N702AL

Part: COUPLING — DISTORTED (INPUT SHAFT) · airframe 24,042 hrs

IN CRUISE FLIGHT, CREW FELT A SUDDEN HIGH FREQUENCY VIBRATION IN THE AIRFRAME AND HEARD A CORRESPONDING NOISE. NO ABNORMAL COCKPIT INDICATIONS WERE NOTED. CREW PROCEEDED TO LAND AT BASE. UPON INSPECTION, MX FOUND NR1 INPUT DRIVESHAFT FWD COUPLING DISTORTED AND CRACKED. FURTHER INVESTIGATION FOUND NUMEROUS BREAKS IN THE COUPLING LAMINATES.

Part: BATTERY — THERMAL RUNAWAY (MASTER) · airframe 23,510 hrs

DURING APPROACH, NR 1 GENERATOR FAILED AND WOULD NOT RESET. GENERATOR WAS TURNED OFF. ON TOUCHDOWN, ALL ELECTRICAL POWER WAS LOST EXCEPT FOR BATTERY. SMOKE WAS OBSERVED COMING OUT OF THE BOTTOM OF THE ACFT. BATTERY WAS FOUND TO BE IN THERMAL RUNAWAY. MX REMOVED AND REPLACED BATTERY.

Part: SHAFT — SHEARED (STARTER GEN)

DURING CRUISE FLIGHT, GENERATOR CAUTION ILLUMINATED AND WOULD NOT RESET. LANDED ON EI-120 AND NOTIFIED MAINTENANCE. STARTED/GENERATOR SHAFT FOUND SHEARED. REMOVED AND REPLACED STARTER/GENERATOR WITH SERVICEABLE UNIT IAW MM. (K)

Part: AMPLIFIER — MALFUNCTIONED (FIRE DETECTOR)

PRIOR TO TAKEOFF THE PILOT NOTICED NR 1 ENGINE FIRE LIGHT AND TONE ACTIVATED. AFTER SHUTDOWN, PASSENGERS WERE EVACUATED AND THE PILOT AND COPILOT VISUALLY CHECKED ENGINE COMPARTMENTS, NO SIGN OF FIRE WAS DETECTED. MAINTENANCE WAS NOTIFIED. TROUBLESHOOTING REVEALED THAT NR 1 ENGINE FIRE DETECTOR AMPLIFIER HAS MALFUNCTIONED. THE MECHANIC REMOVED AND REPLACED NR 1 ENGINE FIRE DETECTOR AMPLIFIER AND AIRCRAFT RETURNED TO SERVICE. (K)

Part: AMPLIFIER — UNSERVICEABLE (FIRE WARNING)

ON TAKE OFF, IN FLIGHT, THE NR 1 FIRE WARNING LIGHTS AND TONE CAME ON, HAD NO OTHER INDICATION OF FIRE. MAINTENANCE REMOVED CONTROL AMPLIFIER AND INSTALLED SERVICEABLE AMPLIFIER, OPS CHECK WAS GOOD.

Part: AMPLIFIER — INOPERATIVE (NR 1 FIRE WARN)

ON TAKE OFF, IN FLIGHT THE NR 1 FIRE WARNING LIGHTS AND TONE CAME ON, HAD NO OTHER INDICATION OF FIRE. MAINTENANCE REMOVED CONTROL AMPLIFIER AND INSTALLED SERVICEABLE AMPLIFIER, OPS CHECK WAS GOOD.

Part: GEAR — SPALLED (M/R GEARBOX) · airframe 4,948 hrs

FOUND HEAVY SPALLING ACROSS GEAR TEETH OF PTO GEAR.

Part: AMPLIFIER — INOPERATIVE (CARGO BAY)

THE BAGGAGE SMOKE DETECTOR CAUTION LIGHT CAME ON 3 TIMES OVER A TWO MINUTE PERIOD. THERE WAS NO OTHER INDICATION OF FIRE OR SMOKE, WITH THE LIGHT OUT WE LANDED. MAINTENANCE REPLACED SMOKE DETECTOR CONTROL AMPLIFIER AND REPLACED CONNECTOR AT THE SMOKE DETECTOR.

Part: PLUG — DEBONDED (TAIL ROTOR BLADE)

DISCOVERED DURING ROUTINE MAINTENANCE INSPECTION. SPAR ELLIPTICAL PLUG 100 PERCENT DEBONDED. NEW PLUG INSTALLED AT MFG O AND R 12-26-00 AT COMPONENT TOTAL TIME 11978.5.

