N779LF

Part: UNKNOWN — FUMES (CABIN) · airframe 8,841 hrs

SHORTLY AFTER TAKEOFF STARTED TO SMELL FUMES IN THE CABIN.

Part: SKIN — CRACKED (TAILBOOM) · airframe 5,814 hrs · 17,553 cycles

DURING A SCHEDULED MAINTENANCE EVENT, A CRACK WAS DISCOVERED ON TOP OF THE TAIL BOOM. THIS AIRCRAFT REMAINS OOS AT THE TIME OF THIS SUBMISSION AWAITING THE APPROVED REPAIR.

Part: STIFFENER — CORRODED (COCKPIT) · airframe 5,231 hrs · 15,832 cycles

WHILE REMOVING THE VIBRATION DAMPER UNDER PILOTS SEAT FOUND STIFFENER ASSEMBLY CORRODED THAT THE VIBRATION DAMPER ATTACHES TO.

Part: DRAIN — CLOGGED (NR 1 ENGINE DECK) · airframe 5,146 hrs · 15,597 cycles

DURING ZONE INSPECTIONS, PULLED OFF THE VENT LINE GOING FROM RIGHT SIDE OF THE NR 1 ENGINE TO THE ENGINE DECK. FOUND THAT THE DRAIN COLLECTOR WAS CLOGGED WITH DEBRIS ON THE RIGHT SIDE OF THE Y-FITTING.

Part: BLADE — CRACKED (M/R HEAD) · airframe 2,599 hrs · 8,089 cycles

AFTER REMOVAL OF BLADE FITTINGS FOR NDT, CRACK DETECTED IN GRIP AREA.

Part: BLADE — CRACKED (M/R HEAD) · airframe 2,599 hrs · 8,089 cycles

AFTER REMOVAL OF BLADE FITTINGS FOR NDT, CRACK DETECTED IN GRIP AREA. T

Part: BLADE — CRACKED (M/R HEAD) · airframe 2,599 hrs · 8,089 cycles

AFTER REMOVAL OF BLADE FITTINGS FOR NDT, CRACK DETECTED IN GRIP AREA.

Part: STARTER GEN — MALFUNCTIONED (NR 1 ENGINE) · airframe 2,458 hrs · 7,712 cycles

GENERATOR DISCONNECT LIGHT CAME ON FOR THE NR 1 GENERATOR. LANDED WITHOUT INCIDENT UNDER POWER FROM BOTH ENGINES. SWAPED STARTER/GENERATOR FROM SIDE TO SIDE. FOUND ISSUED FOLLOWED GENERATOR.

Part: ENGINE — MAKING METAL (NR 2) · airframe 2,439 hrs · 7,658 cycles

20 MINUTES INTO FLIGHT, THE NR 2 ENGINE CHIP LIGHT ILLUMINATED. ACTIVATED THE FUZZ BURNER FOR APPROX 1 SECOND AND THE LIGHT EXTINGUISHED. APPROX 1 SECOND LATER THE CHIP LIGHT ILLUMINATED AGAIN. ACTIVATED THE FUZZ BURNER AGAIN AND LIGHT EXTINGUISHED. APPROX 1 SECOND LATER THE LIGHT ILLUMINATED AGAIN. DIVERT AND MONITORED ENGINE TEMPERATURE AND PRESSURE WHICH REMAINED NORMAL. KEPT BOTH ENGINES AT FLY AND LANDED WITHOUT INCIDENT UNDER POWER FROM BOTH ENGINES. MECHANIC INSPECTED CHIP PLUG IAW MM FOUND CHIP TO BE LEVEL A. TOOK OIL SAMPLE, CHANGED OIL FILTER, AND REINSPECTING OIL FILTER IN THE NEXT 25 FLIGHT HOURS.

Part: GEARBOX — MAKING METAL (TAIL ROTOR) · airframe 2,041 hrs · 6,567 cycles

UPON SEVERAL ATTEMPTS TO BALANCE THE TAIL BLADE ASSY, THE MECHANIC HAD NUMEROUS CHIP LIGHT EVENTS. THE LAST INSPECTION OF THE CHIP PLUG FOUND NUMEROUS FLAKES TO DEEM THE TAIL ROTOR GEARBOX AS UNAIRWORTHY. TAIL ROTOR GEARBOX WAS REPLACED AND THE ACFT WAS RETURNED TO SERVICE.

