HELICOPTER CONSULTANTS OF MAUI, LLC.

ENGINE CHIP EVENT - INTERMITTENT ILLUMINATION OF ENGINE CHIP INDICATION DURING CRUISE FLIGHT AFTER MAKING A TURN. DURING DESCENT AND LANDING AT A LOCAL BALL FIELD, THE CHIP LIGHT FLICKERED MULTIPLE TIMES. MAINTENANCE DISPATCHED FROM HONOLULU AND INSPECTED THE CHIP DETECTOR WITH NO CHIPS PRESENT. CLEANED DETECTOR AND CONNECTOR, INSPECTED ASSOCIATED WIRING AND RETURNED TO SERVICE AFTER GROUND RUN AND OPS CHECK FLIGHT. NO FURTHER INDICATIONS. RETURNED TO BASE AND ORDERED A DETECTOR AND CONNECTOR AS A PRECAUTION.

WHILE HOVER TAXIING THE AIRCRAFT DURING CHECK FLIGHTS, THE PILOT REPORTED A FUEL P LIGHT AND TURNED THE AIRCRAFT AROUND TO RETURN TO THE RAMP. DURING THE FLIGHT BACK, THE PILOT WAS ALERTED TO AN AMBER GOV LIGHT AND NOTICED THAT THE AIRCRAFT WAS LOSING POWER. THE PILOT SAFELY LANDED THE AIRCRAFT BETWEEN THE TAXIWAY AND THE RAMP FROM AN ALTITUDE OF THREE TO FIVE FEET AND SHUTDOWN THE AIRCRAFT UTILIZING NORMAL PROCEDURES. DURING INSPECTION TO DETERMINE PROBABLE CAUSE, IT WAS DISCOVERED THAT THE FUEL CELL'S RIGID INTERNAL FUEL SUPPLY LINE WAS KINKED/BENT IN TWO PLACES.

DURING A TOUR FLIGHT, SMOKE WAS SEEN IN THE COCKPIT AND A BURNING SMELL WAS NOTED. THE AIRCRAFT RETURNED TO THE AIRPORT WITHOUT INCIDENT. AFTER SHUTDOWN, IT WAS DISCOVERED THAT THE AIR CONDITIONING COMPRESSOR BELT HAD SHREDDED. THE AIR CONDITIONING BELT AND A/C OOMPRESSOR WERE REPLACED AND NO FURTHER ISSUES FOUND

DURING A TOUR FLIGHT FIRE LIGHT ILLUMINATED AND PILOT PERFORMED A PRECAUTIONARY LANDING. UPON INSPECTION OF FIRE DETECTION SYSTEM, FOUND LOOSE WIRE TO LOWER FIRE DETECTOR. WIRE WAS ADJUSTED AND RE-SECURED TO FIRE DETECTOR AND NO FURTHER PROBLEMS WERE FOUND.

DURING A TOUR FLIGHT, THE FIRE LIGHT ILLUMINATED IN FLIGHT AND THE PILOT PERFORMED A PRECAUTIONARY LANDING IN A FIELD. UPON INSPECTION OF THE FIRE DETECTION SYSTEM, WATER WAS FOUND IN THE CONNECTOR PLUG ON THE ENGINE DECK. WATER WAS REMOVED AND NO FURTHER PROBLEMS FOUND

PILOT REPORTED FOUL ODOR AND THEN LIGHT SMOKE IN THE CABIN. ONCE DETERMINED NO OTHER ANOMALIES, PERFORMED A PRECAUTIONARY LANDING WITH NO FURTHER ISSUES. MECHANIC ARRIVED AND DETERMINED THE SMOKE ORIGINATED IN FORWARD CABIN AIR CONDITIONING VENTS. AFTER DISASSEMBLY THE FORWARD EVAPORATOR MOTOR WAS NOTICED TO HAVE SMOKE STAINS. AT BASE THE MOTOR WAS REMOVED AND FINAL DETERMINATION WAS MADE THAT IT WAS THE FAILED PART. THE UNIT WAS REPLACED.

