N1545K

Part: DOOR — OUT OF ADJUST (LANDING GEAR) · airframe 20,295 hrs

WITH LANDING GEAR HANDLE, UP THE THREE GREEN POSITION LIGHTS WENT OUT BUT RED UNLOCK LIGHT REMAINED ON. LOWERED GEAR NORMAL AND LANDED GC52. INSPECTED GEAR AND FOUND NO OBVIOUS DEFECTS, REMOVED PINS. AIRCRAFT JACKED UP AND GEAR RETRACTED, NOTED LEFT HAND MAIN GEAR DOOR HANGING DOWN ABOUT TWO AND ONE-HALF INCHES. REALIGNED FORWARD FLOAT LINE - RESTING AGAINST STRUT WITH GEAR UP AND PERFORMED GEAR RETRACTION TESTS. ALL INDICATOR LIGHTS WORKED NORMALLY THROUGH ALL RETRACTION TESTS.

Part: PROXIMITY SWITCH — OUT OF ADJUST (LG SYS) · airframe 20,254 hrs

AFTER TAKEOFF RAISED THE LANDING GEAR LEVER. THE THREE GREEN LIGHTS REMAINED ON AND THE RED UNLOCKED LIGHT REMAINED ON. MAINTENANCE ADJUSTED THE NOSE GEAR PROXIMITY SWITCH.

Part: SERVO — MALFUNCTIONED (FLIGHT CONT SYS) · airframe 19,979 hrs

ON LANDING AND AFTER LANDING ON OFFSHORE HELIPORT DECK, WHEN PUTTING COLLECTIVE DOWN TO FLAT PITCH, COLLECTIVE WOULD NOT STAY DOWN; EVEN WITH COLLECTIVE TRIM RELEASED AND SWITCH OFF. AFTER ATTEMPTING A NUMBER OF TIMES TO GET COLLECTIVE TO STAY DOWN THE FORCES REVERSED, THEN COLLECTIVE WANTED TO STAY DOWN AND REQUIRED MORE THAN NORMAL FORCE TO LIFT FROM FLAT PITCH. AIRCRAFT WAS SHUT DOWN AND MAINTENANCE WAS NOTIFIED. COLLECTIVE TRIM SYSTEM WAS APPARENTLY WORKING PROPERLY, AND WAS CHECKED AGAIN AFTER SHUTDOWN. AIRCRAFT WAS NOT RESTARTED AND LEFT TIED DOWN AND SECURED OFFSHORE. MAINTENANCE REPLACED ALL THREE MAIN ROTOR SERVOS S/N 0679X, 0754 AND 0752.

Part: TUBE — LEAKING (HYD SYSTEM) · airframe 19,031 hrs

AFTER TAKEOFF, THE ODOR OF HYDRAULIC OIL WAS NOTED IN THE COCKPIT, THE AIRCRAFT WAS TURNED AROUND AND LANDED. AFTER LANDING, THE NR 2 HYDRAULIC PRESSURE FLUCTUATED AND STARTED TO GO DOWN, THE AICRAFT WAS SHUTDOWN, AND MAINTENANCE FOUND PIN HOLE IN THE TUBE CAUSING LEAK. REPLACED TUBE ASSY.

Part: INDICATOR — PRECESSES (COCKPIT) · airframe 17,544 hrs

ADI ERRATIC, INTERMITTENTLY PRECESSES IN FLIGHT. SHOP REPAIR.

Part: BLOWER — INOPERATIVE (CABIN COOLING) · airframe 17,541 hrs

BLOWER ASSY FOUND TO BE INOPERATIVE.

Part: MOTOR — SPLIT (BEEP) · airframe 17,515 hrs

TORQUE SPLIT, DEAD SPOT BEEPING FROM 60 TO 90 PERCENT. TO BE SENT TO VENDOR FOR REPAIR.

Part: IGNITER — FAILED (ENGINE) · airframe 17,507 hrs

ENGINE WOULD NOT START. IGNITER TO BE SENT TO VENDOR FOR REPAIR.

Part: BATTERY — OVERHEATED (MASTER) · airframe 17,502 hrs

BATTERY HOT LIGHT CAME ON IN FLIGHT. REPAIRED.

