 AND RBL 70 WERE FOUND CRACKED. THE (P/N 65B13044-3), 4 SUPPORT FITTINGS WERE FOUND WITH A CRACK THROUGH THE VERTICAL AND HORIZONTAL FLANGES, MADE REPAIR PER EA 67-51752.

Part: CONNECTOR — CONTAMINATED (NR 4 ENG)

DURING CRUISE, THE NR 4 ENGINE FIRE WARNING LIGHT ILLUMINATED AND BOTH TEMPERATURE LOOPS WERE READING FULL SCALE. THE ENGINE WAS SHUT DOWN. THE LEFT FIRE BOTTLE WAS DISCHARGED AND THE FLIGHT CONTINUED TO NRT WHERE AN UNEVENTFUL THREE ENGINE LANDING WAS ACCOMPLISHED. NO FUEL WAS DUMPED. A METACAL WAS REMOVED FROM THE LOWER FIRE LOOP CONNECTORS AND THE SYSTEM OPERATIONS THEN CHECKED OK.