N136MF

Part: VALVE — MALFUNCTIONED (NR 2 ENGINE) · airframe 5,788 hrs · 17,025 cycles

DURING CRUISE FLIGHT IN ROUTE TO REQUESTING FACILITY, MED CREW REPORTED SMELLING JET FUEL IN THE CABIN. WE IMMEDIATELY CANCELED THE FLIGHT, LANDED ASAP AND SHUT DOWN AIRCRAFT. POST FLIGHT INSPECTION FOUND JET FUEL ON THE ENGINE DECK OF THE NUMBER 2 ENGINE AND ON THE RIGHT SIDE OF THE AIRFRAME.

Part: BULKHEAD — CORRODED (FUSELAGE) · airframe 5,204 hrs · 14,890 cycles

DURING SCHEDULED INSPECTION FOUND CORROSION FORWARD BULKHEAD UNDER CABIN FLOOR AT THE FARTHEST POINT OUT BOARD BETWEEN THE COMPOSITE PANEL AND BOTTOM FLANGE OF BULKHEAD APPX LOCATIONS, STATION 1600MM, BUTT LINE -600MM, WATER LINE 1300MM.

Part: INJECTOR — UNSERVICEABLE (NR 1 ENGINE) · airframe 5,176 hrs · 14,781 cycles

DURING AIRCRAFT START UP, IT WAS NOTICED THAT THE NR 1 ENGINE HAD FIRE EXITING THE EXHAUST. THROUGH TROUBLESHOOTING PROCEDURES, WE NOTICED WE COULD NOT GO MORE THAN 30% N1 BEFORE THE FIRE STARTED. AFTER MORE TROUBLESHOOTING IT WAS DETERMINED THAT BOTH START (FUEL) INJECTORS ON THE NR 1 ENGINE WERE AT FAULT. AFTER REPLACEMENT OF BOTH START INJECTORS THE NR 1 ENGINE WORKED AND STARTED AS SHOULD.

Part: UNKNOWN — VIBRATION · airframe 5,199 hrs · 14,580 cycles

EXPERIENCED VERY HIGH FREQUENCY VIBRATION AND WHINING SOUND AFTER TAKE OFF FROM THE BASE ENROUTE FOR AN INTERFACILITY TRANSFER. TOOK IMMEDIATE ACTION AND LANDED BACK AT THE AIRPORT SAFELY. WHINING AND VIBRATION WAS NOT ACCOMPANIED BY ANY CAUTION LIGHTS, OR FLUCTUATION IN ANY OIL TEMPERATURES OR PRESSURES. WE PERFORMED INSPECTIONS OF THE ENTIRE AIRCRAFT AND FLIGHT CONTROLS. WE PERFORMED OPERATIONAL CHECKS OF ALL THE HYDRAULICS. WE PERFORMED TRACK AND BALANCE ON THE GROUND AND IN FLIGHT. WE PERFORMED THREE DIFFERENT OPERATIONAL CHECK FLIGHTS AND COULD NOT DUPLICATE THE SAID DISCREPANCY.

Part: BEARING — MISMANUFACTURED (MODULE 2) · airframe 4,727 hrs · 13,197 cycles

WHILE CHANGING THE FRONT BEARING ASSEMBLY, FOUND THE NEW 0 TSN FRONT BEARING ASSEMBLY SLEEVE HOLES MANUFACTURED TO THE INCORRECT SIZE. EACH TIME WE TRIED TO INSTALL THE NEW SLEEVES INTO THE FRONT BEARING HOUSING THE SILVER COATING WOULD PEAL OFF OF THE SLEEVES. ORDERED A NEW FRONT BEARING ASSEMBLY AND THE NEW SLEEVES WENT RIGHT IN AS THEY SHOULD.

Part: AUDIO PANEL — SMOKE (COCKPIT) · airframe 3,794 hrs · 9,885 cycles

WHILE ENROUTE TO A SCENE, SMELLED & WITNESSED SMOKE COMING FROM THE PILOTS AUDIO PANEL LOCATION. THE ICS WAS INOPERABLE, HOWEVER HE COULD STILL TRANSMIT ON THE VHF RADIOS. ABORTED THE MISSION & LANDED AT THE NEAREST AIRPORT WHICH WAS ONLY 5 MINUTES AWAY. INSPECTED THE ACFT & CONFIRMED THE PILOTS AUDIO PANEL TO BE THE FAULT. A REPLACEMENT WAS RECEIVED & INSTALLED. THE PILOTS ICS & ACFT WERE THEN RETURNED TO SERVICE.

Part: BOTTLE — LOOSE (NR 1 ENGINE) · airframe 3,591 hrs · 9,207 cycles

THE FLIGHT CREW DETECTED A STRONG FUEL SMELL UPON LANDING AT THE HOSPITAL HELIPAD FOR A PATIENT PICKUP. THE MECHANIC ARRIVED AT THE HELICOPTER AND INSPECTED THE ACFT. HE FOUND THAT THE NR1 ENGINE FUEL COMPARTMENT HAD FUEL RESIDUE COLLECTING ON THE AFT FIREWALL, DECK AND THE COLLECTOR DRAIN BOTTLE. THE COMPARTMENT WAS CLEANED AND THE FUEL DRAIN LINES AND COUPLING NUTS ATTACHED TO THE COLLECTOR DRAIN BOTTLE WERE ALL TORQUE CHECKED. THESE LINES WERE ALL RETORQUED AND SAFETIED. THE ACFT WAS GROUND RAN AND HOVER CHECKED WITH NO DEFECTS NOTED. THE ACFT WAS RETURNED TO SERVICE.

Part: HMU — LEAKING (NR2 ENGINE) · airframe 2,791 hrs

UPON LANDING, ACFT WENT TO FLAT PITCH PILOT DETECTED A STRONG ODOR OF FUEL AND COCKPIT FILLED WITH VISIBLE EXHAUST THAT SMELLED STRONGLY OF FUEL. PRIMARY TROUBLESHOOTING WITH REP POINTED TO AN INTERNAL LEAK IN BOTH NR1 AND NR2 ENGINE HMU'S ALLOWING FUEL IN THE P2 SYS. WHICH WITH CABIN HEATER OPERATING ALLOWS FUMES AND VAPORS TO ENTER CABIN/COCKPIT.

Part: HMU — LEAKING (NR 1 ENGINE) · airframe 2,791 hrs

UPON LANDING ACFT WENT TO FLAT PITCH PILOT DETECTED A STRONG ODOR OF FUEL AND COCKPIT FILLED WITH VISIBLE EXHAUST THAT SMELLED STRONGLY OF FUEL. PRIMARY TROUBLESHOOTING WITH MFG REP POINTED TO AN INTERNAL LEAK IN BOTH NR1 AND NR2 ENGINE HMU'S ALLOWING FUEL IN THE P2 SYS. WHICH WITH CABIN HEATER OPERATING ALLOWS FUMES AND VAPORS TO ENTER CABIN/COCKPIT.

Part: TRANSMISSION — MISALIGNED (MAIN ROTOR) · airframe 2,721 hrs

MAIN TRANSMISSION CHIP LIGHT. SLIGHT ABRASION ON CHIP DETECTOR. CLEANED CHIP DETECTOR INSTALLED CLEAN FILTER ALL IAW EC135-63A-012 REV 4 STAGE A PROCEDURES. ACFT RETURNED TO SERVICE.