Part: TRANSCEIVER — MALFUNCTIONED (ADF) · airframe 17,497 hrs

AUDIO FADES OUT. SENSE COAX CONNECTOR IS LOOSE. IN SHOP REPAIR.

Part: PANEL — MALFUNCTIONED (COCKPIT) · airframe 17,478 hrs

COCKPIT CAUTION PANEL LAMPS WILL NOT LIGHT UP WHEN FAULTS OCCUR. SHOP REPAIR.

Part: BLADE — CRACKED (MAIN ROTOR) · airframe 17,472 hrs

MAIN ROTOR BLADE HAS A CRACK IN THE ABRASION STRIP NEAR STATION 152.5 INCHES WITH THE FIBERGLASS BELOW THE STRIP CRACKED AND SEPARATED. THE TIP RIB AND NUT PLATE ARE BOTH UNBONDED.

Part: ACTUATOR — ERRATIC (AFCS) · airframe 17,397 hrs

AFCS ACTUATOR ERRATIC THEN QUIT. TO BE SENT TO VENDOR.

Part: INDICATOR — INTERMITTENT (COCKPIT) · airframe 17,393 hrs

T5 INDICATOR, FLUCTUATED AND WENT TO ZERO. SHOP REPAIR.

Part: ANTENNA — INOPERATIVE (OUTERLINK)

OUTERLINK ANTENNA INOPERATIVE. TO BE SENT TO VENDOR FOR REPAIR.

Part: ANTENNA — INTERMITTENT (VHF SYSTEM) · airframe 17,377 hrs

ANTENNA INTERMITTENT RECEPTION. REPAIRED.

Part: CALIPER — WORN (ROTOR BRAKE) · airframe 17,326 hrs

WORN PUCKS - SLOW TO RELEASE. SHOP REPAIR.

Part: FUEL CONTROL — MALFUNCTIONED (ENGINE) · airframe 17,326 hrs

ANTICIPATOR ROUGH, CAUSING TRIM MOTOR SLOW RESPONSE.

Part: CALIPER — WORN (ROTOR BRAKE) · airframe 17,326 hrs

WORN PUCKS - SLOW TO RELEASE. SHOP REPAIR.

Part: ACTUATOR — ERRATIC (ENGINE) · airframe 17,349 hrs

ACTUATOR OPERATES ERRATICALLY AND HESITATES DURING MID TRAVEL. TO BE SENT TO VENDOR FOR REPAIR.

Part: GPS — MALFUNCTIONED (COCKPIT) · airframe 17,264 hrs

GPS LOSES RAIM. SHOP REPAIR.

Part: GPS — INTERMITTENT (COCKPIT) · airframe 17,276 hrs

INTERMITTENTLY WILL NOT READ DATABASE CARD. SHOP REPAIR.

Part: GPS — FAILED (COCKPIT) · airframe 17,266 hrs

GPS FAILED IN FLIGHT. UNABLE TO ACQUIRE SIGNALS. SHOP REPAIR.

Part: CONTROL UNIT — FAILED (COMMS) · airframe 17,179 hrs

FAILS TO REPORT. SENT TO OUTERLINK FOR INSPECTION AND REPAIR.

Part: COMPUTER — FAILED (WX RADAR SYS) · airframe 17,027 hrs

WEATHER RADAR COMPUTER FAILED IN FLIGHT. TO BE SENT TO VENDOR FOR REPAIR.

Part: INDICATOR — MALFUNCTIONED (WX RADAR SYSTEM)

WEATHER RADAR PICTURE IS NOT BRIGHT ENOUGH.

Part: FACEPLATE — DAMAGED (INTERPHONE BOX)

FACEPLATE WORN. FOUND LIGHT PANEL AND SELECTOR KNOB BAD. REPLACED. REPAIRED. BENCH CHECK GOOD.

Part: GPS — DAMAGED (COCKPIT) · airframe 16,938 hrs

BROKEN KNOB. FOUND ON/OFF KNOB MISSING AND ON/OFF SWITCH SHAFT BROKEN. REPLACED KNOB AND SWITCH. CLEANED FACEPLATE AND TOUCHED UP WITH BLACK PAINT. BENCH CHECK GOOD.

