N749SA

Part: BOLT — SHEARED (PYLON) · airframe 80,056 hrs · 14,081 cycles

DURING THE ROUTINE TROUBLESHOOTING OF A FUEL LEAK IN THE PYLON AREA, TECHNICIANS DISCOVERED MULTIPLE PYLON ATTACH FITTING FASTENERS SHEAR ON THE NR 1 AND NR 4 PYLON. REFERENCE FASTENERS ARE COVERED UNDER AD 2005-14-08 AND ASSOCIATED SERVICE BULLETINS. THE SUBJECT AIRCRAFT HAD PREVIOUSLY HAD SUBJECT AD TERMINATED PER STEP (M) OF AFOREMENTIONED AD AND REFERENCE FASTENERS REPLACED WITH TITANIUM FASTENERS PER SB 747-57A2312. Q2SA HAS ACCOMPLISHED RESEARCH OF HISTORY OF AIRCRAFT FOR EVIDENCE OF HARD LANDING, OR OTHER CONTRIBUTING FACTORS. ROOT CAUSE HAS NOT BEEN DETERMINED AT THIS TIME. SUBJECT AIRCRAFT IS BEING REPAIRED PER SB 57A2312 AND ADDITIONAL SUPPLEMENTAL INSPECTION TO BE ACCOMPLISHED PER BOEING INSTRUCTIONS.

Part: TIRE — BLOWN (LANDING GEAR)

ON TAKEOFF ROLL, CREW EXPERIENCED A SEVERE VIBRATION AT APPROX 150-155 KNOTS. REJECTED TAKEOFF ACCOMPLISHED AT 160 KNOTS. WHILE TURNING OFF RUNWAY, FLUID FROM HYD SYSTEM NR 1 DEPLETED & PRESSURE LOST. APU STARTED & ENGINES TURNED OFF. AS A CONSEQUENCE OF EVENT, 2 TIRES ON LT MLG HAD BLOWN & FRAGMENTS PIERCED A HYD LINE; TWELVE OTHER TIRES DEFLATED ON MLG DUE TO AN OVERTEMP FROM REJECTED TAKEOFF. ALL TIRE ASSEMBLIES R & R, FOUND OPERATIONALLY SATISFACTORY PER AMM 32-40. DIGITAL FLT DATA RECORDER R & R FOR PENDING INVESTIGATION, OPS CHECK PERFORMED FOR REPLACEMENT PER AMM 31-31-01. COCKPIT VOICE RECORDER REMOVED FOR PENDING INVESTIGATION, OPS CHECK PERFORMED FOR REPLACEMENT PER AMM 23-71-01.

Part: SKIN — DAMAGED (LT WING)

(KADY) REPLACED TIME LIMITED REPAIR WITH PERMANENT REPAIR - LT WING L/E SKIN.

Part: SKIN — DAMAGED (LT WING)

(KADY) REPLACE TIME LIMITED REPAIR WITH PERMANENT REPAIR - LT WING L/E SKIN.

Part: DOOR — DELAMINATED (RT STRUT)

(KADY) DISBOND (24.0" X 3.5") WAS FOUND BETWEEN OUTER SKIN (65B90036-2) AND ALUMINUM HONEYCOMB CORE (65B90036-18) OF THE NR 1 RT STRUT FAIRING DOOR (65B90032-28).

Part: LONGERON — WORN (NACELLE)

(KADY) WORN AND BROKEN OF UPPER LONGERON AT NR 1 ENGINE RT SIDE COWL. MINOR REPAIR ACCOMPLISHED BY TRIM OUT THE DAMAGED UPPER LONGERON AND INSTALL REPAIR PARTS.

Part: LONGERON — WORN (NACELLE)

(KADY) WORN AND BROKEN OF UPPER LONGERON AT NR 2 ENGINE RT SIDE COWL. MINOR REPAIR ACCOMPLISHED BY TRIM OUT THE DAMAGED UPPER LONGERON AND INSTALL REPAIR PARTS.

Part: DOOR — DELAMINATED (LT STRUT)

DISBOND (21.0" X 5.0") WAS FOUND BETWEEN OUTER SKIN (65B90036-2) AND ALUMINUM HONEYCOMB CORE (65B90036-18) AND CRACK (2.0", 1.3" LONG) ON OUTER SKIN (65B90036-2) OF THE NR 1 LT STRUT FAIRING DOOR (65B90032-29).

Part: FRAME — CRACKED (NACELLE)

(KADY) CRACK AT AFT FLANGE OF UPPER FRAME OF NR 1 ENGINE. MAJOR REPAIR ACCOMPLISHED BY TRIM OUT OF DAMAGED FRAME AND INSTALL REPAIR PARTS.

Part: FLOORBEAM — CRACKED (FUSELAGE)

(KADY) CRACK WAS FOUND ON THE WEB OF THE UPPER DECK FLOORBEAM AT STA 340 RT SIDE.

Part: SKIN — DAMAGED (NACELLE)

(KADY) SHARP NICK AND GOUGES AT NR 4 LT SIDE COWL SKIN NAC STA 165.0. MINOR REPAIR ACCOMPLISHED BY TRIM OUT THE DAMAGED SKIN AND INSTALL REPAIR PARTS.

