N629US

Part: FRAME — CRACKED (BS 840) · airframe 94,818 hrs · 21,623 cycles

DURING "L" CHECK, FOUND CRACKS IN FRAME FASTENER HOLES AND SHORT EDGE MARGIN IN TENSION TIE AREA AT BS 840. REPAIRED PER EA 67-209728.

Part: PRESSURE PANEL — CRACKED (NLG WW) · airframe 94,818 hrs · 21,623 cycles

DURING "L" CHECK, FOUND CRACKS IN LT NOSE WHEEL WELL WEB BS 320-340 WL 150. REPAIRED PER EA 67-209735.

Part: FRAME — CRACKED (BS 900) · airframe 94,818 hrs · 21,623 cycles

DURING "L" CHECK, FOUND CRACK IN FRAME AND FORWARD CHANNEL FASTENER HOLE IN TENSION TIE AREA AT BS 900 LT. REPAIRED PER EA 67-209733.

Part: FRAME — CRACKED (BS 800) · airframe 94,818 hrs · 21,623 cycles

DURING "L" CHECK, FOUND CRACKS IN FRAME AT TENSION TIE AREA AND LT AFT AND LT FORWARD CHANNEL AT BS 800. REPAIRED PER EA 67-209731.

Part: FRAME — CRACKED (BS 940) · airframe 94,818 hrs · 21,623 cycles

DURING "L CHECK FOUND FRAME DOUBLER FASTENER HOLE WITH PLUG INSTALLED AND FRAME WEB WITH FASTENER HOLE CRACKED AT BS 940. REPAIRED PER EA 67-209730.

Part: FRAME — CRACKED (BS 820) · airframe 94,818 hrs · 21,623 cycles

DURING "L" CHECK, FOUND CRACKS IN FRAME WEB AND TENSION TIE FORWARD CHANNEL FASTENER HOLES AT BS 820. REPAIRED PER EA 67-209727.

Part: SMOKE DETECTOR — MALFUNCTIONED (CARGO BAY) · airframe 94,678 hrs · 21,593 cycles

DURING CRUISE, MAIN DECK CARGO SMOKE DETECTOR NR 4 CARGO FIRE LIGHT AND MASTER FIRE WARNING CAME ON. THERE WAS NO SMOKE OR FIRE VISIBLE ON MAIN DECK. LIGHT STAYED ON UNTIL 12,000 FT ON DESCENT FOR LANDING (ON STEADY FOR 20 MIN). FLIGHT CONTINUED ON TO NRT, AND LANDING WAS UNEVENTFUL. MAINTENANCE REMOVED AND REPLACED BOTH 4A AND 4B MAIN DECK SMOKE DETECTORS PER MC REQUEST. OPERATIONAL CHECKED GOOD, AND AIRCRAFT RETURNED TO SERVICE.

Part: CONNECTOR — DIRTY (SMOKE DETECTOR) · airframe 94,678 hrs · 21,593 cycles

WHILE IN CRUISE, MAIN DECK CARGO SMOKE DETECTOR NR 4 CARGO FIRE LIGHT AND MASTER FIRE WARNING CAME ON. NO SMOKE OR FIRE WAS VISIBLE IN MAIN DECK. FLIGHT CONTINUED ON TO ICN AND LANDING WAS UNEVENTFUL. LIGHTS STAYED ON UNTIL 5,500 FT ON DESCENT FOR LANDING (ON STEADY FOR 20 MINUTES). MAINTENANCE CLEANED BOTH 4A AND 4B SMOKE DETECTOR ELECTRICAL PLUGS AND SECURED LAMP HOLDER. OPERATIONAL CHECKED GOOD, AIRCRAFT RETURNED TO SERVICE.

Part: PUSHROD — FAILED (CARGO DOOR) · airframe 56,093 hrs · 11,828 cycles

DURING THRU FLIGHT, FOUND DAMAGE TO MAIN DECK CARGO SIDE CARGO DOOR LOWER BEAM WEB AND STIFFENER AT BS 1800. IT WAS DETERMINED THAT DAMAGE WAS A RESULT OF IMPACT WITH A FAILED DOOR PUSHROD. REPAIR ACCOMPLISHED PER EA 67-209695.