Part: CONTROL UNIT — INTERMITTENT (WX RADAR SYS)

VOLUME KNOB IS INTERMITTENT. FOUND FACEPLATE, VOLUME KNOB, CHANNEL SELECTOR KNOB, TONE SWITCH S2 BAD. REPAIRED. ALSO CLEANED MINOR CORROSION ON CASE. BENCH CHECK GOOD.

Part: BEARING — WORN (POSITIONING ROD)

POSITIONING ROD HAS WORN BEARINGS. REPAIRED.

Part: TRANSCEIVER — INOPERATIVE (VHF SYSTEM) · airframe 16,333 hrs

WEAK RECEIVE AND TRANSMIT. FOUND RECEIVER GOOD BUT FOUND TRANSMIT POWER AND MODULATION DROPPING OFF AND INTERMITTENT. FOUND RF CONNECTOR NOT SOLDERED PROPERLY. RESOLDERED RF CONNECTOR. MODULATION STILL DROPS OFF. SWAPPED Q109 AND Q110 TRANSISTORS. NO HELP. SENT TO GREATLAKES AVIONICS FOR INSPECTION AND REPAIR.

Part: BLADE — ERODED (TAIL ROTOR) · airframe 16,614 hrs

TAIL ROTOR BLADE END CAP ON PADDLE "A" ERODED BEYOND LIMITS.

Part: GPS — INOPERATIVE (COCKPIT) · airframe 16,175 hrs

GPS UNIT INOPERATIVE.

Part: BEARING — WORN (SWASHPLATE)

SWASHPLATE BUSHING WORN. REPLACED WITH SERVICEABLE BEARINGS.

Part: CARBON SEAL — WORN (COMPRESSOR) · airframe 16,754 hrs

COMPRESSOR CARBON SEAL HAS WORN TANGS AND SLOTS.

Part: BLADE — CRACKED (MAIN ROTOR) · airframe 16,342 hrs

LEADING EDGE TITANIUM STRIP HAS A COMPLETE CHORDWISE CRACK WITH MULTIPLE BRANCH WHICH EXTENDS BEYOND LIMITS. PENDING VENDOR REPAIR.

Part: SPINDLE — BINDING (MAIN ROTOR) · airframe 16,433 hrs

DROOP STOP BINDS UP WHEN INSTALLED. FOUND WHEN TORQUEING UP SPINDLE. A BIND PREVENTS THE DROOP STOP FROM RETURNING TO STATIC POSITION AT SHUTDOWN. IT IS FREE TO MOVE WHEN NOT INSTALLED. PENDING VENDOR REPAIR.

Part: VALVE — LEAKING (FLOAT BOTTLE)

WHILE IN FLIGHT THE LT NOSE FLOAT ASSEMBLY STARTED TO DEPLOY. MAINTENANCE FOUND FLOAT VALVE LEAKING INTERNALY AND STARTED TO INFLATE BAG.

Part: AMPLIFIER — INTERMITTENT (VIB ABSORBER)

AMPLIFLIER HAD INTERMITTENT OPERATION.

Part: AMPLIFIER — INOPERATIVE (PITCH SLICE)

NR 2 PITCH CHANNEL INOPERATIVE.

Part: WX RADAR — INTERMITTENT (COCKPIT)

PICTURE INTERMITTENT, GOES ON AND OFF.

Part: RATE GYRO — FAILED (COCKPIT)

GYRO WILL NOT POWER UP.

Part: VERTICAL GYRO — CHATTERS (COCKPIT)

ROLL CHATTERS IN-FLIGHT.

Part: VERTICAL GYRO — KICKING (COCKPIT)

NR 1 PITCH KICKING ON VERTICAL GYRO.

Part: PUMP — MISMANUFACTURED (ENGINE OIL)

IMPROPER CAGE INSTALLED IN OIL PUMP PRESSURE BODY. REVEALED DURING RECEIVING INSPECTION. REFERENCE: AFA NR 41389A.