Part: LONGERON — WORN (NR 4 COWL)

(KADY) WORN AND BROKEN OF UPPER LONGERON AT NR 4 ENGINE SIDE COWL. MONOR REPAIR ACCOMPLISHED BY TRIM OUT THE DAMAGED UPPER LONGERON AND INSTALL REPAIR PARTS.

Part: FLOORBEAM — CRACKED (FUSELAGE)

(KADY) CRACK WAS FOUND ON THE WEB OF THE UPPER DECK FLOORBEAM AT STA 340 RT SIDE.

Part: CREASE BEAM — CRACKED (FUSELAGE)

(KADY) CRACK AT CREASE BEAM AT BS 1260 STG R 5 BOTH SIDES. MINOR REPAIR ACCOMPLISHED BY REPLACING OF CRACKED CREASE BEAM WEBS.

Part: CREASE BEAM — CRACKED (FUSELAGE)

(KADY) CRACK AT CREASE BEAM AT BS 1240, STG 7L. MINOR REPAIR ACCOMPLISHED BY REPLACING OF CRACKED CREASE BEAM WEB.

Part: BULKHEAD — CRACKED (NACELLE)

(KADY) CRACKED 2 PLACES AT NR 1 ENGINE REAR MOUNT BULKHEAD WEB. MAJOR ALTERATION ACCOMPLISHED BY REPLACING OF AFFECTED FRAME WEBS.

Part: CONTROL BOX — WORN (NR 3 ENGINE) · airframe 73,621 hrs · 13,059 cycles

IN FLIGHT FROM PANC TO RKSI, CREW HAD NO FORWARD THROTTLE MOVEMENT RESPONSE ON ENGINE NR 3, THE ENGINE RESPONDED NORMALLY DURING RETARDING THROTTLE MOVEMENT. CREW SHUT DOWN ENGINE NR 3 AS PRECAUTION ON TOP OF DESCENT INTO RKSI AND LANDED SAFELY AT RKSI. AFTER LANDING, MAINTENANCE CREW TROUBLESHOT ENGINE NR 3 THROTTLE SYSTEM AND FOUND THE THROTTLE DRUM PUSH-PULL CABLE CONTROL BOX INSIDE THE NR 3 ENGINE PYLON WORN. REMOVED AND REPLACED WORN CONTROL BOX AND PERFORMED THROTTLE CONTROL SYSTEM ADJUSTMENT TEST ON ENGINE NR 3 IN ACCORDANCE WITH BOEING 747 AMM 76-11-06 AND 76-11-00, ALL OPERATION NORMAL. AIRCRAFT RESTORED TO NORMAL.

Part: INU — MALFUNCTIONED (NAVIGATION SYS) · airframe 73,593 hrs · 13,055 cycles

AFTER TAKEOFF FROM RKSI, DURING CLIMB, ALL THREE INERTIAL NAVIGATION SYSTEMS INS 1, INS 2, AND INS 3 FAILED AND CREW WAS UNABLE TO NAVIGATE FLIGHT PLAN WAYPOINTS THROUGH REST OF INTENDED FLIGHT. CREW TERMINATED FLIGHT, DUMPED 160,000 POUNDS OF FUEL, RETURNED TO RKSI AND LANDED SAFELY AT RKSI. UPON LANDING MAINTENANCE CREW TROUBLESHOT SYSTEM, SECURED AND REALIGNED ALL THREE NAVIGATION UNITS, INU 1, INU 2, AND INU 3, IN ACCORDANCE WITH BOEING 747 AMM 34-41-03 AND 34-41-00 CONFIGURATION 2, ALL OPERATIONS NORMAL THEREAFTER.

Part: ENGINE — POWER LOSS (NR 4) · airframe 73,153 hrs · 12,985 cycles

AT CRUISE LEVEL, NR 4 ENGINE FAILED AT 1945Z THREE HOURS AFTER TAKING OFF FROM RKSI. POP SOUND CAME FROM ENGINE, N1 AND N2 WENT LOW, EGT ROSE TO 615 AND CLIMBING. CREW SHUT DOWN NR 4 ENGINE IAW QRH. CREW ATTEMPTED NR 4 ENGINE FLIGHT START UNSUCCESSFULLY, HAD FUEL FLOW, IGNITION, AND EGT, BUT N1 AND N2 REMAINED LOW. CREW TERMINATED FLIGHT, DIVERTED TO RKPK AND LANDED SAFELY AT RKPK.

Part: ENGINE — FIRE (NR 4) · airframe 71,737 hrs · 12,772 cycles

AFTER NORMAL LANDING WHEN BRINGING ENGINES OUT OF REVERSE, TOWER REPORTED TO CREW THAT FIRE WAS COMING FROM NR 4 ENGINE. CREW REPORTED NO FIRE WARNING INDICATIONS IN COCKPIT, BUT COMPRESSOR STALL WAS HEARD. NO HIGH NACELLE TEMPS WERE NOTED. EGT WAS MAXED OUT AT 750 - 755 DEGREES F FOR APPROXIMATELY 20 SECONDS. EMERGENCY SHUTDOWN OF ENGINE WAS ACCOMPLISHED AND FIRE EXTINGUISHER BOTTLE DISCHARGED. FURTHER ENGINE BOROSCOPE EXAMINATION BEING ACCOMPLISHED.

