N407WH

Part: HMU — FAULTY (ENGINE)

PILOT DECIDED TO MAKE A PL ON FIRST FLIGHT OF THE DAY DUE TO INCREASING VIBES FROM THE MAIN ROTOR. BLACK SMOKE COMING FROM ENG NO SECONDARY INDICATIONS. THE HMU WAS CHANGED OUT THE NIGHT BEFORE. HMU WAS FRESH OUT OF OVERHAUL FROM STANDARD AERO. MX ARRIVED AND LOOKED OVER THE ACFT. DID NOT FIND ANYTHING VISIBLY WRONG WITH ANY BEARINGS MR HUB SWASH PITCH LINKS BELLCRANKS SERVOS ETC. PERFORMED A GROUND RUN ON THE ACFT AND THE ENG WAS SURGING AND COMPRESSOR WAS POPPING AND STALLING BLACK SMOKE WAS VISIBLE. PILOT PUT ACFT IN MANUAL MODE AND THE SURGING WENT AWAY. BACK IN AUTO THE SURGING STARTED AGAIN. MX PUT ON THE OLD HMU THAT WAS REMOVED THE NIGHT BEFORE BACK INTO THE ACFT. RUN UP OCF COMPLETE WITH NO VIBRATIONS ISSUES. PROBABLE CAUSE IS THAT SOMETHING WAS WRONG WITH THE OVERHAULED HMU INTERNALLY.

Part: HMU — MALFUNCTIONED (ENGINE) · airframe 14,302 hrs

PILOT DECIDED TO MAKE A PL ON FIRST FLIGHT OF THE DAY DUE TO INCREASING VIBES FROM THE MAIN ROTOR. BLACK SMOKE COMING FROM ENGINE, NO OTHER SECONDARY INDICATIONS. THE HMU (HYDROMECHANICAL UNIT) WAS CHANGED OUT THE NIGHT BEFORE. HMU WAS FRESH OUT OF OVERHAUL. MAINTENANCE DID NOT FIND ANYTHING VISIBLY WRONG WITH ANY BEARINGS, M/R HUB, SWASH, PITCH LINKS, BELLCRANKS, SERVOS, ETC. PERFORMED A GROUND RUN ON THE AIRCRAFT AND THE ENGINE WAS SURGING AND COMPRESSOR WAS POPPING AND STALLING, BLACK SMOKE WAS VISIBLE. PILOT PUT AIRCRAFT IN MANUAL MODE AND THE SURGING WENT AWAY. BACK IN AUTO AND THE SURGING STARTED AGAIN. MAINTENANCE INSTALLED THE OLD HMU T. ENGINES RUN UP, OPS CHECK FLIGHT COMPLETE WITH NO VIBRATIONS AND NO SURGING. ALL INDICATIONS NORMAL. REPLACED WITH A NEW HMU.

Part: CHANNEL — CRACKED (FUSELAGE)

DURING ROUTINE SCHEDULED MX, A CRACK WAS FOUND IN THE FUSELAGE AFT UPPER LT CHANNEL PN 206-031-314-145. THE CRACK IS LOCATED WHERE THE CHANNEL & THE AFT UPPER LT LONGERON ARE RIVETED TOGETHER. THE CRACK SPANS THE ENTIRE WIDTH OF THE CHANNEL. PROBABLE CAUSE IS NORMAL WEAR & TEAR.

Part: TRANSMISSION — MAKING METAL (MAIN ROTOR) · airframe 8,014 hrs

TRANSMISSION CHIP LIGHT DURING FLIGHT. PRECAUTIONARY LANDING PREFORMED. MX DISPACHED WITH COMPANY ACFT AND PASSENGERS WERE FLOWN FOR CONTINUATION OF THE FLIGHT. FOUND SMALL METAL PARTICALS ON LOWER CHIP PLUG, CLEANED PLUG PERFORMED PENALTY RUN WITHOUT FURTHER LIGHT OR METAL PARTICALS.

Part: TURBINE WHEEL — FAILED (ENGINE) · airframe 7,320 hrs

TURBINE RUBBING SOUND DETECTED ON SHUTDOWN. TURBINE SECTION REMOVED FROM SERVICE FOR INSPECTION. INSPECTION FOUND NR 1 AND NR 2 TURBINE WHEELS RUBBING DUE TO NR 2 NOZZLE WARPING. BOTH TURBINE WHEELS AND NR 2 NOZZLE UNSERVICEABLE.

Part: INDICATOR — ERRATIC (FUEL PRES.)

REPLACED FUEL PRESSURE INDICATOR WITH NEW FROM BELL HELICOPTER. (X)

Part: BEARING — ROUGH (T/R DRIVESHAFT)

WHILE C/W BELL A3B-407-00-35, FOUND 4 EACH BEARINGS TO BE ROUGH. SUBMITTER STATED THESE WERE NOT THE OIL COOLER BEARINGS AS REFERENCED IN AD 2000-02-12. (X)

Part: BEARING — ROUGH (T/R DRIVESHAFT)

WHILE C/W BELL A3B-407-00-35, FOUND 4 EACH BEARINGS TO BE ROUGH. SUBMITTER STATED THESE WERE NOT THE OIL COOLER BEARINGS AS REFERENCED IN AD 2000-02-12. (X)

Part: BEARING — ROUGH (T/R DRIVESHAFT)

WHILE C/W BELL A3B-407-00-35, FOUND 4 EACH BEARINGS TO BE ROUGH. SUBMITTER STATED THESE WERE NOT THE OIL COOLER BEARINGS AS REFERENCED IN AD 2000-02-12. (X)

Part: BEARING — ROUGH (T/R DRIVESHAFT)

WHILE C/W BELL A3B-407-00-35, FOUND 4 EACH BEARINGS TO BE ROUGH. SUBMITTER STATED THESE WERE NOT THE OIL COOLER BEARINGS AS REFERENCED IN AD 2000-02-12. (X)

Part: INDICATOR — MALFUNCTIONED (ENGINE NG)

NG INDICATOR MALFUNCTIONED. REPLACED WITH NEW INDICATOR FROM BELL HELICOPTER.

Part: SLAT — DAMAGED (HORIZONTAL)

REPLACED WITH NEW SLATS FROM BELL HELICOPTER. C/W BELL ASJ 407-99-32. (X)

Part: SIGNAL COND UNIT — INTERMITTENT (FUEL SYSTEM)

REPLACED WITH NEW FUEL SIGNAL CONDITIONER FROM BELL HELICOPTER. (X)

Part: INDICATOR — FAILED (FUEL QUANTITY)

REPLACED FUEL QUANTITY INDICATOR WITH NEW INDICATOR FROM BELL HELICOPTER DUE TO FAILURE.

Part: SEAL — DAMAGED (FREEWHEEL UNIT)

REPLACED WITH NEW SEAL FROM BELL HELICOPTER. (X)

Part: INDICATOR — MALFUNCTIONED (COCKPIT)

H.A.S. REPLACED WITH NEW FUEL QUANTITY INDICATOR FROM BELL HELICOPTER.