N163BK

Part: CYCLIC CONTROL — BINDING (CYCLIC STICK) · airframe 10,912 hrs

DURING MX TEST FLIGHT, AFTER COMPLETION OF 3600 HR INSPECTION, COMPLETED GROUND RUN AND HOVER CHECKS. PROCEEDED TO TAKEOFF, AT APPROX 100 FT AGL SLOWLY ACCELERATED ACFT THROUGH ETL, CYCLIC CONTROL LOCKED UP IN THE PITCH AXIS. NOSE OF ACFT CONTINUED TO PITCH UP, AFTER APPLICATION OF A LARGE AMOUNT OF FORCE TO THE CYCLIC, THE CONTROL BROKE FREE. RESUMED CONTROL OF THE ACFT, CIRCLED BACK TO POINT OF DEPARTURE AND LANDED. AT THE POINT THE CYCLIC BROKE FREE HAD MOMENTARY ILLUMINATION OF THE MASTER CAUTION LIGHT, AND PITCH CAUTION LIGHT.

Part: ENGINE — POWER LOSS (NR 1) · airframe 10,778 hrs · 49,298 cycles

ON APPROACH, MASTER CAUTION LIGHT ILLUMINATED WITH A NR 1 ENGINE LOW LIGHT FOLLOWED BY A LARGE TORQUE SPLIT ( NR 1 LOW AT 20 PERCENT AND NR 2 HIGH AT 80 PERCENT ). ABORTED APPROACH AND PROCEEDED TO NEAREST AIRPORT FOR A PRECAUTIONARY LANDING. WHILE ON APPROACH THERE WERE TRANSIENT FLUCTUATIONS OF THE NR AND BOTH THE NR 1 AND NR 2 N2 BETWEEN 102 PERCENT AND 110 PERCENT THAT COULD NOT BE CORRECTED WITH THE TRIM BEEPER. LANDED ACFT WITH POWER ON BOTH ENGINES AND PERFORMED NORMAL SHUTDOWN.

Part: FIREWALL — CRACKED (ENGINE BAY) · airframe 10,108 hrs · 47,586 cycles

CRACK IN FIREWALL AFT MOUNTING HOLE.

Part: SEAL RING — WORN (TURBINE SECTION)

FIRST TURBINE SHROUD SEAL RING WORN BEYOND SERVICE LIMITS. REPLACED WITH NEW UNIT CORRECTED PROBLEM.

Part: SEAL — LEAKING (NR 2 BEARING)

NR 2 BEARING SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SEAL — LEAKING (NR 3 BEARING)

NR 3 BEARING SEAL, LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: BEARING — FAILED (BELLCRANK)

THE AC EXPERIENCED ABNORMAL UNCOMMANDED YAW AND ROLL MOTION ON LANDING. LATERAL CYCLIC BELLCRANK CENTER BEARING FOUND TO HAVE FAILED. THIS CAUSED THE BELLCRANK TO HAVE EXCESSIVE PLAY RESULTING IN LOSS OF POSITIVE CYCLIC CONTROL. AC PERFORMED SUCCESSFUL LANDING WITHOUT DAMAGE, HOWEVER THE LOSS OF CONTROL WAS QUITE SEVERE. AN INSPECTION OF THE BELL CRANK BEARING ON 6/19/2001, FOUND THAT THE BEARINGS WERE MISSING. THE PART MAY HAVE AS MUCH AS 6065 HRS. IT APPEARS THAT THE BALLBEARING INSTALLATION SLOTS MAY HAVE LINED UP AND ALLOWED THE BALLBEARINGS TO BE EJECTED FROM THE BEARING, ONE AT A TIME.