Part: SKIN PANEL — DEPARTED (BS 2690-2701) · airframe 71,459 hrs · 12,729 cycles

DURING FLIGHT, FUSELAGE SKIN PANEL SECTION BROKEN OFF (APPROXIMATELY 10 INCH BY 20 INCH BETWEEN STA 2690.85 AND 2701.5 AT WL 310). VEERED AFTER LANDING DURING MAINTENANCE INSPECTION ACTIVITY. REPAIR IN PROGRESS, TO BE PERFORMED IN ACCORDANCE WITH BOEING STRUCTURAL REPAIR MANUAL.

Part: ENGINE — FAILED (NR 2) · airframe 70,158 hrs · 12,531 cycles

AFTER TAKEOFF AND CLIMBING THROUGH FLIGHT LEVEL 220, NR 2 ENGINE COMPRESSOR STALLED VIOLENTLY, EGT 940 DEGREES C. REDUCED THRUST AND NR 2 STABILIZER THEN STALLED VIOLENTLY AGAIN. AS EGT REACHED 700 DEGREES C, THRUST WAS REDUCED. COMPLETED ENGINE FIRE/SEVERE DAMAGE QUICK REFERENCE HANDBOOK PROCEDURES & ACCOMPLISHED ENGINE SHUTDOWN. DUMPED 86,000 LBS OF FUEL AND RETURNED TO PANC. AWAITING ENGINE TO REPLACE WITH SERVICEABLE UNIT. (A)

Part: COMPRESSOR — STALLED (NR 1 ENGINE) · airframe 70,034 hrs · 12,511 cycles

WHILE THROTTLING ENGINE TO TAKEOFF POWER, ENGINE NR 1 HAD MULTIPLE COMPRESSOR STALLS. TAKEOFF POWER WAS 1.53, COMPRESSOR STALLS STARTED WHEN POWER WAS APPROACHING 1.35. AIRCRAFT RETURNED TO BLOCKS. (K)

Part: STRINGER SPLICE — CRACKED (FUSELAGE)

(KADY) CRACK AT STRINGER SPLICE AT BS 520, STGR 10 RT SIDE. MAJOR REPAIR ACCOMPLISHED BY FABRICATION AND REPLACING OF THE AFFECTED SPLICE FITTING.

Part: SKIN — CRACKED (NACELLE)

(KADY) CRACK WAS FOUND ON THE NR 2 ENG RT SIDE COWL UPPER SKIN AT NAC STA 226.95-236.85.

Part: SKIN — DEBONDED (NACELLE)

(KADY) DISBONDED INNER DOUBLER WAS FOUND ON THE NR 1 LT SIDE COWL SKIN AT NAC STA 192.05-204.55, NAC WL 100-110.

Part: LONGERON — CRACKED (NACELLE)

(KADY) CRACK WAS FOUND ON THE UPPER LONGERON AND SKIN OF THE NR ENG LT SIDE COWL.

Part: FITTING — DAMAGED (NACELLE)

(KADY) FRETTING DAMAGE.

Part: DOOR FRAME — CRACKED (FUSELAGE)

FRAME CRACK NR 2 LT SIDE AND 4 BOTH SIDES MAIN ENTRY DOOR. MAJOR REPAIR ACCOMPLISHED BY CUT OUT CRACKED FRAME AND INSTALL REPAIR FILLER AND REPAIR DOUBLERS.

Part: SKIN — DAMAGED (NACELLE)

(KADY) A BENT DAMAGE WAS FOUND ON THE NR 1 RT SIDE COWL SKIN AT NAS STA 155.61, NAC WL100.

Part: FRAME — CHAFED (FUSELAGE)

(KADY) FRAME DAMAGE CAUSED BY CHAFING WITH SCREW AT BS 1540 BETWEEN STGR 19 AND 22 RT SIDE. MAJOR REPAIR ACCOMPLISHED BY CUT AND REMOVE FRAME AND INSTALL REPAIR PARTS INCLUDING ORIGINAL SEGMENT AND SPLICE PLATE.

Part: SKIN — WORN (PYLON)

(KADY) WORN DAMAGE WAS FOUND ON THE CAP SKIN OF THE NR 1 PYLON. THE DAMAGED CAP SKIN IS REPAIRED IAW SRM.

Part: INTERCOSTAL — CRACKED (FUSELAGE)

(KADY) FASTENER HOLE CRACK AT INTERCOSTAL WEB OF BS 1265 RT SIDE AND REPLACEMENT OF EXISTING REPAIR FOR LT SIDE TO REPLACE TIME LIMITED REPAIR INSTALLED LAST VISIT. MAJOR REPAIR ACCOMPLISHED BY CUT OUT OF END PORTION OF INTERCOSTAL WEB AND INSTALL REPAIR PARTS INCLUDING FILLERS AND REPAIR DOUBLERS.