PILOT WAS CONDUCTING A HELICOPTER TOUR FLIGHT ON THE BIG ISLAND, AT APPROX 1325 HOURS THE PILOT HEARD A LOUD ELEC BUZZING SOUND IN HIS HEADSET THAT MADE THE RADIO COMMUNICATIONS VERY DIFFICULT, PILOT ALSO NOTICED A MOMENTARY INTERMITTENT ILLUMINATION OF THE ENG FIRE WARNING LIGHT ON THE CAUTION WARNING PANEL. THE PILOT PERFORMED A PRECAUTIONARY LANDING, ANOTHER ACFT WAS DISPATCHED TO TAKE MX TO THE SITE & TO PICK UP THE PAXS. UPON INSPECTION, IT WAS VERIFIED THAT NO ENG FIRE EXISTED. THE FIRE DETECTION SYS WAS INSPECTED, ELEC CONNECTIONS CLEANED & NO DEFECTS FOUND. FURTHER INSPECTION REVEALED THAT THE 30 ALPHA CONTROL PANEL WAS DEFECTIVE, CAUSING THE LOUD BUZZING NOISE IN THE COMMUNICATION RADIOS, WHEN THE NR 1 INSTRUMENT LIGHT SWITCH WAS IN THE ON POSITION, THIS DEFECTIVE 30 ALPHA BOARD ALSO WAS DETERMINED TO BE CAUSING THE INTERMITTENT ILLUMINATION OF THE FIRE ENG LIGHT. THIS 30 ALPHA CONTROL BOARD ALSO CONTAINS THE WARNING LIGHT TEST FOR THE FIRE DETECTION SYS. A NEW 30 ALPHA CONTROL BOARD PN 350A61256703 WAS INSTALLED. NOTE THIS 30 ALPHA PCB IS AN ON CONDITION PART.

THE DIGITAL NR READING WAS FLUCTUATING IN FLIGHT. AFTER TROUBLESHOOTING OF THE NR PICKUP ON THE NR GAUGE, IT WAS DECIDED TO INSPECT THE PHONIC WHEEL FOR SECURITY. UPON REMOVAL OF THE EPICYCLIC, IT WAS FOUND THAT SIX ATTACHMENT BOLTS, 2 WERE TORQUED TO 100 IN LBS & 4 WERE AT 20 IN LBS, 195 IN LBS IS BOOK TORQUE. UPON INSPECTION OF THE PHONIC WHEEL IT WAS DETERMINED THAT IT WAS SPINNING DUE TO LOSS OF TORQUE ON THE BOLTS, WHICH WAS DUE TO THE GRAPH OIL COATING DETERIORATING FROM THE MATING SURFACES OF THE PHONIC WHEEL, EPICYCLIC & MAST CONTACT SURFACES. REPLACEMENT OF THE PHONIC WHEEL HAS FIXED THE NR FLUCTUATING READING.

DURING A DAILY INSPECTION IT WAS NOTICED THAT THE LEFT HAND SERVO INPUT LEVER HAD LATERAL PLAY. UPON REMOVING THE COVER, IT APPEARS THAT THE SHIM UNDER THE BEARING ASSEMBLY WAS COMING OUT OF THE BORE.

DURING AN INSPECTION FOUND A CRACK APPROXIMATELY SEVEN INCHES LONG ON THE TAILBOOM JUNCTION RING FRAME. THIS CRACK IS LOCATED ON THE FWD SIDE OF THE JUNCTION RING FRAME & RUNS ALONG THE RADIUS OF THE RING FRAME WEB & THE FWD FLANGE. ACFT WAS IMMEDIATELY GROUNDED FOR TAILBOOM CHANGE. OTHER ACFT OF SAME MODEL IMMEDIATELY INSPECTED & NO OTHER CRACKS FOUND.

DURING FLIGHT, ENGINE CHIP LIGHT ILLUMINATED AND PILOT MADE A PRECAUTIONARY LANDING. MECHANIC INSPECTED ENGINE CHIP PLUGS. A SIGNIFICANT AMOUNT OF METAL WAS FOUND ON THE ELECTRIC PLUG, MODULE 01 CHIP PLUG AND THE ENGINE OIL TANK CHIP PLUG. IT WAS DETERMINED TO CHANGE THE ENGINE IN THE FIELD.

ACFT DEPARTED. APPROX 10 MINUTE INTO FLIGHT, PILOT NOTICED SMALL ELECTRICAL PROBLEMS SUCH AS A SCRATCHY INTERCOM AND VOLUME CHANGING. NOTICED RADIO, GPS, VIDEO SCREEN AND AIR CONDITIONING SYS GO OFF LINE. DID NOT NOTICE A GENERATOR LIGHT AT THIS TIME. RETURNING TO BASE NOTICED GENERATOR LIGHT AND TRIED TO RESET IT UNSUCCESSFULLY. ELECTED TO DO A PRECAUITIONARY LANDING WITHOUT INCIDENT. MX REPLACED THE BATTERY, STARTER GENERATOR AND SWAPPED THE K1 AND K2 RELAYS. LANDING AFTER OPS FLIGHT, GENERATOR LIGHT ILLUMINATED AGAIN. AFTER TROUBLESHOOTING THE ENTIRE ELECTRICAL SYSTEM, IT WAS DETERMINED THAT A BAD SPLICE IN THE TERMINAL "A" WIRE WAS SHORTING OUT CAUSING THE GENERATOR TO GO OFF LINE.

DURING A TOUR FLIGHT WITH 6 PASSENGERS AND THE PILOT ON BOARD, THE ACFT LEFT THE HELIPAD AND 10 MINUTES INTO FLIGHT, THE AMBER "GOV" LIGHT ILLUMINATED ON THE CAUTION PANEL. THE PILOT RETURNED TO THE HELIPORT WITHOUT INCIDENT. THE ACFT WAS SHUTDOWN NORMALLY. THE TROUBLESHOOTING CODE ON THE MX PAGE WAS 122. MX REPLACED THE COLLECTIVE POTENTIOMETER ASSY.