Part: BUSHING — WORN (ACTUATOR)

BUSHINGS WORN BEYOND SERVICEABLE LIMITS AND ALSO LEAKS HYDRAULIC FLUID. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: FUEL NOZZLE — CRACKED (ENGINE)

FUEL NOZZEL CRACKED. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: ROTOR — ERODED (COMPRESSOR)

ROTOR HAS EROSION. PENDING FURTHER INSPECTION . REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: CURL — CRACKED (COMBUST CHAMBER)

CURL CRACKED BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SEAL RING — WORN (TURBINE SHROUD)

WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SEAL — LEAKING (NR 1 BEARING)

LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SEAL — LEAKING (NR 3 BEARING)

LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SEAL — LEAKING (NR 2 BEARING)

LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: CURL — BURNED (COMBUST CHAMBER)

EXCESSIVE BURN IN SOME AREAS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SPRING — WORN (SEAL RING)

WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SLEEVE — WORN (BEARING)

WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SHROUD — DAMAGED (TURBINE ROTOR)

EXCESSIVE GP BLADE TIP RUB. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: IGNITION LEAD — SHORTED (ENGINE) · airframe 5,554 hrs

IGNITION HAD INTERNAL SHORT. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. (X)

Part: SEAL — WORN (1ST TURB SHROUD)

SEAL RING - FIRST TURBINE SHROUD, WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. (X)

Part: SPRING — WORN (SEAL RING)

SPRING - SEAL RING EXPANDER, WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. (X)

Part: MANIFOLD — MALFUNCTIONED (ENGINE FUEL) · airframe 5,525 hrs

FUEL MANIFOLD ASSY CAUSES ENGINE TO RUN HOT. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. (X)

Part: FITTING — CRACKED (VERTICAL FIN)

UPON INSPECTION, NOTICED A CRACK BEHIND UPPER LEFT BOLT HOLE EXTENDING TO RIVET HOLE. (X)

Part: BLADE — DEBONDED (MAIN ROTOR)

LEADING EDGE SKIN UNDER BONDED PV-FILM IN NOSE AREA TO APPROXIMATELY BLADE STA 922 (SECTION 1) IS DEBONDING ON TRAILING EDGE, BOTH UPPER/LOWER SURFACES. (X)

Part: BLADE — DEBONDED (MAIN ROTOR)

LEADING EDGE SKIN UNDER BONDED PV-FILM IN NOSE AREA TO APPROX BLADE STA 922 (SECTION 1) IS DEBONDING ON TRAILING EDGE, BOTH UPPER/LOWER SURFACES. (X)

Part: BLADE — DEBONDED (MAIN ROTOR)

LEADING EDGE SKIN UNDER BONDED PV-FILM IN NOSE AREA TO APPROXIMATELY BLADE STA 922 (SECTION 1) IS DEBONDING ON TRAILING EDGE, BOTH UPPER/LOWER SURFACES. (X)

Part: BLADE — DEBONDED (MAIN ROTOR)

LEADING EDGE SKIN UNDER BONDED PV-FILM IN NOSE AREA TO APPROXIMATELY BLADE STA 922 (SECTION 1) IS DEBONDING ON TRAILING EDGE, BOTH UPPER/LOWER SURFACES. (X)

Part: SEAL — LEAKING (NR 2 BEARING)

SEAL LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: COMBUSTION CHAMB — DAMAGED (ENGINE)

EXCESSIVE BURN IN SOME AREAS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: TUBE — LEAKING (FUEL SYSTEM)

TUBE LEAKING BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: LEAD — WORN (IGNITION S YSTEM)

LEAD WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: TAIL PIPE — WARPED (EXHAUST)

TAIL PIPE HAS EXCESSIVE WARPAGE. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SWITCH — INOPERATIVE (M/R DRIVE)

THERMO SWITCH UNIT INOPERATIVE. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: SENSOR — INOPERATIVE (ENGINE OIL)

SENSOR UNIT INOPERATIVE. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: CONTROL UNIT — FAILED (EXTERNAL LIGHTS)

CONTROL UNIT FOR EXTERNAL LIGHTS HAS INTERNAL SHORT. TRIPPED CIRCUIT BREAKERS UPON INSTALLATION. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: BLADE — DEFECTIVE (T/R)

T/R BLADE PAINT BEGINNING TO PEEL. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: BLADE — DEFECTIVE (T/R)

T/R BLADE PAINT BEGINNING TO PEEL. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: BEARING — WORN (T/R)

BEARING WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS, CORRECTED PROBLEM.