Part: FUEL FILTER — DIRTY (NR 2 ENGINE) · airframe 93,753 hrs · 21,405 cycles

DURING CRUISE AT FL390, IN CODE 5 TURBULENCE, NR 2 ENGINE FLAMED OUT. DESCENDED TO FL270 AND SUCCESSFULLY RESTARTED ENGINE. FLIGHT CONTINUED TO NRT AND LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED TO FUEL FILTER. THE ENGINE WAS INSPECTED, TESTED AND RETURNED TO SERVICE.

Part: ENGINE — OVERHEATED (NR 4) · airframe 87,004 hrs · 20,106 cycles

SHORTLY AFTER TAKEOFF, THE NR 4 ENGINE NACELLE TEMPERATURE BEGAN TO INCREASE FOLLOWED BY THE FIRE WARNING ANNUNCIATION. THE CREW FOLLOWED COM PROCEDURES AND WHEN POWER WAS REDUCED THE FIRE WARNING CEASED AND THE NACELLE TEMPERATURE BEGAN TO DECREASE. THE NR 4 ENGINE WAS SHUT DOWN AND THE FLIGHT RETURNED TO MSP LANDING WITHOUT INCIDENT. THE ENGINE WAS REPLACED. OPERATIONAL CHECK GOOD.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 84,883 hrs · 19,687 cycles

DURING L-CHECK AND ARMAR FOUND CRACK IN FLOORBEAM WEB AT BS 380 BETWEEN S12L & S13L. REPAIRED PER EA 67-165144.

Part: PCU — MALFUNCTIONED (RUDDER) · airframe 80,049 hrs · 18,699 cycles

APPROACHING TOP OF CLIMB AT FL350, THE LOWER RUDDER WAS POSITIONED 5 DEGREES LEFT OF CENTER WITH THE UPPER RUDDER ONE DEGREE RIGHT OF CENTER. AFTER LEVEL OFF THE LOWER RUDDER SUDDENLY MOVED TO 5 DEGREES RIGHT OF CENTER. THE AUTOPILOT WAS THEN DISCONNECTED AND THE CREW USED AILERON INPUT TO MAINTAIN LATERAL AND DIRECTIONAL CONTROL. APPROXIMATELY ONE MINUTE LATER BOTH RUDDERS RETURNED TO A NORMAL ZERO DEGREE DEFLECTION. NO FURTHER RUDDER MALFUNCTIONS WERE EXPERIENCED. THE FLIGHT RETURNED AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED BOTH THE UPPER AND LOWER RUDDER PCU'S BOTH UPPER AND LOWER YAW DAMPER COMPUTERS AND THE NR 2 INU.

Part: FRAME — CRACKED · airframe 76,799 hrs · 18,038 cycles

During "L" check found crack in frame at BS 300 between STR 40L and 41L. Repaired per EA 67-165017.

Part: WEB — CRACKED · airframe 76,799 hrs · 18,038 cycles

During "L" check found crack in bulkhead web holes at BS 1480. Repaired per EA 67-162020.

Part: CLAMP — FAILED (NR 1 ENGINE) · airframe 73,871 hrs · 17,443 cycles

DURING INITIAL CLIMB AT 300 FEET, THE NR 1 ENGINE FIRE WARNING ACTIVATED. THE NACELLE TEMPERATURE INDICATION WAS PEGGED IN THE WARNING RANGE AND THE POWER LEVER WAS STUCK IN MID RANGE. THE ENGINE WAS SHUT DOWN PER COM AND ONE FIRE BOTTLE WAS DISCHARGED. AFTER DUMPING 60K LBS OF FUEL, THE AIRCRAFT RETURNED TO KIX AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE ENGINE AND FOUND A FAILED PNEUMATIC DUCT CLAMP. THE ENGINE WAS REPLACED.

Part: FIRE DETECTOR — FALSE INDICATION (MAIN CARGO BAY) · airframe 73,446 hrs · 17,360 cycles

DURING CRUISE, THE MAIN DECK FIRE WARNING BELL SOUNDED AND LIGHT ILLUMINATED. AIRCRAFT DECLARED AN EMERGENCY AND DIVERTED TO YWG AND LANDED WITHOUT INCIDENT. REPLACED THE MAIN DECK 1B FIRE DETECTOR AND TEST SWITCH. OPERATIONAL CHECK GOOD.

