N547AL

Part: BLEED VALVE — FAILED (ENGINE)

DURING OPS FLIGHT CHECK, WHILE ACCELERATING, (CHECK INSTRUMENT LIGHT) ILLUMINATED, THE PILOT IMMEDIATELY REDUCED POWER AND THE COMPRESSOR STALLED. PILOT RETURNED TO BASE AND NOTIFIED MAINTENANCE. THE MECHANIC REMOVED AND REPLACED THE BLEED VALVE AND THE AC WAS RETURNED TO SERVICE UPON COMPLETION OF FUNCTION CHECKS IAW MFG. (K)

Part: PITCH LINK — BINDING (M/R HEAD) · airframe 7,632 hrs

BINDING, ROUGH, AXIAL PLAY BEYOND MAX. REPLACED WITH NEW BY FIELD MAINTENANCE.

Part: BEARING — VIBRATION (TAIL ROTOR) · airframe 7,199 hrs

FAILED VIBRATION CHECK. REPLACED WITH NEW BY FIELD MAINTENANCE.

Part: BEARING — VIBRATION (TAIL ROTOR) · airframe 7,199 hrs

FAILED VIBRATION CHECK. REPLACED WITH NEW BY FIELD MAINTENANCE.

Part: BEARING — WORN (TAIL ROTOR) · airframe 7,199 hrs

FAILED VIBRATION CHECK. REPLACED WITH NEW BY FIELD MAINTENANCE.

Part: BEARING — DEFECTIVE (T/R DRIVE) · airframe 6,756 hrs

HBMV FAULT LIGHT NR 2 BEARING (AFT) REMOVED AND REPLACED WITH NEW PART.

Part: BEARING — DAMAGED (T/R DRIVE) · airframe 6,770 hrs

FOUND GREASE DISCOLORATION ON NR 2 BEARING HBVM LIGHT.

Part: CHANNEL — CRACKED (FUSELAGE) · airframe 6,497 hrs

CHANNEL CRACKED LOWER EDGE AND MIDDLE DZUS RECEPTICALES AREA. PROBABLE CAUSE IS ASB407-02-54. REC. DOUBLERS AT RECEPTICALE AREAS.

Part: SUPPORT — CRACKED (FUSELAGE) · airframe 6,497 hrs

SUPPORT CRACKED AT DZUS RECEPTICALES. PROBABLE CAUSE IS ASB407-02-54. REC. DOUBLERS AT RECEPTICALE AREAS.

Part: CHANNEL — CRACKED (FUSELAGE) · airframe 6,497 hrs

CHANNEL CRACKED LOWER EDGE AND MIDDLE CHANNEL. PROBABLE CAUSE IS ASB407-02-54. REC. DOUBLERS AT RECEPTICALE AREAS.

Part: PINION GEAR — GALLED (GEARBOX) · airframe 6,362 hrs

ENGINE REMOVED DUE TO METAL IN OIL. CAUSE FOUND TO BE GALLING ON PINION GER TEETH. REMOVED AND REPLACED PINION GEAR.

Part: PINION GEAR — WORN (ACCESSORY G/B) · airframe 6,098 hrs

FOUND PINION GEARS SHOWING HEAVY WEAR ON DRIVE SIDE. THIS IS A REOCCURRING EVENT.

Part: UNIVERSAL — WORN (MAIN ROTOR) · airframe 5,842 hrs

FOUND BEARINGS WORN. BEARINGS HAS A 5000 HR. RETIREMENT LIFE.

Part: BEARING — FAILED (T/R DRIVESHAFT)

DURING CRUISE FLIGHT THE PILOT FELT A SEVERE VIBRATION IN THE AIRFRAME AND PERFORMED A PRECAUTIONARY LANDING ON A NEARBY PLATFORM. FORWARD BEARING ON NR 2 TAILROTOR DRIVESHAFT BLOWER ASSEMBLY FAILED.

Part: LINK — CORRODED (SWASHPLATE)

IN SHOP REPAIR, EXCESSIVE CORROSION AROUND BUSHINGS AND UNDER BUSHINGS. BETTER ALLOYS, BETTER PRIMER AND SURFACE TREATMENT RECOMMENDED.

