N5447C

Part: WARNING LIGHT — ILLUMINATED (M/R TRANSMISSION) · airframe 26,710 hrs

MAIN TRANSMISSION CHIP LIGHT ILLUMINATED INBOUND TO VENICE. NO SECONDARY INDICATIONS NOTED.

Part: GEARBOX — MAKING METAL (MAIN ROTOR) · airframe 26,696 hrs

(AC2R) APPROX 2 MILES FROM LANDING, THE MAIN GEARBOX CHIP LIGHT ILLUMINATED. PERFORMED THE MAIN GEARBOX CAUTION LIGHT ILLUMINATED EMERGENCY PROCEDURE AND LANDED. MX FOUND 1 FLAKE ON PLUG, PERFORMED A SERVICEABILITY CHECK AND RETURNED ACFT TO SERVICE. RECHECK OF CHIP PLUGS IN 3 TO 8 HOURS.

Part: WARNING LIGHT — ILLUMINATED (NR 2 ENGINE) · airframe 26,552 hrs

NR 2 ENGINE CHIP LIGHT ILLUMINATED INBD TO BASE. FOLLOWED EMERGENCY PROCEDURES CHECKLIST, PLACED NR 2 ENGINE LEVER TO IDLE AND LANDED AS SOON AS PRACTICAL. ENGINE LEVER PLACED TO FLIGHT FOR LANDING AND RETURNED TO IDLE AFTER LANDING.

Part: BOLT — CORRODED (MAIN ROTOR) · airframe 24,091 hrs

NEW BOLTS HAVE A PIT IN THE SHANK OFF THE BOLT.

Part: COUPLING — CRACKED (TAIL ROTOR DRIVE) · airframe 22,735 hrs

COUPLING WAS FOUND CRACKED ON 110 HR, AIRFRAME INSPECTION.

Part: FLEX COUPLING — CRACKED · airframe 22,434 hrs

DISCOVERED CRACKED COUPLING DURING 50 HOUR INSPECTION. INSTALLED NEW COUPLING.

Part: LATCH — BROKEN (NACELLE DOOR) · airframe 19,252 hrs

RT FWD ENGINE COWL LATCH FAILED IN FLIGHT. UPON LANDING IT WAS DISCOVERED THAT THE COWLING HAD LIFTED 2 INCHES ON RIGHT HAND SIDE. THE LATCH HOOK ON THE FWD. LATCH WAS COMPLETELY MISSING AND THE AFT LATCH WAS CLOSED BUT NOT HOOKED TO THE AIRFRAME FITTING. FWD. LATCH HOOK WAS REPAIRED.

Part: SEAL — LEAKING (ENGINE)

ENGINE STARTED LEAKING OIL AFTER OIL FLOW CHECK. REPLACED SEAL

Part: CONTROL CABLE — DAMAGED (THROTTLE)

AFTER LANDING ON SS169C, MOVED ENGINE THROTTLES TO GROUND IDLE WHILE LOADING AND UNLOADING PASSENGERS. WHEN THROTTLES MOVED BACK TO FLY, NR 2 THROTTLE MADE A NOTICEABLE CLICK AT THE FULL OPEN POSITION AND TRAVEL FURTHER FORWARD IN THE QUADRANT. PULLED THROTTLE BACK SLIGHTLY, RPM RESPONDED. RETURNED THROTTLE TO FULL OPEN. CAREFULLY LIFTED TO A HOVER AND POWER SEEMED NORMAL. UPON TAKEOFF, NR 2 ENG WOULD NOT PRODUCE MORE THAN 75 PERCENT TORQUE WHILE NR 1 WOULD INCREASE TO 100 PERCENT. WHEN COLLECTIVE REDUCED, NR 2 ENG REMAINED AT 75 PERCENT TORQUE. RETURNED TO ICY, MADE A SLOW RUN-ON LANDING. WHEN NR 2 ENGINE LEVER RETARDED TO IDLE, WORKED NORMAL, HOWEVER ENGINE RPM WOULD NOT GO BACK TO FLY WHEN ADVANCED.

Part: METER — CORRODED (FUEL NOZZLE)

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

Part: PINION GEAR — SPALLED (ENGINE GEARBOX)

ENGINE REMOVED FOR METAL IN OIL. UPON DISASSEMBLY OF GEARBOX, HELICAL POWER TRAIN PINION GEAR PN 6893672 WAS FOUND TO HAVE SPALLING ON GEAR TEETH. HELICAL TORQUEMETER GEAR ALSO HAD SPALLING ON GEAR TEETH. BOTH PARTS WERE REJECTED DUE TO SPALLING. PINION GEAR FAILED AT LOW TOTAL TIME IN SERVICE. 632.5 HRS. TORQUEMETER GEAR HAD 5,000 PLUS HRS IN SERVICE. ENGINE REPLACED. (X)

Part: SCROLL — DAMAGED (COMPRESSOR)

