N5402T

Part: BATTERY — WEAK (MASTER) · airframe 22,207 hrs

LOW VOLTAGE. REPLACED BATTERY. ATTEMPTED TO CHARGE BATTERY BUT IT WOULDN'T TAKE A CHARGE.

Part: DISC PACK — CRACKED (MAIN ROTOR) · airframe 21,352 hrs

NR 1 ENGINE, MAIN ROTOR DRIVE SHAFT HAD 10 CRACKED DISCS ON FORWARD DISC PACK. DISC PACKS WERE REPLACED ON BOTH ENDS OF DRIVESHAFT. THE ENGINE TO TRANSMISSION DRIVESHAFT ALIGNMENT WAS CHECKED AND FOUND TO BE WITHIN LIMITS. A VIBRATION CHECK WAS RUN ON THE TRANSMISSION INPUT SECTIONS AND FOUND TO BE OK.

Part: DISC PACK — CRACKED (MAIN ROTOR) · airframe 19,581 hrs

DISC PACK IS CRACKED. DISC PACK WAS FOUND CRACKED IN EIGHT PLACES DURING SCHEDULED INSPECTION. PART WAS REPLACED.

Part: FUEL CONTROL — MALFUNCTIONED (NR 1 ENGINE) · airframe 12,214 hrs

ENGINE WENT TO 40.6 PERCENT N1 UPON LANDING. REPLACED FUEL CONTROL.

Part: FITTING — CRACKED (COLLECTIVE STICK)

FITTING, PILOTS COLLECTIVE STK IS CRACKED. VERIFIED CRACK WITH NDT. REPLACED FITTING. (X)

Part: METERING VALVE — ERODED (FUEL NOZZLE)

PART IS ERODED AT METER SET CAUSING STREAKING AND VOIDS IN THE SPRAY PATTERN. (X)

Part: SCREEN — DAMAGED (INTAKE)

BROKEN WIRES IN SCREEN. REPLACED SCREEN WITH LIKE ITEM. (X)

Part: POTENTIOMETER — FAILED (ELECTRICAL)

FEEDBACK POTENTIOMETER PREMATURE FAILURE. SUBMITTER STATED SHOULD LAST UNTIL OVERHAUL TIME OF 3,000 HOURS. CAUSED ACTUATOR TO KICK IN-FLIGHT. COMPONENT P/N 7690001802106.

Part: POTENTIOMETER — FAILED (AFCS)

FEEDBACK POTENTIOMETER EXPERIENCED PREMATURE FAILURE. SUBMITTER STATED POTENTIOMETER SHOULD LAST UNTIL OVERHAUL, 3,000 HOURS. COMP P/N 76900-01802-106.

Part: POTENTIOMETER — FAILED (AFCS)

FEEDBACK POTENTIOMETER HAD PREMATURE FAILURE, SUBMITTER STATED SHOULD LAST UNTIL OVERHAUL TIME OF 3,000 HOURS. CAUSES ACTUATOR TO KICK IN-FLIGHT. COMP P/N 76900-01802-106.

Part: BLADE — CRACKED (MAIN ROTOR)

CRACKED SPAR AT ROOT END. REPLACED MAIN ROTOR BLADE. (X)

Part: BLADE — DEFECTIVE (TAIL ROTOR)

TAIL ROTOR BLADE ASSY WAS REPAIRED BY SIKORSKY JUST 422.4 HOURS AGO. PAINT AND EROSION STRIP NEEDS TO BE REWORKED.

Part: GOVERNOR — MALFUNCTION (ENGINE)

UNRESPONSIVE AT HIGH TORQUE RANGES. SHAFT RATCHETY AND STIFF. REPLACED GOVERNOR.

Part: BLADE — DISBONDED (M/R)

MAIN ROTOR BLADE S/N AC86-00479 HAS AREAS OF DISBOND ON LOWER SIDE SKIN JUST AFT OF TITANIUM LEADING EDGE. FIRST AREA IS 47.50 INCHES OUTBOARD OF ROOT END AND IS APPROXIMATELY 13 INCHES BY 1 INCH. SECOND AREA IS 201 INCHES OUTBOARD OF ROOT END AND APPROXIMATELY 8 INCHES BY 1 INCH.

Part: BLADE — DISBONDED (M/R)

MAIN ROTOR BLADE S/N A086-00655 HAS AREA OF DISBOND ON UPPER SIDE SKIN JUST OUTBOARD OF THE ROOT END LAMINATE APPROXIMATELY 6 INCHES BY 6 INCHES AT A PREVIOUS REPAIR C/W BY SIKORSKEY 20.50 INCHES OUTBOARD FROM ROOT END APPROXIMATELY 2 INCHES FORWARD OF TRAILING EDGE.

Part: RETAIN WASHER — LOOSE (T/R)

TAIL ROTOR PITCH BEAM WAS FOUND LOOSE ON PITCH SHAFT WITH .1250 INCH GAP BETWEEN WASHER-RETAINER AND NUT. INSPECTION REVEALED PITCH BEAM NUT WAS BOTTOMING OUT ON PITCH SHAFT, PREVENTING PITCH BEAM AND WASHER FROM SEATING. THE PITCH SHAFT HAD 80 HOURS SINCE INSTALLATION WITH TAIL GEARBOX. (NUT WAS PROPERLY TORQUED). REPLACED PITCH SHAFT ASSY, PITCH BEAM AND WASHER-RETAINER.

Part: PITCH BEAM — LOOSE (T/R)

TAIL ROTOR PITCH BEAM WAS FOUND LOOSE ON PITCH SHAFT, WITH .1250 INCH GAP BETWEEN WASHER-RETAINER AND NUT. INSPECTION REVEALED PITCH BEAM NUT WAS BOTTOMING OUT ON PITCH SHAFT, PREVENTING PITCH BEAM AND WASHER FROM SEATING. THE PITCH SHAFT HAD 80 HOURS SINCE INSTALLATION WITH TAIL GEARBOX (NUT WAS PROPERLY TORQUED). REPLACED PITCH SHAFT ASSY, PITCH BEAM, AND WASHER-RETAINER.

Part: PITCH SHAFT — LOOSE (T/R)

TAIL ROTOR PITCH BEAM WAS FOUND LOOSE ON PITCH SHAFT WITH .1250 INCH GAP BETWEEN WASHER AND NUT. INSPECTION REVEALED PITCH BEAM NUT WAS BOTTOMING OUT ON PITCH SHAFT, PREVENTING PITCH BEAM AND WASHER-RETAINER FROM SEATING. THE PITCH SHAFT HAD 80 HOURS SINCE INSTALLATION WITH TAIL ROTOR. GEARBOX, PITCH SHAFT, PITCH BEAM, AND WASHER-RETAINER ARE WORN (NUT WAS PROPERLY TORQUED). REPLACED PITCH SHAFT ASSY, PITCH BEAM, AND WASHER-RETAINER.