N703AL

Part: UNKNOWN — UNKNOWN (UNKNOWN) · airframe 16 hrs · 9 cycles

MAINT LIGHT ILLUMINATED ON ROLLOUT. ENG 2 VIBRATION MONITOR. GROUNDED - YES. ON DEFERRAL.

Part: ODOR — DETECTED (COCKPIT)

ON TAKE OFF. JUST AS AIRCRAFT CLEARED HELIPORT DEPARTING EI333; DETECTED ODOR SIMILAR TO OVERHEATED BRAKE OIL OR CLUTCH MATERIAL. HAD NO CAUTION, WARNING OR ADVISORY LIGHTS OR INOP EQUIP, CONTINUED 12 MINUTE FLIGHT TO EI 365. ODOR LINGERED AND BECAME ACRID, LIKE BURNING PLASTIC. AFTER LANDING ON GORILLA VI AT EI 365, 2 PASSENGERS IN THE AFT ROW OF SEATS SAID THEY SAW A LITTLE SMOKE AT THE FWD CABIN CEILING. SHUTDOWN AND CALLED MAINT. THE MECH REMOVED OVERHEAD INTERIOR PANELS AS REQUIRED AND FOUND STRONGEST ELECTRICAL TYPE ODOR COMING FROM ROLL PITCH AND YAW ACTUATOR AREA. NO BURNING SIGNS NOTICED, ALL SYSTEMS NORMAL. AC FLOWN TO BASE, FLIGHT NORMAL, AC RETURNED TO SERVICE.

Part: WARNING LIGHT — FALSE INDICATION (CAUTION PANEL)

PRIOR TO TAKE OFF, DURING THE FLOAT SYSTEM TEST, WHEN THE TEST SWITCH WAS PLACED IN THE TEST POSITION ALL CAUTION LIGHTS ILLUMINATED. (SAME AS PRESSING CAUTION PANEL TEST SWITCH). THE PILOT ALERTED MAINTENANCE, THE MECHANIC REMOVED AND REPLACED THE CAUTION PANEL AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: FIRE DETECTOR — WILL NOT TEST (CARGO BAY)

DURING PREFLIGHT START, AFT BAGGAGE FIRE DETECTION SYSTEM DID NOT TEST. THE MECHANIC REMOVED AND REPLACED THE SMOKE DETECTOR.

Part: RADAR — FAILED (COCKPIT)

IN CRUISE FLIGHT, RADAR WORKING INTERMITTENTLY FOLLOWED BY SMOKE IN THE COCKPIT.

Part: TRIM TAB — DEBONDED (M/R BLADE)

DISCOVERED DURING 500-HOUR INSPECTION, M/R HEAD TRIM TAB DEBONDED. SKIN CRACKED BENEATH TRIM TAB.

Part: FLAME DETECTOR — FAILED (NR 1 ENGINE)

NR 1 ENGINE T-HANDLE FIRE LIGHTS ILLUMINATED INTERMITTENTLY. CHECKED THE CANNON PLUG FOR MOISTURE, FUNCTIONALLY TESTED AND FOUND TO STILL BE INTERMITTENT. REMOVED AND REPLACED NR 1 ENGINE FLAME DETECTOR.

Part: BORE LINER — DISPLACED (RT GEAR OIL JET)

MAIN TRANSMISSION OIL PRESSURE DROPPED TO 30.35 PSI AND REMAINED STEADY. FOUND RT BEVEL GEAR OIL JET BORE LINER BACKED OUT CAUSING OIL LEAKAGE ON TRANSMISSION. REPAIRED RT BEVEL GEAR OIL JET BORE LINER IAW S76 OVERHAUL AND REPAIR INSTRUCTIONS 76350-065 SECTION 2. AIRCRAFT RETURNED TO SERVICE.

Part: TIP CAP — DEBONDED (M/R)

FOUND AT 500-HOUR INSPECTION, INNER CRESCENT DOUBLER DEBONDED UNDER C-CHANNEL. COMPONENT MODEL NR 7615009000049.

Part: TIP CAP — CRACKED (M/R)

DURING 500-HOUR M/R INSPECTION, CRACK FOUND AT HOLE ON UPPER INNER CRESCENT DOUBLER. COMPONENT NR 7615009100051.

Part: VISCOUS DAMPER — DEBONDED (T/R DRIVE)

POST-FLIGHT INSPECTION FOUND DAMPER TUBE DEBONDED BEYOND LIMITS.

Part: BUSHING — WORN (DAMPER)

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

Part: BUSHING — WORN (DAMPER)

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

Part: PISTON ROD — WORN (DAMPER)

DURING SHOP TEAR DOWN FOR REPAIR OF DAMPER ASSY DUE TO WEAK OPERATION, FOUND INBOARD PISTON ROD BUSHING SURFACE WORN PAST LIMITS. SUSPECT WEAR CAUSED BY HYDRAULIC OIL CONTAMINATION.

Part: BEARING — WORN (DAMPER)

DURING SHOP TEAR DOWN FOR REPAIR OF DAMPER DUE TO WEAK OPERATION, FOUND WEAR BETWEEN INNER AND OUTER RACES BEYOND LIMITS. SUSPECT CAUSE - OIL CONTAMINATED.

Part: BEARING CONE — FAILED (INPUT QUILL)

DURING GROUND RUN, INTERMEDIATE GEARGBOX BEARING FAILED. CAUSE UNKNOWN. BEARINGS, INPUT QUILL HOUSING AND INPUT GEAR SENT TO SIKORSKY FOR EVALUATION. CONE PN SB3167101, CUP PN SB3167201.