Part: TIRE — SEPARATED (RT MLG) · airframe 72,742 hrs · 17,219 cycles

DURING TAKEOFF, A LOUD NOISE WAS HEARD BY THE FLIGHT CREW AND THE AIRCRAFT EXPERIENCED EXCESSIVE VIBRATION. AIRCRAFT ABORTED TAKEOFF AT 140 KNOTS AND EXITED OFF THE END OF THE RUNWAY. FOUND THE NR 11 AND NR 12 TIRES SEPARATED CAUSING FOD DAMAGE TO THE ENGINES, FLAPS, LANDING GEAR DOORS, AND HYDRAULIC LINES. THE HIGH SPEED ABORTED TAKEOFF CAUSED EIGHT TIRES TO BLOW. REPLACED TIRES AND REPAIRED DAMAGE TO THE ENGINES, FLAPS, LANDING GEAR DOORS, AND HYDRAULIC LINES. OPERATIONAL CHECK GOOD.

Part: FRAME — CRACKED (FUSELAGE) · airframe 72,408 hrs · 17,151 cycles

DURING L CHECK, FOUND CRACK ON FRAME WEB AT BS 360 STRINGER 23R. REPAIRED PER EA 67-178856.

Part: ENGINE — MALFUNCTIONED (NR 4) · airframe 71,315 hrs · 16,921 cycles

DURING CLIMB AT 7000 FEET, THE NR 4 ENGINE OIL QUANTITY RAPIDLY DECREASED TO ZERO WITH DROPPING OIL PRESSURE. POWER WAS REDUCED TO IDLE WHEN THE NR 4 ENGINE FIRE WARNING ACTIVATED. THE CREW DISCHARGED BOTH FIRE BOTTLES, DECLARED AN EMERGENCY, AND RETURNED TO ANC. CFR VEHICLES MET THE AIRCRAFT AT THE END OF THE RUNWAY THOUGH NO FIRE SUPPRESSION WAS REQUIRED. AFTER MULTIPLE TIRE AND BRAKE CHANGES, THE AIRCRAFT WAS TOWED FROM THE RUNWAY. INSPECTION FOUND HEAT DAMAGE TO THE NR 4 ENGINE REQUIRING AN ENGINE CHANGE.

Part: TR UNIT — MALFUNCTIONED (NR 1 ENGINE)

AT 100 KTS ON TAKEOFF ROLL, THE NR 1 ENGINE THRUST REVERSER UNLOCK LIGHT ILLUMINATED. THE TAKEOFF WAS ABORTED AND THE AIRCRAFT RETURNED TO THE GATE, MAINTENANCE DEFERRED THE REVERSER PER MEL 78-1 AND LOCKED OUT THE REVERSER PER DDG.

Part: PUMP — MALFUNCTIONED (NR 4 HYD SYST)

DURING CLIMB, THE NR 4 HYDRAULIC QUANTITY INDICATED ZERO. AIRCRAFT RETURNED TO MNL AND LANDED WITHOUT INCIDENT. REPLACED THE HYDRAULIC QUANTITY TRANSMITTER AND ENGINE DRIVEN HYDRAULIC PUMP. OPERATIONAL CHECK GOOD.

Part: LINE — LEAKING (NR 1 HYD SYST)

THE NR 1 HYDRAULIC SYSTEM LOST FLUID EN ROUTE FROM TPE-NRT. AIRCRAFT CONTINUED TO NRT, LANDED WITHOUT INCIDENT, AND WAS TOWED INTO THE GATE. RETIGHTENED THE HYDRAULIC PRESSURE LINE FOR THE LEFT BODY LANDING GEAR TRUCK POSITION ACTUATOR. OPERATIONAL CHECK GOOD.

Part: WARNING LIGHT — ILLUMINATED (LANDING GEAR)

DURING APPROACH, THE RED LANDING GEAR WARNING LIGHT ILLUMINATED. RECYCLED LANDING GEAR AND ALL INDICAITONS WERE NORMAL. AIRCRAFT LANDED WITHOUT INCIDENT. INSPECTED LANDING GEAR SYSTEM VISUAL AND OPERATIONAL CHECKS WERE GOOD. EXACT PART CAUSING DISCREPANCY TO BE DETERMINED.

