N135TG

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 8,759 hrs · 25,253 cycles

PILOT AND CREW REPORTED FUMES IN CABIN/ COCKPIT AREA AND RETURNED TO LAND AS A PRECAUTION. THE MECHANIC WAS CALLED TO INVESTIGATE. THE DOOR SEALS AND ATTACHING HARDWARE WERE EXAMINED FOR DEFECTS. THE METRO AIR / HEATING SYSTEM WAS INSPECTED FOR DEFECTS IN THE HOSES AND FITTINGS. NONE WERE FOUND. IT IS SUSPECTED LOW AMBIENT TEMPERATURES AND A TAILWIND CAUSED SOME FUMES TO BE DRAWN INTO THE CABIN AREA.

Part: SHAFT — CORRODED (COLLECTIVE) · airframe 6,860 hrs · 19,027 cycles

WHILE INSPECTION OF AN AVIONICS INSTALLATION FOUND CORROSION ON THE COLLECTIVE SHAFT AT THE FRICTION BRAKE ATTACH POINT

Part: CHANNEL — CRACKED · airframe 6,397 hrs · 17,236 cycles

CRACKS FOUND IN THE RT CHANNEL BELOW FLOOR AT AFT FRAME OF SLIDING DOOR. TWO CRACKS ARE PRESENT. ONE IS ON THE MAIN STRINGER THAT MAKES UP THE STRUCTURAL FRAME FOR THE MGB FORWARD MOUNTS AND THE OTHER IS DIRECTLY ON THE OTHER SIDE OF THAT STRINGER ON A DOUBLER SUPPORT. THIS AIRCRAFT REMAINS OUT OF SERVICE AT THE TIME OF THIS SUBMISSION AWAITING AN APPROVED REPAIR PROCEDURE FROM THE OEM.

Part: VALVE — LEAKING (ENGINE) · airframe 6,046 hrs · 15,917 cycles

THE PILOT & MEDICAL CREW WERE ON FINAL APPROACH TO THE HOSPITAL LZ, THE MEDIC IN THE CABIN SMELLED FUEL. THE PILOT CONTINUED THE APPROACH & LANDED AT THE HOSPITAL. UPON SHUTDOWN, FUEL WAS OBSERVED TO BE ALL OVER THE CLAMSHELL DOORS, EXTERIOR. FUEL WAS OBSERVED ALL OVER THE ENG DECK AS WELL. THE MECHANIC ARRIVED & CONFIRMED THE FUEL VLV TO BE THE CAUSE OF THE DISCREPANCY. THE PART WAS REPLACED & THE ACFT WAS RETURNED TO SERVICE.

Part: CONTROL ROD — CRACKED (ZONE 200) · airframe 5,693 hrs · 14,510 cycles

DURING AAIP INSPECTION, LONGITUDINAL CONTROL ROD TO HYDRAULIC PACK WAS FOUND TO BE CRACKED.

Part: VALVE — LEAKING (ENGINE) · airframe 5,406 hrs · 13,781 cycles

DURING CRUISE FLIGHT AT 1,000 FT AGL, PILOT NOTICED AN ODOR OF FUEL IN COCKPIT. COULD SEE A CLEAR LIQUID RUNNING DOWN THE REAR CLAM SHELL DOOR. TURNED BACK TO THE AIRPORT AND LANDED WITHOUT INCIDENT. POST FLIGHT INSPECTION FOUND THE ADJUSTED FUEL VALVE ASSY TO BE THE SOURCE OF LEAK. PART WAS REMOVED AND REPLACED. ACFT RETURNED TO SERVICE WITH NO FURTHER DEFECTS NOTED.

