Jack Harter Helicopters, Inc.

Operated by JACK HARTER HELICOPTERS INC — Rotorcraft external load (133), On-demand air taxi (135), Commercial air tour (136) Operator Does Business As: (per NTSB report)

Maintenance personnel’s noncompliance with maintenance manual procedures that required the removal of the overrunning clutch output bearing during the regreasing procedure, which resulted in inadequate regreasing of the bearing and the subsequent failure of the overrunning clutch assembly.

Sanction: $12,612 · case closed 2015-01-13

Part: BLADE — DENTED (MAIN ROTOR) · airframe 25,471 hrs · 10,810 cycles

AT LANDING PILOT REPORTED MAIN BLADE CONTACT WITH TREE BRANCHES WITH NO CHANGE IN RPM. MECHANIC DETERMINED PER MDHI CSP HMI-2 THAT THERE WAS NO SUDDEN STOPAGE DUE TO NO CHANGE IN ROTOR RPM. MECHANIC INSPECTED AIRCRAFT MAIN ROTOR BLADES FOR DAMAGE AND FOUND SMALL DENTS ON THE BOTOM OF THE YELLOW S/N 733F AND GREEN SN 731F BLADES. MECHANIC MEASURED THE DENTS AND FOUND THEM TO BE IN ACCEPTABLE LIMITS THAT REQUIRE NO REPAIRS AND THE BLADES CAN CONTINUE IN SERVICE.

Part: TRANSMISSION — MAKING METAL (MAIN ROTOR) · airframe 23,428 hrs · 32,431 cycles

PILOT REPORTED INTERMITTENT MAIN GEARBOX CHIP LIGHT DURING APPROACH TO LANDING. MAGNETIC PLUG INSPECTION REVEALED METAL CONTAMINATION BEYOND ACCEPTABLE LIMITS AND TRANSMISSION WAS REMOVED FOR REPAIR.

Part: BLADE — DENTED (TAIL ROTOR)

DURING A POST FLIGHT MAINTENANCE INSPECTION A SMALL DENT WAS DISCOVERED ON THE OUTBOARD FACE OF ONE OF THE AIRCRAFT TAIL ROTOR BLADES. PILOT REPORTED THERE WAS NO INDICATIONS OR NOISE OF ANYTHING STRIKING THE BLADE. THE BLADE DENT WAS FOUND TO BE WITHIN SERVICEABLE LIMITS. TAIL GEARBOX, HORIZONTAL AND VERTICAL FINS, TAILBOOM, AND DRIVSHAFTS AND COUPLINGS INSPECTED PER MDHI SPECIAL INSPECTIONS SECTION. NO DAMAGE NOTED. AIRCRAFT WAS APPROVED FOR RETURN TO SERVICE.

Part: STIFFENER — CRACKED (ZONE 100) · airframe 24,979 hrs · 31,118 cycles

FOUND SMALL CRACK IN LEFT HAND STIFFENER UNDER CABIN FLOOR.

Part: STRUCTURE — CORRODED (ZONE 200) · airframe 24,979 hrs · 31,118 cycles

LIGHT CORROSION DISCOVERED BENEATH COWLING LATCHES ON LEFT AND RIGHT HAND FLOOR EDGING PART NUMBERS 350A21-1359-21 AND 350A21-1359-20

Part: DOOR FRAME — CORRODED (ZONE 200) · airframe 24,979 hrs · 31,118 cycles

LIGHT CORROSION FOUND ON RIGHT AND LEFT HAND AFT DOOR JAMBS.

Part: WEB — CRACKED (ZONE 100) · airframe 24,979 hrs · 31,118 cycles

SMALL CRACK FOUND WEBBING UNDER CABIN FLOOR.

Part: STIFFENER — CRACKED (ZONE 100) · airframe 24,979 hrs · 31,118 cycles

SMALL CRACK FOUND IN STIFFENER UNDER CABIN FLOOR.

Part: RIB — CRACKED (ZONE 100) · airframe 24,979 hrs · 31,118 cycles

SMALL CRACK FOUND IN LEFT HAND RIB UNDER CABINE FLOOR.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 24,979 hrs · 31,118 cycles

LIGHT CORROSION FOUND ON THE CABIN FLOOR UNDER THE PILOT AND COPILOT SEAT RAILS. DURING A 12 YEAR INSPECTION OF THE AIRCRAFT.

Part: SKIN — CORRODED (ZONE 200) · airframe 24,979 hrs · 31,118 cycles

LIGHT CORROSION SPOTS FOUND ON LEFT AND RIGHT HAND FUSELAGAGE SKINS UNDER STAILESS ENGINE DECK. LH SKIN PART NUMBER 350A21-1022-127 AND RIGHT-HAND SKIN PART NUMBER 350A21-1022-128

Part: CANOPY — CRACKED (ZONE 200) · airframe 24,979 hrs · 31,118 cycles

SERVERAL CRACKS FOUND IN FUSELAGE CANOPY ALONG THE INTERIOR LOWER FRAME FOR THE LEFT AND RIGH-HAND WINDOWS.

