N902R

ATA 3423

Part: COMPASS — FAILED (ZONE 100) · airframe 8,777 hrs · 15,348 cycles

AIRCRAFT N902R AND CREW WERE FLYING A ROUTINE VERTICAL REPLENISHMENT MISSION IN THE SOUTH PACIFIC OCEAN. WEATHER WAS CLEAR AND 28 DEGREES CELSIUS. A LITTLE OVER ONE HOUR INTO THE FLIGHT THE FLIGHT CREW DECLARED TO THE SHIP THAT THEY COULD SMELL SMOKE IN THE COCKPIT. CREW WAS IMMEDIATELY CLEARED TO LAND. PILOT IN COMMAND LAND THE HELICOPTER ON DECK SAFELY. AFTER AIRCRAFT SHUT DOWN WE PROCEEDED TO OPEN BOTH CABIN DOORS. THE SMOKE SEEMED TO BE COMING FROM TWO LOCATIONS THE TAIL CONE AND BILLOWING UP FROM THE CARGO HOOK COMPARTMENT. AFTER THE AIRCRAFT WAS SHUT DOWN CO-PILOT SAID THEY HAD LOST THE YAW CHANNEL CONTROL AND PILOT SAID THE CONTROL FELT UNUSUAL DURING HIS FINAL APPROACH. UPON FURTHER INVESTIGATION WE DISCOVERED THE #1 COMPASS GYRO CIRCUIT BREAKER HAD POPPED. THIS LEAD US TO OPENING THE COMPARTMENT JUST FORWARD OF THE CARGO HOOK AND DISCOVERED THE COMPASS GYRO SMELLED LIKE ELECTRONICS BURNING AND HAD CHARRED GREASE COMING OUT THE SIDE OF IT. REMOVED DEFECTIVE GYRO AND REPLACED WITH A SERVICEABLE GYRO. PERFORMED BITE CHECK AND GYRO WORKED AS ADVERTISED.

ATA 2420

Part: RELAY — FAILED (ELECTRICAL PANEL) · airframe 8,691 hrs · 15,098 cycles

WHILE ON APPROACH FOR A SLING LOAD PICK THE AIRCRAFT EXPERIENCED A DUAL ALTERNATOR FAILURE. THE NR 2 TRANSFORMER RECTIFIER UNIT WAS INDICATING IT REMAINED ONLINE. THE NR 1 ALTERNATOR DISPLAYED 116 VAC ON ALL PHASES. "ELEC" AND "NAV" LIGHTS ON THE 7 ALPHA PANEL ILLUMINATED. ALL EQUIPMENT ON THE AC BUS BARS AND THE SECONDARY DC BUSES WERE OFF LINE.

ATA 5310

Part: BEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 8,536 hrs · 14,435 cycles

CORROSION FOUND ON NLG WELL BEAM AT FS 3223, WL 0, LT BUTT LINE 310. REPAIRED IAW DWG 13021-2029.

ATA 5345

Part: DOUBLER — CORRODED (ZONE 100) · corrosion level 2 · airframe 8,536 hrs · 14,435 cycles

MOORING RING EXTERNAL DOUBLER RT FUSELAGE FS 6815 FOUND TO BE CORRODED. REPAIRED DOUBLER BY ADDING A REPAIR DOUBLER IAW STS EA 10-2013-124.

ATA 5310

Part: STRUCTURE — CRACKED (ZONE 200) · airframe 8,536 hrs · 14,435 cycles

WHILE PERFORMING P4 INSPECTION, FOUND UPPER DECK STRUCTURE CRACKED IN FOUR PLACES BETWEEN FS 6138 AND 6405, LT SIDE. REPAIRED IAW DWG 13021-2026.

ATA 5330

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 8,536 hrs · 14,435 cycles

CORROSION FOUND RT FUSELAGE SKIN FS 5905 AND 7225. REPAIRED IAW STS EA 10-2013-071.

ATA 5330

Part: SKIN — CORRODED (ZONE 100) · corrosion level 2 · airframe 8,536 hrs · 14,435 cycles

CORROSION FOUND LT FUSELAGE SKIN JUST BELOW CABIN WINDOW BETWEEN FS 6405 AND 6815. REPAIRED IAW STS EA 10-2013-070.

ATA 5310

Part: STRUCTURE — CRACKED (ZONE 200) · corrosion level 2 · airframe 8,536 hrs · 14,435 cycles

WHILE PERFORMING P4 INSPECTION, FOUND UPPER DECK STRUCTURE CRACKED IN THREE PLACES AT FS 6405, RT SIDE, BUTT LINE RBL260. REPAIRED IAW AIRLIFT DWG 13021-2027 AND 13021-2028.

ATA 5312

Part: ANGLE — CORRODED (BULKHEAD) · corrosion level 2 · airframe 8,536 hrs · 14,435 cycles

CORROSION FOUND ON BULKHEAD HORIZONTAL ANGLE FLANGE AT FS 2480. REPAIRED IAW STS EA 10-2013-068.

ATA 5311

Part: FRAME — CORRODED (ZONE 100) · corrosion level 2 · airframe 8,536 hrs · 14,435 cycles

CORROSION FOUND LT FRAME FS 2480, WL 1010 TO 1100 AND WL 1200 TO 1265. REPAIRED IAW STS EA 10-2013-069.

ATA 6320

Part: OIL COOLER — DESTROYED (M/R GEARBOX) · airframe 8,324 hrs · 9,177 cycles

AFTER 1 HOUR AND 40 MINUTES OF INSTRUMENT TRAINING A LOUD NOISE WAS HEARD FROM THE REAR OF THE ACFT AND A SLIGHT VIBRATION WAS FELT BY THE CREW. AFTER A COUPLE OF MINUTES, 1 OF THE MAIN GEAR BOX OIL COOLER FAN BELTS LIGHT ILLUMINATED. AN IMMEDIATE TURN TO THE SHIP WAS MADE AND ABOUT 1 AND ½ NM FROM THE SHIP THE OTHER MAIN GEAR BOX OIL COOLER FAN BELT LIGHT ILLUMINATED. THE MAIN GEAR BOX TEMPERATURE ROSE TO 92 DEGREES C AND PRESSURE REMAINED STEADY. A NORMAL LANDING WAS MADE TO THE DECK OF THE SHIP AND AN IMMEDIATE ENGINE SHUTDOWN WAS MADE. AFTER SHUT DOWN SEVERAL HOLES WERE DISCOVERED IN THE REAR DOG HOUSE COWLING AND ALSO THRU THE CABIN ROOF OF THE ACFT. AFTER INSPECTION, THE MGB OIL COOLER BLOWER, BEARINGS, FAN, COWLING AND TRANSMISSION DECK AND BOTH BELTS WERE FOUND TO BE DAMAGED. BLOWER FAN BLADES WERE FOUND SEPARATED EXTERNAL TO THE BLOWER HSG.