Part: GUIDE VANE — CRACKED (MODULE 2) · airframe 5,048 hrs · 12,852 cycles

WHILE PERFORMING DISASSEMBLY OF ENGINE SN 32072 FOR A REAR BEARING OIL PIPE LEAK, FOUND DAMAGE TO THE FOLLOWING COMPONENTS INCLUDING THE PT NOZZLE GUIDE VANE: HP SEGMENT ASSY PN 0319217910, SN 653B FOUND CRACKED. FLAME TUBE PN 031917850, SN 664 CRACKED. HP NOZZLE GUIDE VANE PN 0319218310, SN 0023FN CRACKED. DIFFUSER, PN 0319210050, SN 37 FOD DAMAGE. ALSO FOUND THE T-4 HARNESS BROKEN. ALL OF THESE PARTS ARE BEING REPLACED.

Part: SHUTOFF VALVE — LEAKING (NR 1 ENGINE) · airframe 4,663 hrs · 11,833 cycles

SHORTLY AFTER TAKEOFF THE MED CREW NOTICED A STRONG FUEL SMELL IN THE CABIN AND COULD SEE LIQUID ON THE BACK CLAMSHELL WINDOW. THE PILOT IMMEDIATELY RETURNED TO THE DEPARTURE AIRPORT AND AWAITED THE MECHANIC TO ARRIVE. THE MECHANIC TROUBLESHOT THE FUEL LEAK AND DETERMINED THAT THE FUEL SHUTOFF VALVE HAD FAILED. THE ACFT WAS TAKEN OUT OF SERVICE TO AWAIT THE PART TO BE RECEIVED THE NEXT DAY. THE PART WAS RECEIVED AND REPLACED. THE OPS CHECK WAS GOOD AND THE ACFT WAS RETURNED TO SERVICE.

Part: SPACER — WORN (M/R MAST) · airframe 4,044 hrs · 10,212 cycles

MAIN ROTOR MAST NUT TORQUE CHECK WAS PERFORMED DURING MX. THE MAST NUTS WERE FOUND TO BE LOOSE. THE MAST WAS REMOVED AND THE SPACER TUBE WAS INSPECTED. THE PROJECTIONS ON THE SPACER TUBE WAS WORN BEYOND ALLOWABLE LIMITS.

Part: SPACER — WORN (M/R MAST) · airframe 4,044 hrs

WHILE COPLIYING WITH MAIN ROTOR MAST NUT TORQUE CHECK IT WAS DISCOVERED THAT THE NUT HAD LOST SIGNIFICANT TORQUE. THE TORQUE WRENCH USED FOR THIS CHECK WAS SET AT MINIMUM TORQUE VALUE. THE ROTOR HUB SHAFT WAS REMOVED TO INSPECT THE SPACER TUBE ASSY. THE PROJECTIONS ON THE ASSEMBLY WERE WORN BEYOND THE ALLOWABLE LIMITS OF .21IN.

Part: CIRCUIT BOARD — BURNED (NR 1 GENERATOR)

NR 1 GENERATOR DISCONNECT CAUTION LIGHT ILLUMINATED, FOLLOWED BY NR 1 BUSS TIE OPEN CAUTION LIGHT. PILOT PLACED NR 1 GENERATOR CONTROL SWITCH TO OFF POSITION. THE VOLTAGE AND LOAD FOR NR 2 GENERATOR APPEARED NORMAL. APPROXIMATELY TWO MINUTES LATER, NR 2 BUSS TIE OPEN CAUTION LIGHT ILLUMINATED FOLLOWED BY BATTERY DISCONNECT CAUTION LIGHT. A SMELL OF ELECTRICAL FUMES WAS NOTED BY PILOT AND MEDICAL CREWMEMBERS. ACFT LANDED AND BATTERY DISCONNECTED. MX FOUND THE Z-200 CARD IN THE MASTER ELECTRICAL PANEL BURNT.

Part: FRAME — CRACKED (ZONE 200) · airframe 2,386 hrs · 6,007 cycles

A CRACKED FRAME 5A WAS DISCOVERED DURING INSPECTION.

Part: BRACKET — CRACKED (NACELLE)

EJECTOR COWLING ALIGNMENT BRACKET CRACKED DUE TO VIBRATION. (K)