DURING CRUISE FLIGHT, ENGINE "CHIP" WARNING LIGHT ILLUMINATED. PILOT MADE A PRECAUTIONARY LANDING. UPON INSPECTION OF THE ENGINE MAGNETIC AND ELECTRICAL CHIP PLUGS, SUBSTANTIAL AMOUNTS OF "MAGNETIC" METAL WAS FOUND ON THE MODULE 1 (ENGINE ACCESSORY GEARBOX) AND OIL TANK MAGNETIC PLUGS AND ON THE FULL FLOW ELECTRICAL CHIP DETECTOR, METAL DETERMINED TO BE "LEVEL C" FLAKES AND SPLINTERS IAW MM, ENGINE REMOVED "ON SIGHT" ENGINE OIL COOLER REPLACED AND ALL OIL SYS HOSES AND OIL TANK CLEANED, SERVICABLE ENGINE INSTALLED IAW MM, RECOVERED METAL PARTICLES SENT TO LAB FOR ANALYSIS. ENGINE AND OR EFFECTED ENGINE MODULES SENT TO MFG FOR INSPECTION & REPAIR. NOTE: THIS ENGINE HAD NO PRIOR CHIP LIGHT EVENTS, METAL PARTICLES FOUND ON ENGINE OIL SYS MAG PLUGS OR CHIP PLUGS, ALL OIL ANALYSIS SAMPLES HAVE BEEN NORMAL PRIOR TO THIS EVENT.

ACFT LEFT AIRPORT ON A TOUR FLIGHT AT 1:31PM, APPROX 20 MINUTES INTO THE FLIGHT, PILOT SMELLED A "BURNED" TYPE ELECTRICAL SMELL IN THE CABIN. PILOT RETURNED TO BASE AT AIRPORT AND MADE A NORMAL LANDING. MX INSPECTED THE ACFT AND FOUND THAT THE 7 INCH CONDENSOR (ELECTRICAL) BLOWER MOTOR FOR THE AIR CONDITIONING SYSTEM WAS DEFECTIVE AND THE CONDENSOR MOTOR CIRCUIT BREAKER WAS POPPED IN THE AIR CONDITIONING CONTROL BOX. THE DEFECTIVE AIR CONDITIONING SYSTEM CONDENSOR BLOWER MOTOR WAS REMOVED AND REPLACED WITH A NEW BLOWER MOTOR AND THE AIR CONDITIONING CONTROL BOX WAS ALSO REPLACED WITH A SERVICEABLE UNIT AS A PRECAUTIONARY MEASURE. NO FURTHER DEFECTS FOUND. AIR CONDITIONING SYSTEM INSTALLED ON THIS ACFT (STC SH3509SW).

10 MINUTES INTO A TOUR FLIGHT, HYD LIGHT ILLUMINATED. PILOT RETURNED TO BASE, WHERE THE HYD LIGHT WENT OUT PRIOR TO LANDING. RT HYD PRESSURE SWITCH WAS CHANGED. THE RT PRESSURE SWITCH WAS CHOSEN DUE TO THE FACT THAT THE RT HYD MANIFOLD INCLUDING THE PRESSURE SWITCH WERE CHANGED 15.4 HRS EARLIER.

AT APPROXIMATELY 1.5 HOURS INTO A TOUR FLIGHT, THE PILOT NOTICED THAT LANE 1 AND LANE 2 OF THE VEMD WERE BLANK. THE PILOT ATTEMPTED TO REST THE VEMD AND IT DID NOT RESET. THE PILOT LANDED AT THE HELIPORT WITHOUT INTERRUPTING HIS TOUR. THE VEMD WAS CHANGED AND THERE WERE NO FURTHER PROBLEMS WITH THE VEMD.

ACFT DEPARTED AIRPORT ON A SIGHT SEEING FLIGHT AT 11:54 AM, SHORTLY BEFORE RETURNING, AT APPROX 12:40 PM AT 1,000 FT AGL THE ENGINE "CHIP" LIGHT ILLUMINATED, THE PILOT REDUCED POWER AND WITHIN 4 TO 5 SECONDS ADDITIONAL CAUTION LIGHTS ILLUMINATED AND THE AURAL WARNING ACTIVATED. PILOT REPORTED ENGINE POWER LOSS AND PROCEDED TO EXECUTE A "POWER OFF" AUTOROTATION LANDING AT APPROX 3/4 OF A MILE FROM AIRPORT WITH NO FURTHER INCIDENT. NO INJURIES OCCURRED TO PILOT OR PASSENGERS. MX WAS DISPATCHED TO SIGHT. INSP REVEALED EXCESSIVE METAL ON THE MODULE 1 ACCESSORY GB MAGNETIC PLUG, THE ENG ELECTRICAL CHIP PLUG AND SMALL AMOUNTS OF METAL ON MODULE 5 MAGNETIC PLUG AND OIL TANK MAG PLUG. INSPECTIONS ALSO REVEALED THAT THE FREE TURBINE AND AXIAL COMPRESSOR ROTATED FREELY BY HAND AND THE ENG OIL LEVEL WAS NORMAL. FURTHER INVESTIGATION REVEALED THAT WHEN THE AXIAL COMPRESSOR WAS ROTATED THE STARTER GEN AND ACCESSORY DRIVES WERE NOT ROTATING, INDICATING A POSSIBLE INTERNAL FAILURE OF THE MODULE 1 ACCESSORY GB. (TSO 1318.1 AT TIME OF INCIDENT.