Part: AMPLIFIER — MALFUNCTIONED (FIRE DETECTOR)

CONTROL AMPLIFIER LIGHT STAYS ON.

Part: TRANSCEIVER — MALFUNCTIONED (DME)

SENSITIVITY AND POWER LOW ON TRANSCEIVER..

Part: BRAKE — LOOSE (AUTOFLIGHT)

BRAKE SHAFT LOOSE.

Part: RELAY — MALFUNCTIONED (COCKPIT)

NR 2 GENERATOR LIGHT STAYS ON ALL OF THE TIME WITH GENERATOR ON-LINE. ALSO, NUT STRIPPED PN TERMINAL NR 11.

Part: PUMP — MALFUNCTIONED (HYDRAULIC SYS)

HYDRAULIC PUMP FLUCTUATES 100 PSI.

Part: ACTUATOR — CHATTERING (AFCS)

AFCS ACTUATOR CHATTERING IN-FLIGHT.

Part: AMPLIFIER — MALFUNCTIONED (ROLL SLICE)

NR 1 ROLL CHANNEL CHATTERS, ALSO HAS BURN SPOT ON LOWER CORNER AT P NR 2.

Part: GYRO — MALFUNCTIONED (AFCS)

NR 1 AFCS ROLL CHANNEL CHATTERS. TIME SINCE REPAIR 82:45 HOURS.

Part: ALTIMETER — INACCURATE (COCKPIT)

RADAR ALTIMETER SHOWS 25 FEET WHEN AIRCRAFT IS LANDED.

Part: FIRE DETECTOR — MALFUNCTIONED (NR 1 ENGINE)

NR 1 ENGINE FIRE WARNING LIGHT ILLUMINATED IN-FLIGHT. SECURED ENGINE AND FIRED BOTH ENGINE COMPARTMENT FIRE EXTINGUISHERS. LANDED WITHOUT INCIDENT. NO APPARENT FIRE, INDICATION ONLY. MAINTENANCE FOUND DEFECTIVE LT FORWARD FLAME DETECTOR. REF: S-76 IPC, CHAPTER 26-11-00, FIGURE 1, ITEM 21.

Part: INDICATOR — FAILED (FUEL QUANTITY)

F1 ADJUSTER NOT EFFECTIVE ON FUEL QUANTITY INDICATOR, AND CANNOT CALIBRATE.

Part: VALVE — INOPERATIVE (AIR SHUTOFF)

SHUT OFF VALVE INOPERATIVE. WILL NOT ACTUATE.

Part: ARM — MISINSTALLED (DAMPENER)

DAMPENER ARM IMPROPERLY INDEXED.

Part: RECEIVER — FAILED (COCKPIT)

RMI BAD AND COMPASS CARD NOT FOLLOWING CORRECTLY.

Part: SENSOR — MALFUCNTIONED (FUEL CELL)

TANK UNIT WILL NOT CALIBRATE.

Part: VERTICAL GYRO — CHATTERS (AFCS PITCH)

ROLL CHANNEL CHATTERS IN-FLIGHT.

Part: CVR — FAILED (COCKPIT)

CVR TEST LIGHT WILL NOT ILLUMINATE.

Part: VERTICAL GYRO — MALFUNCTIONED (AFCS PITCH)

VERTICAL GYRO SPINS UP SLOWLY, ADI WILL NOT STAY ERECT.

Part: ACTUATOR — INTERMITTENT (CYCLIC TRIM)

TRIM ACTUATOR SLOW WITH INTERMITTENT OPERATION.

Part: PUMP — FAILED (HYDRAULIC SYS)

O-RING FAILURE ON PLUG ON PUMP HOUSING. SYSTEM LOST OIL AND PRESSURE.

Part: GENERATOR — FAILED (AC SYSTEM)

GENERATOR WILL NOT COME ON-LINE.

Part: GYRO COMPASS — DAMAGED (COCKPIT)

GYRO COMPASS HAS LOOSE HARDWARE IN ASSY.

Part: ACTUATOR — FAILED (CYCLIC TRIM)

CANNOT ADJUST TRIM ACTUATOR TO PROPER SETTINGS.