Part: ENGINE — MAKING METAL (ZONE 100) · airframe 22,049 hrs · 73,276 cycles

PILOT EXPERIENCED AN ENGINE CHIP LIGHT DURING LANDING. ENGINE REMOVED FROM AIRCRAFT FOR FURTHER INVESTIGATION.

Part: ENGINE — MAKING METAL (ZONE 100) · airframe 22,045 hrs · 73,264 cycles

PILOT EXPERIENCED AN ENGINE CHIP INDICATION DURING APPROACH. MAINTENANCE PERFORMED CLEANING AND GROUND RUNS AND RETURNED TO SERVICE.

Part: CLUTCH — MAKING METAL (DRIVE TRAIN) · airframe 24,021 hrs · 21,538 cycles

DURING A SCHEDULED 100 HOUR MAINTENANCE INSPECTION ON THE AIRCRAFT. THE MECHANIC QUESTIONED THE DARK BURNT APPEARANCE OF THE GREASE IN THE • BEARING, OVERRUNNING CLUTCH BALL OUTPUT. PER OPERATOR REQUEST THE CLUTCH ASSEMBLY WAS DISASSEMBLED AND A SIGNIFICANT AMOUNT OF METAL WAS DISCOVERED IN THE RACE, CLUTCH OUTER. THE ASSEMBLY WAS SENT TO AN MD REPAIR STATION FOR INSPECTION. WEAR WAS FOUND ON THE CAGE OF THE SPRAG ASSEMBLY. NO EXTERNAL LOAD OPERATIONS WERE PERFORMED WITH THIS CLUTCH IN SERVICE.

Part: CLUTCH — MAKING METAL (ZONE 100) · airframe 23,948 hrs · 21,423 cycles

DURING AIRCRAFT INSPECTION AN AIRCRAFT MECHANIC QUESTIONED DISCOLORING OF THE OVERRUNNING CLUTCH OUTPUT BEARING GREASE. THE BEARING DID NOT DEMONSTRATE ANY ABNORMAL PLAY OR ROUGHNESS. THE CLUTCH HAD THE CORRECT AMOUNT OF OIL INSTALLED. IT WAS DECIDED TO DISASSEMBLE THE CLUTCH ASSEMBLY. IT APPEARED THE FORWARD BEARING WAS ROTATING IN THE OUTER RACE HOUSING. UNOFFICIAL MEASUREMENT OF THE OUTER RACE HAD IT OVER LIMITS. METAL PARTICLES WERE FOUND IN THE REMAINING OIL IN THE BOTTOM OF THE OUTER RACE HOUSING. THE PART WAS REMOVED FROM SERVICE FOR FURTHER INSPECTION.

Part: FUEL CONTROL — MALFUNCTIONED (ENGINE) · airframe 24,417 hrs · 30,113 cycles

AFTER DEPARTURE PILOT EXPERIENCED SLIGHT NG FLUCTUATION AND SLIGHT YAW MOTION. PILOT RETURNED FOR LANDING. DURING TROUBLE SHOOTING MAINTENANCE OF THE ENGINE FUEL CONTROL UNIT, MAINTENANCE FOUND INSIDE THE ACCELERATION CONTROLLER CHAMBER THAT THE LOWER CIRCLIP WAS MISSING FROM FROM A LEVER PIN AND A SPRING FROM THE PIN WAS DISENGAGED FROM THE PIN. FUEL CONTROL WAS REMOVED FROM ENGINE TO BE SENT TO REPAIR SHOP.

Part: ENGINE — ABNORMAL (ZONE 100) · airframe 22,894 hrs · 48,004 cycles

UDRING STRAIGHT AND LEVEL FLIGHT THE PILOT REPORTED LOW ENGINE TORQUE. THE PILOT SELECTED A LANDING SPOT AND PERFORMED AN UNEVENTFUL PRECAUTIONARY LANDING. THE AIRCRAFT WAS MOVED TO A MAINTENANCE LOCATION AND THE ENGINE WAS REMOVED FOR INSPECTION. NO CAUSE DETERMINED AT THIS TIME.

Part: DOUBLER — CRACKED (ZONE 100) · airframe 20,287 hrs · 67,305 cycles

DURING A POST FLIGHT INSPECTION, THE MECHANIC FOUND A CRACK ON THE AFT END OF THE RIGHT-HAND STATION 174 DOUBLER CONNECTING THE BOOM FAIRING AND TURTLE BACK OF THE UPPER AFT FUSELAGE.