ACFT DEPARTED AIRPORT ON A TOUR FLIGHT AT APPROX 3:20 PM, WHILE FLYING AT 2500 FT, APPROX 100 KNOTS IAS A BIRD STRUCK THE CENTER WINDSHIELD OF THE ACFT, SHATTERING THE UPPER SECTION OF THE WINDSHIELD, THE DEAD BIRD CAME INTO THE CABIN. THE PILOT IMMEDIATELY SLOWED DOWN AND PROCEDED TO THE AIRPORT AND MADE A PRECAUTIONARY LANDING. NO SERIOUS INJURIES OCCURRED. MX PERFORMED A DETAILED CHECK OFTHE ACFT, CABIN STRUCTURE AND OTHER WINDSHIELDS, NO FURTHER DEFECTS FOUND. THE DAMAGED WINDOW WAS REMOVED AND REPLACED IAW MFG MM. (K)

AC DEPARTED AIRPORT ON A SIGHT SEEING FLIGHT AFTER APPROX 20 MINUTES INTO THE FLIGHT THE PILOT OBSERVED A FLICKERING ENGINE CHIP LIGHT, THEN A SOLID ENGINE CHIP LIGHT. THE PILOT PERFORMED A PRECAUTIONARY LANDING. AN ADDITIONAL AC WAS DISPATCHED (WITH MAINT) TO PICK UP THE PASSENGERS AND CREW. MAINT INSPECTED ALL ENGINE CHIP PLUGS AND THE ENGINE OIL FILTER. A VERY SMALL METAL SLIVER (HAIR SIZE) WAS FOUND ON THE FULL FLOW CHIP DETECTOR, NO OTHER DEFECTS FOUND. PERFORMED MAINT ACTIONS IAW TEC. MM 71-02-07 LEVEL A. PERFORMED OPERATIONAL CHECK FLIGHT, AND RE-INSPECTED DETECTORS AGAIN, NO PARTICLES FOUND. NOTE: RECENT OIL ANALYSIS RESULTS WERE ALL NORMAL, NO FURTHER DEFECTS FOUND. REF: TEC MM 71-02-07. NOTE; 100 HR INSP WAS PERFORMED 3.0 HRS PREVIOUS TO THIS EVENT, IT IS POSSIBLE THAT THIS METAL SLIVER CAME FROM CHIP DETECTOR DURING INSPECTION.

APPROX 45 MINUTES INTO A TOUR FLIGHT, THE (ENGINE CHIP) WARNING LIGHT ILLUMINATED. PILOT PERFORMED A PRECAUTIONARY LANDING. MAINT DISPATCHED (ON SIGHT) INSP. REVEALED MANY METAL CHIPS ON THE MODULE 1 AND OIL TANK MAG PLUGS AND FULL FLOW ELECTRICAL CHIP DETECTOR. OIL FILTER CONTAMINATED WITH METAL PARTICLES. ENGINE REMOVED AND REPLACED (ON SIGHT) ENGINE OIL COOLER REPLACED, ALL OIL LINES CLEANED AND FLUSHED. PAST OIL ANALYSIS RESULTS NORMAL, NO HISTORY OF CHIP LIGHTS ETC. SINCE LAST O/H. METAL SENT TO LAB TO BE ANALYZED. SUSPECT ACCY GEARBOX OR MODULE 2 BEARING CAUSING METAL GENERATION.