Part: TRANSMISSION — MAKING METAL (ZONE 200) · airframe 1,793 hrs · 5,847 cycles

TRANSMISSION CHIP LIGHT ILLUMINATED IN FLIGHT, THIS WAS THE 4TH CHIP LIGHT EVENT WITHIN THE PREVIOUS SEVERAL MONTHS. PREVIOUS CHIP EVENTS WERE FUZZ REQUIRING NO FURTHER ACTION, CHIP EVENT ON 6/07/11 REQUIRED TRANSMISSION CHANGE IAW AMM 63-41-00 6-2. TRANSMISSION CHANGE IN PROGRESS.

Part: BLADE — DAMAGED (MAIN ROTOR) · airframe 1,741 hrs · 5,709 cycles

DURING THE PILOTS PRE FLIGHT, FOUND THAT THE TRIMMING SURFACE ON THE YELLOW BLADE WAS MISSING. UPON INSPECTION FOUND THE TWO RIVET HOLES, WHERE THE RIVETS HELP HOLD THE TRIMMING SURFACE TO THE BLADE, WAS IN ALMOST PERFECT CONDITION. SENT MAIN ROTOR BLADE TO AMERICAN EUROCOPTER FOR REPIAR.

Part: WIRE HARNESS — CHAFED (OVERHEAD CABIN) · airframe 1,459 hrs · 4,935 cycles

FIRE EXT WARNING LIGHT ILLUMINATED ON CAD DISPLAY. AFTER INSP OF A/C FOUND, CHAFED WIRES. THE WIRE'S WERE LOCATED JUST AFT OF THE CO-PILOT'S SEAT. IN THE CABIN OVERHEAD, JUST INSIDE OF CABIN DOOR AREA. THEY WERE CHAFING AGAINST AN AIR CONDITIONING LINE. THE WIRE'S WERE REPAIR AS REQUIRED, AN TY-WRAP IN SUCH A WAY THE CHAFING AGAINST THE A/C LINES WOULD NOT HAPPEN AGAIN. GROUND FUNCTIONAL CHECKS AS WELL AS A, A/C GROUND RUN CHECK OF THE AFFECTED SYS WAS DONE. NO DEFECT'S WERE NOTED AT THAT TIME.

Part: UNKNOWN — ODOR (COCKPIT) · airframe 1,350 hrs · 4,000 cycles

ENROUTE, CREW NOTICED A STRONG ELECTRICAL BURNING ODOR. A FEW MOMENTS LATER, COULD SMELL THE FUMES. ASKED IF THERE WAS ANY SMOKE OR FIRE. NONE DETECTED. DIVERTED, OPENED PILOT SIDE SLIDING WINDOW FOR FRESH AIR AND WITHIN 10 SECONDS, A STRONG ODOR OF JET FUEL ENTERED CABIN. HEADED FOR AN OPEN PARKING LOT AND LANDED WITHOUT FURTHER INCIDENT. CREW EXITED UPON LANDING TO SECURE THE AREA AROUND ACFT AND COMPLETED NORMAL ENGINE SHUTDOWNS. ACFT INSPECTED BY MECHANIC, FOUND NO OBVIOUS FUEL LEAKAGE OR ELECTRICAL FAILURES. ACFT GROUND RUN, AND OPS CHECK FLIGHT PERFORMED. NO DUPLICATION OF PREVIOUS PROBLEMS NOTED.

Part: ATTACH BRACKET — CRACKED (LANDING LIGHT) · airframe 1,337 hrs · 4,629 cycles

UPON FINAL APPROACH INTO LANDING, CREW NOTICED ONE OF THE LANDING LIGHTS WOBBLEING UNDERNEATH THE ACFT. UPON SHUTDOWN, RT REAR LANDING LIGHT HAD BROKEN FREE FROM ITS MOUNT AND WAS HANGING BY A SINGLE WIRE. MECHANIC CALLED IN TO REPAIR. VISUAL INSP REVEALED RT AFT CROSSTUBE LIGHT ASSY CRACKED. R & R WITH SERVICEABLE UNIT.

Part: TORQUE BOX — MALFUNCTIONED (NR 2 ENGINE) · airframe 1,271 hrs · 4,493 cycles

NR 2 ENGINE TORQUE SYS FAILURE.