Part: AMPLIFIER — INOPERATIVE (FIRE DETECTION)

DURING GROUND RUN UP, NR 2 ENGINE FIRE DETECTION ACTIVATED. THE MECHANIC REMOVED AND REPLACED THE NR 2 ENGINE CONTROL AMP AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — CORRODED (CAUTION PANEL)

DURING FLIGHT, NR 2 ENGINE FIRE CAUTION LIGHT ILLUMINATED ALONG WITH TWO LIGHTS ON THE (T) HANDLE. NO OTHER INDICATION THAT FIRE DID EXIST (T PERCENT, N1, N2 NORMAL) THE CAUTION LIGHT EXTINGUISHED AFTER 5 SECONDS AND DID NOT ILLUMINATE FOR THE REMAINDER OF 15 MINUTES OF FLIGHT. UPON LANDING, THE MECHANIC FOUND CORROSION ON NR 2 CAUTION CONNECTOR PLUG, HE CLEANED THE PLUG AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WIRE — BROKEN (SMOKE DETECTOR)

DURING RUN UP, BROKEN WIRE AT CONNECTOR PLUG IN BAGGAGE COMPARTMENT.

Part: BLADE RIB — DEDBONDED (M/R)

DISCOVERED DURING 500 HOUR INSPECTION THAT BLADE TIP RIB WAS DEBONDED.

Part: NOZZLE — CRACKED (OUTER BAND/WEB)

UPON MAJOR REPAIR OF TURBINE, FOUND WEB OF OUTER BAND SEEMS TO HAVE BEEN MACHINED BELOW SPECS AND REPLATED. THIS CAUSED A WEAK SPOT IN FLANGE OF NOZZLE THAT CRACKED AND WENT INTO BOTH BLADE TIP PATHS. NOZZLE IS TO BE SCRAPPED. ASSURE THAT PARENT METAL IS MACHINED BELOW SPECS.

Part: SCAVENGE TUBE — BRACKET BROKEN (GEARBOX)

UPON DISASSEMBLY OF GEARBOX, REMOVED OIL PUMP ASSY AND SCAVENGE TUBE. FOUND ALIGNMENT BRACKET ON SCAVENGE BROKEN.

Part: LINE — LEAKING (XMSN AREA)

IN CRUISE FLIGHT APPROXIMATELY 25 MINUTES AFTER TAKEOFF, NR 1 SERVO SYSTEM CAUTION LIGHT ILLUMINATED. RESET SERVO JAM CIRCUIT BREAKER AND LIGHT EXTINGUISHED. TWO MINUTES LATER, NR 1 SERVO SYSTEM LIGHT ILLUMINATED AGAIN. RESET SERVO JAM CIRCUIT BREAKER AND LIGHT EXTINGUISHED. AIRCRAFT TURNED BACK TO BASE. ONE MINUTE LATER, NR 1 HYDRAULIC SERVO SYSTEM LIGHT ILLUMINATED AGAIN. RESET CIRCUIT BREAKER, BUT LIGHT REMAINED ILLUMINATED. AIRCRAFT LANDED FIRST AVAILABLE PLACE. NR 1 HYDRAULIC SYSTEM WAS FOUND TO REQUIRE SERVICING. SERVICED SYSTEM AND GROUND RAN ACFT. TAIL ROTOR RETURN LINE FOUND LEAKING AT B-NUT. ACFT WAS SHUT DOWN. B-NUT FOUND BACKED OFF. B-NUT TIGHTENED, ACFT GROUND RAN AND LEAK CHECKED OK.

Part: BUSHING — WORN (DAMPER)

DURING SHOP TEAR DOWN FOR REPAIR OF DAMPER DUE TO WEAK OPERATION, FOUND BUSHING ID WORN PAST LIMITS. SUSPECT CAUSE - CONTAMINATED OIL.

Part: BUSHING — WORN (DAMPER)

DURING TEAR DOWN AND INSPECTION FOR REPAIR DUE TO WEAK OPERATION, FOUND BUSHING ID WORN PAST LIMITS. SUSPECT CAUSE - CONTAMINATED OIL.

Part: BUSHING — WORN (DAMPER)

DURING SHOP TEAR DOWN AND INSPECTION FOR REPAIR DUE TO WEAK OPERATION, FOUND BUSHING ID WORN PAST LIMITS. SUSPECT CAUSE - CONTAMINATED OIL.