APPROX 1 HR AFTER TAKEOFF ON A TOUR FLIGHT, THE ENGINE CHIP LIGHT ILLUMINATED. THE PILOT MADE A PRECAUTIONARY LANDING. UPON INSPECTION BY MAINT, NO METAL WAS FOUND ON THE ENGINE ELECTRICAL CHIP PLUGS OR ON THE ENGINE MAGNETIC PLUGS. SMALL CARBON DEPOSIT WAS EVIDENT ON FULL FLOW PLUG. C/W GROUND RUNS AND HOVER CHECKS AND AC MAINT FLIGHT PERFORMED. UPON ARRIVAL AT AIRPORT. DURING MAINTENANCE CHECK FLIGHT CHIP LIGHT ILLUMINATED AGAIN. INSPECTION BY MAINTENANCE REVEALED NO METAL CHIPS ON ANY ELECTRICAL PLUGS OR MAGNETIC PLUGS, OIL FILTER INSPECTED AND NO METAL FOUND. FURTHER INVESTIGATION REVEALED FAULTY CHIP DETECTOR WAS THE CAUSE, ELECTRICAL CHIP DETECTOR REPLACED AND NO FURTHER PROBLEMS EVIDENT. (K)

SHORTLY AFTER TAKEOFF OF A TOUR FLIGHT, AT APPROX 9:40 AM, THE PILOT NOTICED THE ENGINE NG SPEED HUNTING AND THE TORQUE FLUCTUATING (LESS THAN 20 PERCENT), THE AC ALSO EXHIBITED SLIGHT YAWING IN CONJUNCTION WITH THE FLUCTUATING NG AND TORQUE. THE PILOT PERFORMED A LOW POWER PRECAUTIONARY LANDING AT AIRPORT. INSPECTION BY MAINTENANCE REVEALED NO DEFECTS WITH THE FCU RIGGING OR WITH THE FUEL FILTERING AND FUEL DELIVERY SYSTEM. A CHECK OF THE FCU WAS FOUND TO BE DEFECTIVE (THE FCU CHARACTERISTICS CHECKS FAILED). THE DEFECTIVE FCU WAS REMOVED AND SERVICEABLE UNIT INSTALLED. NO FURTHER DEFECTS HAVE OCCURRED. (K)

AT APPROX 8000 FT ALTITUDE AT CRUISE FLT, NOTICED 2 MINOR KICKS & SLIGHT YAWS APPROX 30 SECONDS APART, REVIEWED INSTRUMENTS AND GAUGES, NOTHING ABNORMAL DETECTED. FLT CONTINUED, AT 1 HOUR INTO CRUISE FLT, APPROX 100 KNOTS AIRSPEED, AC EXPERIENCED A SUBSTANTIAL YAW NOSE TO THE RT, THEN LOW ROTOR AUDIO WARNING (SOLID TONE) ACTIVATED, PILOT VERIFIED THAT ROTOR RPM HAD DETERIORATED AND WAS BELOW 360 NR AND DECREASING, PILOT ALSO OBSERVED THAT A YELLOW WARNING LIGHT HAD ILLUMINATED (POSSIBLY THE AMBER (GOV) LIGHT (NOT CONFIRMED) ON WARNING PANEL, PILOT ENTERED AN AUTOROTATION AND AFTER APPROX 8 SECONDS RECOVERED ROTOR RPM INTO NORMAL RANGE. PILOT CONTINUED WITH AUTOROTATION AND WHEN APPROACHING HIS SELECTED LANDING SIGHT HE OBSERVED AN OBSTRUCTION IN THE LANDING SIGHT, HE THEN PULLED IN MORE COLLECTIVE AND AT THAT TIME HE NOTICED THAT HE HAD RECOVERED ENGINE POWER TO MAIN ROTOR, PILOT EXTENDED HIS GLIDE PATH AND PROCEEDED WITH A (LOW POWER) PRECAUTIONARY LANDING. AFTER LANDING AND PRIOR TO SHUTDOWN IT WAS NOTED BY PILOT THAT (NO) CAUTION OR WARNING LIGHTS WERE ILLUMINATED. A NORMAL SHUTDOWN WAS PERFORMED. AFTER SHUTDOWN FLIGHT REPORT REVEALED (NO) FAILURES, FAULT CODES OR EXCEEDENCES HAD OCCURRED. RECORDED FLT NR WAS 771. A THROUGH INSPECTION OF FADEC WIRING HARNESS, FUEL AND FUEL SYSTEM, ENGINE AND RELATED CONTROLS WERE PERFORMED BY MAINTENANCE PERSONNEL, NO ABNORMAL DEFECTS WERE FOUND. AIRCRAFT AND ENGINE WAS GROUND RAN AND ALL PARAMETERS FOUND NORMAL A OPERATIONAL HOVER CHECK WAS PERFORMED AND FOUND SATISFACTORY, A OPERATIONAL FLIGHT CHECK WAS PERFORMED AND FOUND SATISFACTORY. MAINT SUSPECTS POSSIBLE ECU INTERNAL FAULT OR POSSIBLE HMU FAULT (DELTA P), NOTE: EBCAU DID NOT ENGAGE DURING THIS OCCURRENCE. MAINTENANCE R & R ECU & HMU. REMOVED ITEMS SENT TO THE MFG FOR ANALYSIS AND INVESTIGATION FOR POSSIBLE DEFECTS RELATING TO THIS OCCURRENCE. OPERATOR STRONGLY SUGGESTS MFG EVALUATE POSSIBLE FAILURES OF THIS NATURE AND EVALUATE POSSIBILITY OF APPROVING PILOT ACTIVATED EBCAU PROCEDURES IN CERTAIN EMERGENCY SITUATIONS. MFG SHOULD EVALUATE INSTALLING A REDUNDANT SAFETY SYS (SUCH AS A PROHIBITING RE-INJECTION PRESSURE SWITCH, OR SIMILAR SYSTEM) TO ELIMINATE POSSIBILITY OF START FUEL SYS BEING (RE-ENERGIZED) DURING NORMAL FLIGHT OPERATIONS, THIS SCENARIO COULD LEAD TO A DECELERATION OF ENGINE AND POSSIBLE FLAMEOUT. FADEC WOULD NOT DETECT THIS TYPE OF DEFECT AS A FAILURE AND WOULD THEREFORE NOT RECORD A FAULT OR ENERGIZE EBCAU. (K)

