N2743E

Part: RELAY — FAILED (DC SYSTEM)

RELAY INSTALLED ON AIRCRAFT. FOUND TERMINALS 12 AND 13 AND TERMINALS 22 AND 23 HAD NO CONTINUITY IN REST POSITION. WHEN POWER IS APPLIED TO X1 AND X2, THEY HAVE CONTINUITY. FUNCTIONAL CHECKED RELAY AS RECEIVED. CONFIRMED PROBLEM. RELAY WAS INADVERTENTLY WIRED IN REVERSE. HOWEVER, RELAY WAS SCRAPPED DUE TO TWO MOUNTING FLANGES WERE CUT OFF TO FACILITATE EASE OF INSTALLATION.

Part: CONTROL UNIT — FAILED (DC SYSTEM)

DC CONTROL - GROUND FAULT WOULD NOT TEST.

Part: CONTROL UNIT — FAILED (DC SYSTEM)

DC CONTROL WOULD NOT TEST ON START-UP.

Part: OIL COOLER — LEAKING (ENGINE)

OIL COOLER LEAKING.

Part: PUMP — LEAKING (HYDRAULIC SYS)

HYDRAULIC PUMP LEAKS FROM SEAL DRAIN.

Part: BEARING — FAILED (ENGINE)

BEARING FAILURE, FOUND METAL SHAVING ON SEALS AND ROUGH ROTATION. REPLACED WITH SERVICEABLE BEARINGS.

Part: POTENTIOMETER — MALFUNCTIONED (ELECTRICAL)

CAUSED ACTUATOR TO BE INOPERATIVE. INSPECTED BY ACCESSORY OVERHAUL SHOP AND FOUND POTS CAUSED ACTUATOR TO TEST OUT OF LIMITS ON TEST POINTS 9(Q) 3 & 5 (MECHANICAL CENTER OUT OF LIMITS AFTER SETTING ELECTRICAL CENTER) AND STRIP CHART INDICATED BADAREAS IN NULL POSITION.

Part: DETECTOR LOOP — FAILED (ENGINE BAY)

SHORTLY AFTER TAKEOFF, NR 1 ENGINE FIRE LIGHT ILLUMINATED. PILOT DEPLOYED FIRE BOTTLE AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND DEFECTIVE FLAME DETECTOR. REF: S-76 IPC, CHAPTER 26-11-00, FIGURE 1, ITEM 21.

Part: AMPLIFIER — FAILED (DROOP COMP)

NR 1 TORQUE INTERMITTENTLY STICKS WHEN PULLING POWER.

Part: TIP CAP — BROKEN (MAIN ROTOR)

MAIN ROTOR TIP CAP OUTER DOUBLER SEPARATED WITH FIBERGLASS BROKEN BETWEEN THE DOUBLER.

Part: GENERATOR — FAILED (AC GEN SYS)

A/C GEN LIGHT CAME ON IN FLIGHT AND WOULD NOT RESET.

Part: GENERATOR — FAILED (AC GEN SYS)

A/C GENERATOR WOULD NOT COME ON LINE.

Part: GYRO — PRECESSES (PILOT ADI)

PILOTS ADI PRECESSES.

Part: AFCS CONTROL — FAIL TEST (FLT CONTROL)

AFCS CONTROL PANEL FAILED CONTINUITY TEST IN MAINT. MANUAL.

Part: RECEIVER — ERRORS (COCKPIT)

PROVIDING HAZARDOUSLY MISLEADING INFORMATION TO THE FLIGHT CREW IS A MAJOR FAILURE CONDITION FOR THE AIRCRAFT. SINGLE LATENT FAILURES OF CDI DEVIATION OUTPUT WIRES (SHORTED AND/OR OPEN) RESULT IN A NON-FLAGGED AND CENTERED DEVIATION BAR, INDICATINGAN ON-COURSE LOCALIZER OR GLIDE SLOPE WITHOUT THE CAPABILITY OF DETECTING AND FLAGGING THE MALFUNCTION. A COUPLED FLIGHT DIRECTOR/AUTOPILOT WOULD CONTINUE OPERATING UNGUIDED, WITHOUT ALERTING THE COCKPIT CREW! THIS CAN BE HAZARDOUSLY MISLEADING.THIS DEFICIENCY IS COMMON TO MOST IF NOT ALL NAV EQUIPMENT DESIGNED TO ILS CRITERIA,

Part: RECEIVER — ERRORS (COCKPIT VOR/LOC)

PROVIDING HAZARDOUSLY MISLEADING INFORMATION TO THE FLIGHT CREW IS A MAJOR FAILURE CONDITION FOR THE AIRCRAFT. SINGLE LATENT FAILURES OF CDI DEVIATION OUTPUT WIRES (OPEN) RESULT IN A NON-FLAGGED AND CENTERED DEVIATION BAR, INDICATING AN ON-COURSELOCALIZER OR GLIDE SLOPE WITHOUT THE CAPABILITY OF DETECTING AND FLAGGING THE MALFUNCTION. A COUPLED FLIGHT DIRECTOR/AUTOPILOT WOULD CONTINUE OPERATING UNGUIDED, WITHOUT ALERTING THE COCKPIT CREW! THIS CAN BE HAZARDOUSLY MISLEADING.