Part: DISC PACK — CRACKED (TAIL ROTOR)

DURING 25 HOUR AD INSPECTION, THE COUPLING IS CRACKED, PROBABLE CAUSE IS EXCESSIVE RIGIDITY IN THE BEARING MOUNT SYSTEM. ALLOW TAILROTOR DRIVESHAFT TO FLOAT SO DISC PACKS DO NOT FLEX AS MUCH OR AS OFTEN. (M)

Part: DISC PACK — CRACKED (TAIL ROTOR)

DURING 25 HOUR AD INSPECTION FOUND DISC PACK CRACKED. RECOMMENDATION TO PREVENT RECURRENCE: ALLOW TAIL ROTOR DRIVE TO FLOAT SO DISC PACKS DO NOT FLEX AS MUCH OR AS OFTEN.

Part: HOUSING — MISMANUFACTURED (COMPRESSOR)

DEFECT FOUND WHEN OLD COATING WAS REMOVED. FOUND THICKNESS OF PARENT METAL BELOW SPECS (PART WAS MANUFACTURED BELOW MINIMUM SPECS).

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND CRACKED BLOWER HOUSING.

Part: DISC PACK — CRACKED (T/R DRVIE)

DURING 25-HOUR AD INSPECTION, FOUND AFT DISC IN PACK CRACKED IN HALF.

Part: SKIN — CRACKED (TAILBOOM)

AFTER FINAL FLIGHT OF THE DAY DURING POST-FLIGHT INSPECTION, A CRACK IN THE TAILBOOM, PN 407-030-801-101, SN 53239, TT: 1,621.3 HOURS, WAS FOUND. THE CRACK INITITATED FROM THE FORWARD EDGE OF THE HORIZONTAL STABILIZER MOUNT AREA. THE TAILBOOM IS CURRENTLY HELD AT THE AIR LOGISTICS, LLC FACILITY IN NEW IBERIA, LA.

Part: SKIN — CRACKED (TAILBOOM)

DURING A POST-FLIGHT INSPECTION, FOUND CRACK IN TAILBOOM SKIN AT FORWARD EDGE OF HORIZONTAL STABILIZER MOUNT AREA ON LEFT HAND SIDE.

Part: DISC PACK — CRACKED (T/R DRIVE)

DISCOVERED DURING 25-HOUR AD 97-24-17, PARAGRAPHS A, B, AND E. FOUND NR 7 DISC PACK CRACKED. NR 1 DISC CRACKED FORWARD DISC OF NR 7 DISC PACK.

Part: ANGLE — CRACKED (HORIZ STABILIZER)

DURING DAILY INSPECTION, FOUND CRACK IN BEND RADIUS.

Part: GEAR — GALLED (GEARBOX)

ENGINE MADE CHIP LIGHT. UPON DISASSSEMBLY AND INSPECTION OF PARTS, FOUND EXCESSIVE GALLING ON PINION GEAR AND T/M GEAR. PINION GEAR HAS EXCESSIVE GALLING ON GEAR TEETH, POSSIBLY DUE TO IMPROPER MESHING OF T/M AND PINION GEARS. SECONDARY DAMAGE: T/M GEAR P/N 6893673 S/N NN144782. TT: 963.3 HOURS. GALLING ON GEAR TEETH.

Part: BOLT — LOOSE (BLEED VALVE)

BLEED VALVE WAS SET UP ON TEST BENCH AND A RE-ALIGNMENT OF 90 DEGREE ELBOW WAS NEEDED TO INSTALL TEST ORIFICE AND JUMPER TUBE AND NOTICED THAT UPON SLIGHT TENSION, BOLT WHICH WAS SAFTIED, MOVED. THESE BOLTS HAVE A 30 TO 35 INCH/POUND TORQUE ATTACHED AND UPON FAILURE FOR TORQUING CORRECTLY, THIS CAUSES EXCESSIVE AIR LEAKAGE ON LEAK TEST.

Part: DISC — CRACKED (T/R)

SCHEDULED INSPECTION FOUND NR 7 SHAFT DISC PACK CRACKED.

Part: DISC — CRACKED (T/R)

SCHEDULED INSPECTION FOUND DISC PACK CRACKED.

Part: DISC PACK — CRACKED (AFT SHORT SHAFT)

DURING DAILY INSPECTION, NR 3 DISC PACK P/N 406-040-340-101 FOUND CRACKED - LOCATED FORWARD END OF AFT SHORT SHAFT P/N 407-040-325-101. NUMBER OF DISCS IN PACK, 10 EACH. NR 10 DISC WAS CRACKED. CRACK WAS LOCATED IN CENTER OF 2 BOLT HOLES.