SHORTLY AFTER TAKEOFF OF A TOUR FLIGHT FROM AIRPORT, THE (ENGINE CHIP) WARNING LIGHT ILLUMINATED. PILOT PERFORMED A PRECAUTIONARY LANDING. INSP REVEALED 1 SMALL METAL SLIVER FOUND ON THE ENGINE FULL FLOW ELECTRICAL CHIP DETECTOR, ALL OTHER ENG DETECTORS INSPECTED, NO FURTHER PARTICLES FOUND. PERFORMED MAINTENANCE ACTIONS IAW MM 71-02-07, LEVEL A, NO PARTICLES FOUND. PERFORMED OPERATIONAL CHECK FLIGHT, AND REINSPECTED DETECTORS AGAIN, NO PARTICLES FOUND. NOTE: ENGINE INSTALLED 11-15-06 AFTER REPAIR. ENGINE TIME SINCE REPAIR AT INCIDENT 88.1 HOURS. OIL ANALYSIS ON 12-11-06 NORMAL, OIL ANALYSIS ON 12-29-2006 NORMAL. NO FURTHER DEFECTS FOUND. (K)

COKING ON INJECTION MANIFOLD LABRYNITH SEAL TO INJECTION WHEEL. CAUSED NG SECTION LOCKUP AFTER SHUTDOWN, PRIOR TO START UP. FUEL SAMPLES AND DELIVERY SYSTEM UNDER INSPECTION AND PARTS SENT FOR EVALUATION. THIS PROBLEM ISOLATED TO AC OPERATIONS. (K)

COKING ON INJECTION MANIFOLD LABRYNITH SEAL TO INJECTION WHEEL. CAUSED NG SECTION LOCKUP AFTER SHUTDOWN, PRIOR TO START UP. FUEL SAMPLES AND DELIVERY SYSTEM UNDER INSPECTION AND PARTS SENT FOR EVALUATION. THIS PROBLEM ISOLATED TO AIRCRAFT OPERATIONS. (K)

COKING ON INJECTION MANIFOLD LABRYNITH SEAL TO INJECTION WHEEL. CAUSED NG SECTION LOCK UP AFTER SHUTDOWN, PRIOR TO START UP. FUEL SAMPLES AND DELIVERY SYSTEM UNDER INSPECTION AND PARTS SENT FOR EVALUATION. THIS PROBLEM ISOLATED TO AIRCRAFT OPERATIONS. (K)

AC MADE PRECAUTIONARY LANDING OFF AIRPORT DUE TO LOSS OF OIL PRESSURE INDICATION. LANDING WAS UNEVENTFUL. NO INJURIES, NO AIRCRAFT OR PROPERTY DAMAGE. MAINT DETERMINED THAT THE OIL PRESSURE TRANSMITTER HAD A POOR ELECTRICAL CONNECTION. CONNECTOR WAS CLEANED AND REINSTALLED. OIL PRESSURE INDICATING SYS WAS CHECKED BY GROUND RUNNING ENGINE. GROUND RUN CHECKS PROVED GOOD. AIRCRAFT RETURNED TO MAINTENANCE BASE EMPTY AND RETURNED TO SERVICE. NORMAL LIGHT ENVIRONMENTAL CORROSION ON ELECTRICAL PIN CONTACT POINTS. REMOVED AND REPLACED CONNECTOR ITSELF, REESTABLISHED A GOOD ELECTRICAL CONNECTION PATHWAY. PLUG WAS REMOVED AND REPLACED SEVERAL TIMES TO ASSURE POSITIVE CONNECTION POINTS. (K)