Part: ARM — MISINSTALLED (VISCOUS DAMPER)

DAMPER ARM IMPROPERLY INSTALLED.

Part: ACTUATOR — NOISY (AFCS)

AFCS ACTUATOR HAS NOISY OPERATION.

Part: RADOME — MISMANUFACTURED (FUSELAGE)

HOLES ON RADOME WILL NOT LINE UP.

Part: TRANSMITTER — ERRATIC (FUEL SYS)

PRESSURE ERRATIC AND FLUCTUATES INTERMITTENTLY.

Part: INDICATOR — ERROR (AIR SPEED)

AIRSPEED INDICATOR FRICTION ERROR.

Part: BEARING — EXCESS WEAR (M/R DRIVE)

BEARING HAS EXCESSIVE WEAR.

Part: BEARING — EXCESS WEAR (M/R DRIVE)

BEARING HAS EXCESSIVE WEAR.

Part: INDICATOR — FAULTY (AIR SPEED)

AIR SPEED NEEDLE DOES NOT RETURN TO ZERO.

Part: INDICATOR — STICKS (ENG OIL)

ENG OIL TEMP AND PRESSURE NEEDLES HAVE STICKY OPERATIONS.

Part: INDICATOR — STICKS (ENG OIL)

INDICATOR PRESSURE NEEDLE INTERMITTENTLY STICKS BETWEEN 100 AND 150.

Part: INDICATOR — MALFUNCTION (COCKPIT HSI)

GS FLAG DOES NOT PULL.

Part: EJECTOR — CRACKED (EXHAUST)

EJECTOR IS CRACKED.

Part: BLADE — TORN (M/R)

M/R BLADE TEAR IN THE UPPER SKIN CENTER AT STA. 118" WITH SOME DEBONDING IN THE REMAINING GLASS.

Part: TIP CAP — UNBONDED (M/R)

TIP CAP HAS TOP INTERNAL DOUBLER UNBONDED BEYOND THE MAXIMUM LIMITS.

Part: AFCS ACTUATOR — FAILED (YAW SLICE)

YAW SLICE SHORTED INTERNALLY, INOPERATIVE.

Part: BLADE — SEPARATION (M/R)

BLADE REACHED TIME FOR EXTENSION. THE LEADING EDGE HAS SEVERAL AREAS OF SEPARATION WITH SOME CHORDWISE CRACKS.

Part: 7000 CDU — DEFECTIVE (LORAN)

SOME LED SEGMENTS IN DISPLAY BURNED OUT. SENT TO NAVIGATION DATA SYSTEMS FOR INSPECTION AND REPAIR.

Part: BLADE — HOLE PLUGGED (T/R)

DRAIN HOLE ON PADDLE "A" PLUGGED UP.

Part: 7000 CDU — MALFUNCTION (COCKPIT)

7000 CDU HAS SEVERAL LED SEGMENTS BAD AND SEVERAL BUTTONS ON KEYPAD STICK.

Part: MODULE — LEAKS (HYD FILTER)

MODULE LEAKS FROM INBOARD FILTER BOWL.

Part: INDICATOR — STICKS (COCKPIT ALT)

INDICATOR INTERMITTENTLY STICKS THROUGHOUT SCALE.

Part: GEARSHAFT — STEP WEAR (SPUR ADAPTER)

ENGINE REMOVED DUE TO CRACKED SCROLL. UPON VISUAL INSPECTION OF COMPRESSOR NOTED THE FOLLOWING: STEP WEAR BEYOND SERVICEABLE LIMITS ON SHAFT AFT SPLINES. INSTALLED A USED SERVICEABLE PART.

Part: BUSHING — WORN (M/R)

BUSHING WORN BEYOND LIMITS. REPLACED WITH SERVICEABLE PARTS.

Part: ANTENNA — DEFECTIVE (COCKPIT LORAN)

LORAN DOES NOT RECEIVE SIGNAL.

Part: PIN — WORN (M/R)

PIN WORN BEYOND LIMITS. REPLACED WITH SERVICEABLE PARTS.