Part: HEAT EXCHANGER — WELD LEAKS (B NUT LINE)

HEAT EXCHANGER LEAKS AT WELD ALONG OUTER B-NUTLINE.

Part: GENERATOR — FAILED (AC SYS)

A/C BEARING LIGHT CAME ON IN FLIGHT.

Part: FLOOR PANEL — MIS MFG (LT OUTBOARD)

NEW FLOOR DOES NOT HAVE PROPER JOGGLE ON INBOARD AND FORWARD EDGES OF PANEL AS NEEDED TO GO BELOW (-051) LARGE FLOOR.

Part: FLOOR PANEL — MIS REPAIRED (INSERTS)

FLOOR PANEL WAS REPAIRED AND EXISTING INSERTS IN FLOOR PANEL WERE LEFT INSIDE OLD CORE MATERIAL AND NEW TOP SKINS WERE INSTALLED. THE OLD INSERTS INSIDE PANEL MAKE IT IMPOSSIBLE TO INSTALL NEW STYLE INSERTS THAT MUST GO THROUGH TOP ANDBOTTOM SKINS. SENT TO DODS FOR WARRANTY REPAIR. TIME SINCE REPAIR 0:00.

Part: FLOOR PANEL — MIS REPAIRED (INSERTS)

FLOOR PANEL WAS REPAIRED AND EXISTING INSERTS IN FLOOR PANEL WERE LEFT INSIDE OLD CORE MATERIAL AND NEW SKINS WERE INSTALLED. THE OLD INSERTS INSIDE THE PANEL MAKE IT IMPOSSIBLE TO INSTALL NEW STYLE INSERTS THAT MUST GO THROUGH TOP ANDBOTTOM SKINS. TIME SINCE REPAIR 0:00.

Part: TIP CAP — DEFECTIVE (M/R)

TIP CAP HAS FIBERGLASS BROKEN BETWEEN INNER DOUBLER AND OUTER DOUBLER ON THE UPPER SURFACE.

Part: TIP CAP — TEAR (M/R BLADE)

INSPECTED BOTTOM SIDE ON M/R BLUE BLADE TIP CAP AND FOUND TEAR ON TIP CAP. SUSPECT AIR BUBBLE IN PAINT MATERIAL CAUSING TEAR. AIR BUBBLE IS NOTABLE.

Part: BLADE — ERODED (T/R)

PART IS ERODED. (EROSION THROUGH THE LEADING EDGE ABRASION STRIP ON PADDLE "B")

Part: BLADE — ERODED (T/R)

PART IS ERODED. (LEADING EDGE ABRASION STRIP HAS EROSION HOLE THROUGH THE STRIP.

Part: BLADE — CRACKED (M/R)

PART IS CRACKED. SPAR CRACK AT THE TIP. THE CRACK STARTED FROM THE OUTER HOLE FOR THE "C" BLOCK BOLT. SCRAPPED M/R BLADE.

Part: ACTUATOR — DEFECTIVE (AFCS)

AFCS ACTUATOR HAS BAD POTS AND EXCESSIVE SHAFT END PLAY.

Part: CONTROL UNIT — DEFECTIVE (COCKPIT VHF)

CONTROL UNIT VOLUME CONTROL WORKS EITHER FULL VOLUME OR OFF. NO CONTROLLING VOLUME. REPLACED R1/S5 VOLUME SWITCH. REPAIRED. FOUND THUMBWHEEL TO INTERMITTENTLY DIAL WRONG FREQUENCIES. REPLACED S1 THUMBWHEEL. REPAIRED.

Part: MODULE — DEFECTIVE (ROTOR BRAKE)

DURING OPS CHECK, NOTED ROTOR BRAKE MOTOR SOUNDED WEAK BUT SEEMED TO OPERATE NORMALLY. TWO DAYS LATER AIRCRAFT WAS FLOWN FOR FIRST TIME AND PILOT'S REPORTED ROTOR BRAKE DOES NOT WORK. REPLACED WITH SERVICEABLE ROTOR BRAKE MODULE.

Part: LORAN — DEFECTIVE (COCKPIT)

LIGHTS WILL NOT DIM. SENT TO ARNAV SYSTEMS FOR INSPECTION AND REPAIR.

Part: NOZZLE — DEFECTIVE (2ND STAGE)

RECEIVING INSPECTION OF NEW, NEVER INSTALLED 2ND STAGE NOZZLE INDICATES .009" RUNOUT IN BOTH TIP PATHS, DIAPHRAGM OFF CENTER. NOTE: DAMAGE TO KEYS AND TANGS BY ADJUSTMENT PRIOR TO RECEIPT BY PHI. INSTALLED NEW 2ND STAGE NOZZLE.

Part: TRANSCEIVER — INOPERATIVE (COCKPIT)

WOULD NOT RECEIVE.

Part: TRANSCEIVER — MALFUNCTION (RADAR)

UNIT SHUTS DOWN DURING WARM UP PERIOD.