Part: FRAME — CRACKED (BS 400)

DURING M-CHECK, FOUND CRACK ON FRAME WEB AT UPPER DECK FLOORBEAM TO BODY FRAME ATTACHMENT FS 400. REPAIRED PER EA 67-164964.

Part: FRAME — CRACKED (BS 420)

DURING M-CHECK, FOUND TWO HOLES CRACKED AT FRAME WEB AT UPPER DECK FLOORBEAM TO BODY FRAME ATTACHMENT, FS 420. REPAIRED PER EA 67-164965.

Part: FRAME — CRACKED (BS 360)

DURING M-CHECK, FOUND CRACK ON FRAME INBOARD FLANGE BETWEEN STR 0L AND 3L, FS 360. REPAIRED PER EA 67-164953.

Part: FRAME — CRACKED (BS 360)

DURING M-CHECK, FOUND CRACK ON FRAME WEB AT FS 360, STR 1R-2R. REPAIRED PER EA 67-164950.

Part: COMPRESSOR — STALLED (NR 3 ENGINE)

DURING LANDING ROLLOUT, WHILE IN REVERSE THRUST, THE NR 3 ENGINE EXPERIENCED A MINOR COMPRESSOR STALL. EGT REACHED MAXIMUM OF 740C BEFORE THE ENGINE WAS SHUT DOWN. MAINTENANCE INSPECTED THE ENGINE WITH NO DEFECTS NOTED AND THE AIRCRAFT WAS RETURNED TO SERVICE. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: ENGINE — FAILED (NR 2)

APPROXIMATELY 30 MINUTES AFTER TAKEOFF, THE NR 2 ENGINE FILTER BYPASS WARNING LIGHT ILLUMINATED. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT RETURNED TO ANC. MAINTENANCE FOUND THE NR 2 ENGINE MAIN OIL FILTER CLOGGED. THE AIRCRAFT WAS FERRIED ON THREE ENGINES TO MSP FOR AN ENGINE CHANGE.

Part: IND SWITCH — MALFUNCTIONED (NR 1 ENGINE)

AT FL250, THE NR 1 ENGINE START VALVE OPEN LIGHT ILLUMINATED. CREW SHUT DOWN THE ENGINE AND RETURNED TO ANC WITHOUT INCIDENT. MAINTENANCE REPLACED THE NR 1 ENGINE START VALVE INDICATING SWITCH. EXACT PART CAUSING PROBLEM TO BE DETERMINED.

Part: FLOORBEAM — CORRODED (BS 640)

DURING PERIODIC CHECK, FOUND CORROSION ON FLOORBEAM AT FS 640, LBL 83. REPAIRED PER EA 67-151495.

Part: FLOORBEAM — CORRODED (BS 1268-1335)

DURING PERIODIC CHECK, FOUND CORROSION ON FLOORBEAM FS 1268 TO 1335, RBL 31 TO 34. REPAIRED PER EA 67-151376.

Part: FLOORBEAM — CORRODED (BS 1015-1038)

DURING PERIODIC CHECK, FOUND CORROSION ON SEAT TRACK FLANGES AT FS 1015 TO 1038, RBL 75. REPAIRED PER EA 67-151556.

Part: FITTING — CRACKED (SERVICE DOOR)

DURING PERIODIC CHECK, FOUND CRACK IN LOWER AFT DOOR STOP SUPPORT FITTING FOR THE UPPER DECK CREW SERVICE DOOR. REPLACED FITTING PER SRM 51-10-1.

Part: TR UNIT — MALFUNCTIONED (NR 3 ENGINE)

DURING LANDING, THE NR 3 ENGINE DID NOT COME OUT OF REVERSE THRUST. OIL PRESSURE DECREASED AND EGT ROSE TO 860 CELSIUS. ENGINE WAS SHUTDOWN. MAINTENANCE RAN ENGINE AND OPERATED THE THRUST REVERSER WITH ALL INDICATIONS NORMAL.

Part: PNEU CONTROL — FAILED (NR 3 ENGINE)

DURING TAKEOFF, THE NR 3 ENGINE DID NOT REACH TAKEOFF POWER. ABORTED TAKEOFF AND RETURNED TO THE GATE. REPLACED THE HIGH STAGE CONTROL AND VALVE, OPERATIONAL CHECK GOOD.