PRECAUTIONARY LANDING, DEVIATION FROM INTENDED ROUTE OF FLIGHT, DUE TO ENGINE OIL CHIP LIGHT ANNUNCIATION. UNEVENTFUL LANDING AT DEPARTURE AIRPORT. NO INJURIES, NO DAMAGE TO AIRCRAFT OR PROPERTY. MAINTENANCE INVESTIGATED AND FOUND NO CHIPS ON THE CHIP DETECTOR. SOME CHIPS FOUND IN OIL AND IN VACINITY OF CHIP DETECTOR PLUGS. ENGINE WAS REMOVED FROM SERVICE FOR REPAIR TEARDOWN INSPECTION. DETERIORATION OF AN INTERNAL OIL WETTED ENGINE COMPARTMENT. CHIP LIGHT MAY HAVE BEEN TRIGGERED BY NON-FERROUS CHIPS CIRCULATING IN THE OIL SYSTEM FROM A DETERIORATING INTERNAL COMPONENT, TBD AT TEARDOWN. LOCATION: ITO HILO HI. (K)

LANDING DUE TO ENG OIL CHIP LIGHT IN FLIGHT. UNEVENTFUL LANDING NO DAMAGE TO AC OR PROPERTY. MAINT FOUND 1 SMALL HAIR LIKE DARK CHIP. PLUG WAS CLEANED, AND ENG WAS TEST RUN FOR 10 MIN. ENG RUN DOWN TIME WAS CHECKED, CKD NORMAL. NO ADDITIONAL CHIPS FOUND. AC WAS FLOWN BACK TO MAINT EMPTY. CHIP PLUG WAS REINSPECTED, ONE VERY SMALL CHIP WAS NOTED THERE AS WELL. ENG OIL WAS DRAINED, STRAINED AND OIL FILTER WAS INSPECTED FOR CHIPS. REPLACED OIL AND FILTER, GROUND RUN FOR 10 MINUTES, CKD CHIP PLUGS, NO CHIPS NOTED. AC OPS FLT PERFORMED AFTER FILTER CHANGE, AC TEST FLOWN. PLUGS WERE PULLED, INSPECTED, NO CHIPS NOTED. FALSE INDICATION BECAUSE CHIP DETECTORS INABILITY TO DIFFERENTIATE 1 VS MANY CHIPS. (K)

AIRCRAFT MADE-AIRPORT PRECAUTIONARY LANDING DUE TO 3 MOMENTARY ENGINE SURGES ACCOMPANIED BY AN ASSOCIATED LOW NR WARNING HORN. PILOT STATES LANDING WAS NORMAL, AND MADE THE LANDING FOR A PRECAUTIONARY SAFETY CHECK. MAINTENANCE REPLACED SEVERAL COMPONENTS INCLUDING THE HMU, FADEC AND DEECU. IT IS BELIEVED TO BE THE HMU WHICH CAUSED THE SURGE, HOWEVER, THIS IS NOT CONCLUSIVE. SUBSEQUENT FLIGHTS AFTER THE COMPONENT CHANGES PROVED GOOD. (K)

PILOT EXPERIENCED AN ENGINE CHIP LIGHT INDICATION. HE CHOSE TO MAKE LANDING. UPON INVESTIGATION BY THE MECHANIC, A SMALL SILVER OF METAL WAS FOUND. THE PLUG WAS CLEANED. THE SYSTEM WAS FLUSHED AND THE OIL FILTER WAS INSPECTED WITH NO EVIDENCE OF METAL AND REPLACED. FOLLOWING GROUND RUN AFTER MAINTENANCE PRESENTED AN ADDITIONAL ENGINE CHIP LIGHT INDICATION WITH NO EVIDENCE OF METAL. ENGINE CHIP PLUG WIRING HARNESS WAS REPLACED. THE AIRCRAFT WAS GROUND RUN AND FLIGHT CHECKED WITH NO FURTHER INCIDENCE. (K)

WHILE ON A SIGHTSEEING FLIGHT ON THE ISLAND OF HAWAII, THE PILOT EXPERIENCED A MAIN ROTOR GEARBOX CHIP INDICATION. A PRECAUTIONARY LANDING WAS MADE AT THE WAIMEA KOHALA AIRPORT AT APPROX 11:30 AM. INVESTIGATION BY THE MECHANIC FOUND SMALL SLIVERS OF METAL. THE METAL WAS REMOVED. THE AC WAS GROUND RUN WITHOUT FURTHER OCCURRENCE. THE AIRCRAFT WAS THEN RETURNED TO BASE. (K)

DURING STARTUP, THE PILOT NOTICED THAT THE CYCLIC CONTROL WAS STIFF IN THE FORE/AFT POSITION. HE ATTEMPTED TO ADJUST THE FRICTION AND FOUND IT RELEASED. THE CYCLIC CONTROL JUMPED FORWARD. AS HE PULLED BACK, HE FELT THE CONTROL APPEARED TO BE INTERMITTENT AND GRABBING. UPON INSPECTION BY THE MECHANIC, IT WAS FOUND THA THE INPUT LEVER WAS STUCK. IT WAS POSSIBLE TO MOVE THE LEVER WITH EXCESSIVE FORCE THE AIRFRAME MFG IS INVESTIGATING THE MATTER.