Part: FUEL CONTROL — LEAKING (ENGINE) · airframe 3,200 hrs · 8,903 cycles

DURING PREFLIGHT FOUND FUEL DRIPPING FROM DRAIN LINE LOCATED ON LOWER LEFT BELLY OF FUSELAGE, DRAIN LINE COVERED AND DRENCHED WITH JET FUEL, AREA FWD OF DRAIN LINE AROUND CROSS TUBE WET ALSO. FWD EDGE OF SX5 HAS A WET RESIDUE ON IT. FIBERGLASS COVER FOR REMOTE COMPASS SENSOR ON BOTTOM OF TAIL BOOM ALSO HAS A WET RESIDUE STRIKING IT AND RUNNING BACK. AIRCRAFT HAD JUST RETURNED FROM A .9 FLIGHT, FUEL DRENCHED LINE AND RESIDUE ON BOTTOM OF TAIL BOOM APPEARED AFTER A .9 FLIGHT (HOME LEG). FUEL CONTROL DID NOT PASS LEAK CHECK BY MECHANIC. ORDERED FUEL CONTROL.

Part: O-RING — DEFECTIVE (FUEL SYSTEM) · airframe 3,147 hrs · 6,009 cycles

SMELL OF JET FUEL EMITTED FROM HEATER AFTER TAKEOFF. IMMEDIATELY RETURNED TO PLACE OF TAKEOFF. SMELL SEEMED TO GO AWAY AFTER HEATER TURNED OFF. PILOT NOTIFIED MECHANIC OF THE FUEL SMELL IN THE COCKPIT. MECHANIC REMOVED THE DRAIN PLUG FROM THE FUEL INLET LINE TO MOD 3. PILOT GROUND RUNS THE HELICOPTER TO SEE IF FUEL WAS DRAINING FROM THE PLUG. THERE WAS NONE. MECHANIC REINSTALLED THE PLUG IAW TEC SPECS AND REPLACED THE START DRAIN VALVE. THE FUEL SMELL WAS STILL PRESENT DURING RUN UP PROCEDURES. REMOVED THE P2 AIRLINE FROM THE FCU. VERIFIED NO FUEL EXISTED IN THE P2 CHAMBER. THERE WAS EVIDENCE OF FUEL IN THE P2 PORT. DETERMINED THE FCU WAS INDEED SERVICEABLE. MECHANIC REPLACED THE 2 O-RINGS AT THE MOD 3 FUEL INLET, FLUSHED BLEED AIR LINES. GROUND RUNS AND A MOC WERE PERFORMED. THE SMELL OF BURNED FUEL VAPORS WERE GONE.

Part: BATTERY — DISCHARGED (MAIN)

LEAD ACID BATTERY WOULD NOT HOLD CHARGE. UNIT SCRAPPED ON SITE. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: LAMINATED HINGE — WORN (TAIL ROTOR)

ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT FROM ONE EACH KIT P/N 355A33. (X)

Part: HINGE — WORN (TAIL ROTOR)

ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT, CORRECTED PROBLEM.

Part: BEARING — WORN (T/R)

LAMINATED BEARING ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 4 EACH NEW UNITS FROM KIT 355A09-1036-01, CORRECTED PROBLEM.

Part: HINGE — WORN (T/R WHITE)

LAMINATED HINGE ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS FROM KIT 350A33-2153-00, CORRECTED PROBLEM.

Part: LAMINATED HINGE — WORN (T/R GREEN)

LAMINATED HINGE ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS FROM KIT 350A33-2153-00, CORRECTED PROBLEM.

Part: LAMINATED HINGE — WORN (T/R WHITE)

LAMINATED HINGE ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS FROM KIT 350A33-2153-00, CORRECTED PROBLEM.

Part: LAMINATED HINGE — WORN (T/R PINK)

HINGE ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS, FROM KIT 350A33-2153-00 CORRECTED PROBLEM.

Part: LAMINATED HINGE — WORN (T/R YELLOW)

HINGE ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED 2 EACH NEW UNITS FROM KIT 350A33-2153-00, CORRECTED PROBLEM.

Part: HINGE — WORN (T/R)

TAIL ROTOR ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS FROM KIT 350A33-2153-00, CORRECTED PROBLEM.

Part: HINGE — WORN (T/R YELLOW)

LAMINATED HINGE HAS ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS, CORRECTED PROBLEM.

Part: SPHERICAL STOP — WORN (M/R)

ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM.

Part: SPHERICAL STOP — WORN (M/R)

SPHERICAL STOP ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM.

Part: SPHERICAL STOP — WORN (M/R)

SPHERICAL STOP ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH NEW UNIT(S) CORRECTED PROBLEM.

Part: HINGE — WORN (T/R)

LAMINATED HINGE ELASTOMERICS WORN BEYOND SERVICEABLE LIMITS. REPLACED WITH 2 EACH NEW UNITS FROM KIT 350A33-2153-00, CORRECTED PROBLEM.