ENGINE WOULD NOT PASS LIMITING CHECK AS OUTLINED IN SIKORSKY S76 FLIGHT MANUAL. ENG ALSO REPORTED FOR LOW POWER. ENG REMOVED. UPON DISASSEMBLY OF TURBINE, 1ST STAGE TURBINE NOZZLE AND 1ST STAGE TURBINE WHEEL WERE FOUND DAMAGED FROM FOREIGN OBJECT PASSING THROUGH TURBINE. BOTH NOZZLE AND WHEEL WERE REJECTED DUE TO THIS DAMAGE. COMPRESSOR DISASSEMBLED, COMP SCROLL, PN 23072848, WAS FOUND WITH ONE PIECE OF TURNING VANE MISSING, AREA BROKEN AWAY IS .50 INCH ACROSS AND ROUGHLY RECTANGULAR AND THIS MISSING PIECE OF TURNING VANE IS OBJECT THAT DAMAGED TURBINE, LEADING TO LOWER POWER. ENG REPLACED. (X)

Part: FIRE DETECTOR — MALFUNCTIONED (NR 2 ENGINE)

AIRCRAFT DEPARTED ICY ON 135 SERVICE FLIGHT AND APPROX 10 MILES SOUTH OF ICY, NR 2 ENGINE FIRE LIGHT ILLUMINATED AND FIRE WARNING HORN SOUNDED. CANCELLED TONE AND IN ABSENCE OF ANY SECONDARY INDICATIONS, RETURNED TO HELIPORT AND MADE A NORMAL APPROACH. MECHANICS DETERMINED THERE WAS A PROBLEM WITH THE SENSOR SWITCH. REMOVED AND REPLACED FLAME DETECTOR WITH A SERVICEABLE DETECTOR. SYSTEM CHECKED OK. (X)

Part: TURBINE WHEEL — DAMAGED (NR 2 ENGINE)

ACFT''''''''S NR 2 ENG HAD A CHIP LIGHT AFTER LANDING. CHIP PLUGS REMOVED, ENG FOUND MAKING METAL. METAL CLEARED FROM PLUGS, ENG RUN. CHIP LIGHT AGAIN CAME ON. PLUGS CLEANED, ENG RE-STARTED. BEFORE ENG REACHED IDLE RPM, CHIP LIGHT CAME ON. MECH REPORTED ENG VIBRATION. ENG REMOVED. UPON DISASSY, TURB FOUND WITH SECT OF NR 1 TURB SHIELD APPROX ONE INCH SQUARE BROKEN OUT OF AND LODGED BETWEEN VANES OF 1ST STAGE NOZZLE. CRACKING ON NR 1 NOZZLE SHIELD. PLACE OF SHIELD LODGED IN VANES DID NOT APPEAR TO HAVE CONTACTED THE 1ST STAGE TURB WHEEL. 1ST STAGE TURB WHEEL HAD ONE BLADE MISSING. FOREIGN OBJECT DAMAGE ON OTHER 1ST STAGE TURB BLADES, NR 2 TURB NOZZLE WARPED, NR 8 BEARING SPALLING. ENG REMOVED AND REP

Part: POTENTIOMETER — FAILED (AFCS)

FEEDBACK POT PREMATURE FAILURE. SUBMITTER STATED SHOULD LAST UNTIL OVERHAUL TIME OF 3,000 HOURS. CAUSED ACTUATOR TO KICK IN-FLIGHT. COMPONENT PN 7690002802106.

Part: SWITCH — SHORTED (FLOAT)

FLOAT INFLATED PREMATURELY. FOUND SWITCH ROTATING IN CYCLIC, LOOSE INSTALLATION, WIRE FRAYED. NO SHIELDING OVER SOLDER JOINT, CAUSING SHORT. UNSOLDERED CONNECTION, INSTALLED SHIELDING OVER WIRES, RESOLDERED, AND INSTALLED SWITCH SECURELY TO PREVENT TURNING.

Part: EXPLOSIVE LINK — FAILED (FLOATS)

EXPLOSIVE LINK DID NOT ACTIVATE WHEN FLOATS WERE DEPLOYED. HARNESS TEST OK. REPLACED LINK.

Part: NOZZLE SHIELD — DAMAGED (1ST STG TURBINE)

THE NR 2 ENGINE FIRST STAGE TURBINE NOZZLE SHIELD WAS FOUND TO HAVE AN .8750 INCH BY 1.75 INCH SECTION MISSING AT THE 6 O'CLOCK POSITION. THIS DEFECT WAS FOUND DURING A ROUTINE INSPECTION. IT WAS SEEN THROUGH THE FUEL NOZZLE MOUNTING HOLE. AFTER REMOVAL OF PART, ALLISON CEB 72-3208 WAS PERFORMED ON THE PART. THE NOZZLE SHIELD PASSED THE TEST WHICH IS USED TO DETERMINE IF THE NOZZLE WAS MADE OF THE PROPER MATERIAL.