ON MARCH 20, 2004 WHILE ON A SIGHTSEEING FLIGHT, THE PILOT EXPERIENCED AN ENGINE CHIP LIGHT INDICATION. HE MADE A PRECAUTIONARY LANDING AT APPROXIMATELY 12:50 PM. A MECHANIC WAS DISPATCHED TO THE SITE AND INSPECTED ALL CHIP PLUGS. A SMALL SLIVER WAS FOUND AT THE OUTPUT OF THE OIL PUMP. NO FURTHER OCCURENCES WERE NOTED.

ON MARCH 9, 2004 WHILE ON A SIGHT SEEING TRIP, THE PILOT NOTICED A HIGH ENGINE OIL TEMPERATURE INDICATION. HE MADE A PRECAUTIONARY LANDING. A MECHANIC WAS FLOWN TO THE SCENE AND REPLACED THE ENGINE OIL TEMPERATURE SENSOR. THE AIRCRAFT WAS FLOWN BACK TO BASE WITHOUT FURTHER INCIDENT.

TEN MINUTES INTO THE FIRST FLIGHT OF THE DAY, A SERIES OF WARNING GONGS WENT OFF IN THE PILOTS HEADSET FOLLOWED BY THE YELLOW (GOV) LIGHT, THE RED (GOV) LIGHT AND THE RED (TWX GRIP) LIGHT ALL BEING ILLUMINATED. THE RED (GOV) LIGHT FLICKERED AND EVENTUALLY WENT OUT. THE PILOT RETURNED TO THE HELIPORT. THE TWIST GRIP WOULD NOT RETARD THE ENGINE SPEED AND THE AIRCRAFT HAD TO BE SHUT DOWN FROM FLIGHT IDLE WITH THE SHUT OFF SWITCH. THIS INDICATES THE AIRCRAFT WAS FLOWN BACK IN THE FULL EMERGENCY (EBCAU) MODE. THE FADEC WAS CHANGED TO CORRECT THE PROBLEM.

WHILE ON A SIGHTSEEING FLIGHT, PILOT EXPERIENCED A MAIN GEARBOX CHIP LIGHT INDICATION. THE PILOT MADE A PRECAUTIONARY LANDING. UPON INSPECTION OF THE MAIN GEARBOX CHIP PLUGS BY MAINTENANCE PERSONNEL, NO METAL WAS FOUND. CLEANED MAGNETIC CHIP PLUGS AND CONNECTORS. OPERATIONAL CHECK AND LEAK CHECK FOUND TO BE SATISFACTORY.

WHILE ON ROUTINE SIGHTSEEING TRIP, THE PILOT EXPERIENCED A FLICKERING GENERATOR FAILURE WARNING LIGHT WHILE TAKING OFF FROM THE AIRPORT. CONTINUED FLIGHT UNTIL RECEIVED A STEADY GENERATOR FAILURE WARNING LIGHT. RETURN TOT AIRPORT. UPON INSPECTION BY MAINTENANCE PERSONNEL IT WAS DETERMINED THAT THERE WAS A FAILURE OF THE REX-K1 GENERATION EXCITATION RELAY LOCATED IN THE MASTER ELECTRICAL BOX. THE RELAY AND THE BATTERY WERE REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. NO RECOMMENDATIONS TO PREVENT RECURRENCE OF THIS RELAY FAILURE.

PILOT EXPERIENCED A RATTLING NOISE IN THE FORWARD PORTION OF THE CABIN DURING HIS SIGHTSEEING FLIGHT. THE PILOT ELECTED TO MAKE A PRECAUTIONARY LANDING, A MECHANIC WAS DISPATCHED TO THE SCENE AND DETERMINED THE PROBLEM TO BE A FAULTY FORWARD AIR CONDITIONING BLOWER MOTOR. THE MAINTENANCE ITEM WAS DEFERRED IAW APPROVED MINIMUM EQUIPMENT LIST AND THE AIRCRAFT WAS FLOWN BACK TO BASE FOR REPAIR. PROBABLE CAUSE WILL BE DETERMINED AT OVERHAUL. INCREASED INSPECTIONS WILL PREVENT RECURRENCE.

TAILBOOM SKIN NOT PROPER THICKNESS.

TAIL ROTOR BLADE CRACKED.

DURING A ROUTINE 100 HOUR INSPECTION IT WAS NOTED THAT THE ELECTRODE WAS MISSING FROM THE IGNITER PLUG. FURTHER INVESTIGATION REVEALED THAT IT HAD CAUSED DAMAGE TO THE NG NR 1 BLADE WHEN IT BROKE LOOSE AND SEPARATED FROM THE IGNITER. FURTHER ANALYSIS IS REQUIRED TO DETERMINE ACTUAL CAUSE OF THE FAILURE.

PART IS WORN BEYOND LIMITS.

PART IS WORN BEYOND LIMITS.

PART IS WORN BEYOND LIMITS.

PART IS WORN BEYOND LIMITS.

PART IS WORN BEYOND LIMITS.

PART IS WORN BEYOND LIMITS.