Part: BLEED CONTL VLV — MALFUNCTIONED (NR 2 ENGINE)

DURING TOP OF DESCENT, THE NR 2 ENGINE EGT STARTED TO CLIMB. NR 2 ENGINE WAS SHUT DOWN AT 36,000 FEET. ENGINE RESTARTED AT 25,000 FEET. ENGINE OPERATED NORMALLY FOR REMAINDER OF FLIGHT. MAINTENANCE REMOVED AND REPLACED BLEED CONVERTER VALVE, PS4 RESTRICTOR, AND ENGINE VANE CONTROL. ENGINE GROUND RUN AND EVC TRIM WAS PERFORMED. PARTS INFORMATION PENDING SHOP REPORTS.

Part: GEAR INDICATION — ILLUMINATED (LANDING GEAR)

DURING APPROACH, THE RED UNSAFE LANDING GEAR LIGHT ILLUMINATED AFTER LANDING GEAR EXTENSION. EXECUTED A GO-AROUND AND RECYCLED THE LANDING GEAR AND THE LIGHT EXTINGUISHED. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND CHECKED LANDING GEAR SYSTEM, OPERATIONAL CHECK GOOD.

Part: COMPRESSOR — STALLED (NR 4 ENGINE)

WHILE WAITING FOR TAKEOFF, THE NR 4 ENGINE EXPERIENCED A SILENT COMPRESSOR STALL. AS EGT ROSE TO 950 DEGREES AND OIL PRESSURE LOW LIGHT ILLUMINATED, CREW FOLLOWED COCKPIT OPERATING PROCEDURE, SHUT DOWN THE ENGINE, AND RETURNED TO THE GATE. MAINTENANCE PERFORMED FIRST STALL PROCEDURE PER MAINTENANCE MANUAL AND NO DISCREPANCIES WERE NOTED. AIRCRAFT RETURNED TO SERVICE.

Part: SUPPORT BEAM — CORRODED (WS 684)

DURING P-CHECK, FOUND CORROSION ON THE RIGHT WING SPOILER SUPPORT BEAM UPPER CHORD AT WS 684. REPAIRED CHORD (P/N 65B11614-6) PER EA 67-99439.

Part: FRAME — CRACKED (FS 281)

DURING PERIODIC CHECK, FOUND A CRACK IN THE BS 281 UPPER CLOSURE FRAME AT LBL 44, WATER LINE 312. REPAIRED FRAME (P/N 65B12888-3) PER EA 67-99438.

Part: SKIN — CRACKED (NR 2 PYLON)

DURING P-CHECK, FOUND A .50 INCH CRACK IN THE NR 2 PYLON INBOARD SKIN OUTER LAYER AT NACELLE STA 175, WATER LINE 151. REPAIRED SKIN PER EA 67-99442.

Part: SEAT TRACK — CORRODED (FS 1960-1982)

DURING PERIODIC CHECK, FOUND CORROSION IN THE RBL 11 SEAT TRACK CROWN FROM BS 1960 TO 1982. REPLACED SEAT TRACK (P/N 65B38274-2) PER EA 67-98620.

Part: LONGERON — CORRODED (FS 1950)

DURING PERIODIC CHECK, FOUND CORROSION ON STR 51L AT FS 1950. REPAIRED STRINGER (P/N 65B04483-6) PER EA 67-96734.

Part: DOOR HINGE — CORRODED (AFT CARGO DOOR)

DURING PERIODIC CHECK, FOUND CORROSION IN THE AFT 3 SEGMENTS OF THE AFT CARGO DOOR HINGE. REPLACED AFT 3 SEGMENTS PER OHM 52-34-11 FIG 601 SEC B.

Part: DNLOCK ACTUATOR — LEAKING (LT MLG)

DURING APPROACH WHEN THE LANDING GEAR WAS EXTENDED, THE NR 4 HYDRAULIC SYSTEM QUANTITY DROPPED TO ZERO. SECURED NR 4 HYDRAULIC SYSTEM AND LANDED WITHOUT INCIDENT. REPLACED THE LEFT WING GEAR DOWNLOCK ACTUATOR. OPERATIONAL CHECK OK.