2011-06 · NASA ASRS report 952136
A B747-700 rejected their takeoff prior to V1 upon receipt of a door warning light.
During the takeoff roll an EICAS message appeared. I pointed to the message and announced 'DOOR'. The Captain looked at the message and proceeded to reject the takeoff. I notified the Tower that we were rejecting the takeoff. The Captain then said that he was going to let the airplane roll to the end and that he was not going to use reverse. I told the Tower that we were planning to turn left at the end. The Tower cleared us to do so and had us hold short of 25L. We were then given clearance to taxi to the gate. During the taxi back I called Operations and notified them we had rejected the takeoff and were returning to the gate. The Captain directed me to inform the agent to have all ground personnel remain well clear of the tires; once parked most of the main gear tires went flat.I believe that the forward overhead door gave an open indication due to faulty rigging in the door mechanism. After we parked the plane at the gate we inspected the overhead door and found that by knocking on the door with ones fist the handle would vibrate out of the closed and locked position. I think that the vibration of the aircraft rolling down the runway caused the door handle to move and caused the door open indication.
The first observer checked the handle of the forward overhead door and that handle was slightly off center from its markings. There was still no open door indication on the door synoptic. After blocking in the mechanic came to the cockpit and asked what happened; we told him and he looked in the CMC and NON fault indications and could not find any indications of a door fault. We cleaned up the cockpit and on the way out I pushed the forward overhead door and the handle moved. I reached up and pushed the door tightly against the opening several times and each time I pushed it the handle moved to the opening position more and more with each push and showed an open door indication on the synoptic page. I called the mechanic up to the cockpit and showed him; he was able to duplicate it and said the door would need to be re-rigged.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.
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