Part: TAPERED WASHERS — WORN (M/R)

TAPERED WASHERWORN BEYOND LIMITS. REPLACED WITH SERVICEABLE PARTS.

Part: 7000 RCU — INOP (LORAN)

LORAN INOPERATIVE. CDU DISPLAY REMAINS BLANK. TIME SINCE REPAIR 0:00.

Part: 7000 RCU — DEFECTIVE (COCKPIT LORAN)

LORAN WILL NOT ACCEPT PROGRAMMING. DISPLAY FAILS CODE 4.

Part: BUSHINGS — WORN (M/R)

BUSHING WORN BEYOND LIMITS. REPLACED WITH SERVICEABLE PARTS.

Part: PINS — WORN (M/R)

PIN WORN BEYOND LIMITS. REPLACED WITH SERVICEABLE PARTS.

Part: BLADE — CRACKED (M/R)

BLADE TRIM TAB CRACKED ON THE LOWER SURFACE.

Part: 7000 CDU — DEFECTIVE (COCKPIT LORAN)

SEVERAL LED SEGMENTS ARE INOPERATIVE.

Part: TIP CAP — CRACKED (M/R)

TIP CAP IS CRACKED. (TIP CAP HAS THE ABRASION STRIP CRACKED AND SEPARATED.

Part: BLADE — CRACKED (M/R)

BLADE IS CRACKED. (BLADE HAS CRACKS IN THE TITANIUM LEADING EDGE AS STATION 167". ALONG WITH SEPARATION AND SECTION LIFTING FROM THE BLADE SURFACE.

Part: ENCODER — INOPERATIVE (COCKPIT ALT)

LIGHT INOPERATIVE. TIME SINCE REPAIR 71:20.

Part: LORAN — DEFECTIVE (COCKPIT)

SEVERAL LED SEGMENTS UNREADABLE.

Part: TIP CAP — CRACKED (M/R)

TIP CAP HAS INTERNAL DOUBLER SEPARATED BEYOND LIMITS AND LEADING EDGE ABRASION STRIP CRACKED AND SEPARATED.

Part: CVR — WONT TEST (COCKPIT)

ONLY GIVES SOLID MONOTONE SOUND DURING TEST.

Part: GEARSHAFT — STEPWEAR (SPUR ADAPTER)

ENGINE REMOVED DUE TO 1750 HOUR INSPECTION. UPON INSPECTION OF COMPRESSOR PARTS NOTED THE FOLLOWING: STEP WEAR BEYOND LIMITS ON SPUR ADAPTER GEARSHAFT AFT SPLINES. NEW PART INSTALLED.

Part: GPS — DEFECTIVE (COCKPIT)

WILL NOT STAY IN AUTO SEQUENCE MODE. WHEN AIRCRAFT IS MOVED, GOES TO HOLD MODE AND STAYS.

Part: 7000 CDU — DEFECTIVE (COCKPIT)

DISPLAY SEGMENTS MISSING.

Part: TIP CAP — CRACKED (M/R)

FIBERGLASS SKIN BROKEN BETWEEN THE INNER AND OUTER DOUBLER ON BOTH SURFACES.

Part: WHEEL — SULFIDATION (1ST STAGE)

ENGINE DISASSEMBLED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULFIDATION ON ALL 1ST STAGE WHEEL BLADES. SCRAPPED 1ST STAGE WHEEL.

Part: WHEEL — SULFIDATION (2ND STAGE)

ENGINE DISASSEMBLED DUE TO TURBINE OVERHAUL. UPON INSPECTION OF TURBINE PARTS NOTED THE FOLLOWING: MINOR SULFIDATION ON OUTER TIP PATH AREAS OF ALL BLADES. SCRAPPED 2ND STAGE WHEEL.

Part: CONTROL UNIT — CORRODED (DC SYS)

CORRODED. REPLACED J1 CONNECTOR P/N MS3470L20-16P, COVER P/N 51530-1055. BENCH CHECK GOOD.

Part: CONNECTOR — DIRTY (FUEL QTY)

FUEL QUANTITY WENT TO ZERO IN FLIGHT. CLEANED CONNECTOR FOR FUEL PROBE.