Part: CONNECTOR — LOOSE (FUEL QTY UNIT) · airframe 22,609 hrs · 46,910 cycles

DURING FLIGHT THE PILOT NOTICED THE FUEL QUANTITY GAUGE DROPPED TO ZERO THEN THE ENGINE OIL TEMP WENT TO ZERO. THE INSTRUMENT CIRCUIT BREAKER THEN POPPED. THE PILOT LANDED WITHOUT ISSUE. THE PILOT RESET THE CIRCUIT BREAKER ONCE SHUT DOWN AND MAINTENANCE COULD NOT DUPLICATE THE PROBLEM. MOISTURE WAS FOUND ON THE FUEL QUANTITY SENDING UNIT CANNON PLUG WHICH WAS CLEANED AND INSPECTED. A LOOSE CONNECTION WAS FOUND ON THE COLLECTIVE HOBBS METER SWITCH AND THE SWITCH WAS REPLACED. OPERATIONAL CHECKS POST MAINTENANCE WERE FOUND GOOD.

Part: ENGINE — MAKING METAL · airframe 19,790 hrs · 63,496 cycles

ENGINE GEARBOX CHIP LIGHT ILLUMINATED DURING APPROACH FOR LANDING. UPON INSPECTION IT WAS DETERMINED THAT THE UPPER GEARBOX MAGNETIC CHIP DETECTOR HAD ILLUMINATED THE WARNING LIGHT WITH METAL ABOVE THE MAXIMUM ALLOWED. A SMALLER AMOUNT OF METAL WAS FOUND ON THE LOWER PLUG AS WELL. THE ENGINE WAS REMOVED FROM THE AIRCRAFT FOR FURTHER INVESTIGATION AS TO THE CAUSE.

Part: ENGINE — MAKING METAL (ZONE 200) · airframe 19,704 hrs · 63,126 cycles

PILOT GOT AN ENGINE CHIP LIGHT DURING FLIGHT AND PERFORMED A PRECAUTIONARY LANDING. MAINTENANCE FOUND EVIDENCE OF CHIPS ON THE LOWER AND UPPER ENGINE GEARBOX CHIP DETECTORS. ENGINE REMOVED FROM AIRCRAFT FOR INSPECTION.

Part: HUB — WORN (MAIN ROTOR) · airframe 22,403 hrs · 20,836 cycles

DURING A PREFLIGHT INSPECTION ONE OF THE MAIN ROTOR HUB DROOP STOP FOLLOWER ROLLER SHAFTS WAS FOUND PROTRUDING DOWNWARD FROM THE PLUNGER ASSEMBLY. FURTHER INSPECTION FOUND THAT THE COTTER PIN HAD WORN INSIDE THE ROLLER SHAFT AND HAD LOST ITS RETAINING ABILITY.

Part: TURBINE WHEEL — BINDING (ENGINE) · airframe 17,921 hrs · 22,030 cycles

DURING MAINTENANCE THE MECHANICS DETERMINED THE FIRST STAGE TURBINE BLADES WERE RUBBING ON THE NOZZLE.ASSEMBLY REMOVED FROM ENGINE

Part: BLADE — DENTED (MAIN ROTOR) · airframe 19,993 hrs · 36,782 cycles

DURING A POST FLIGHT INSPECTION A MECHCANIC FOUND A 1/4 X 1/4 INCH DENT IN THE LEADING EDGE OF A MAIN ROTOR BLADE 42 INCHES IBOARD FROM THE TIP OF THE BLADE.

Part: MODULE — NOISY (ENGINE) · airframe 22,042 hrs · 26,342 cycles

DURING COAST DOWN AFTER POST INSPECTION GROUND RUNS MECHANICS HEARD A NOISE COMING FROM THE ENGINE MODULE 4 AND MODULE 5 AREA. TURBOMECA WAS CONTACTED AND HAS REQUESTED THAT THE MODULES BE SENT IN FOR ANALYSIS.

Part: FUEL CONTROL — LEAKING (ENGINE) · airframe 17,241 hrs · 19,012 cycles

DURING MAINTENANCE GROUND RUN CHECK OPERATIONS ENGINE FUEL WAS NOTICED COMING OUT OF THE FUEL CONTROL CASE AND LEAKING TO THE GROUND. FUEL CONTROL WAS REMOVED FOR INVESTIGATION AND A SERVICABLE UNIT INSTALLED.

Part: BLADDER — LEAKING (FUEL CELL) · airframe 17,066 hrs · 976 cycles

FUEL LEAKING FROM LEFT HAND FUEL BLADDER. REPLACED BOTH LEFT AND RIGHT HAND BLADDERS.

Part: ENGINE — MAKING METAL · airframe 16,843 hrs · 54,400 cycles

ENGINE CHIP LIGHT ILLUMINATED WHEN ENGINE WAS BROUGHT TO FLIGHT IDLE AFTER ENGINE START UP. MAINTENANCE FOUND 2 FLAKES WITHIN LIMITS ON THE UPPER CHIP PLUG.A 30 MINUTE GROUND RUN WAS PERFORMED, THE PLUGS WERE INSPECTED AGAIN AND FOUND CLEAN. AIRCRAFT RETURNED TO SERVICE.

Part: ENGINE — MAKING METAL · airframe 16,418 hrs · 47,865 cycles

ENGINE CHIP LIGHT DURING FLIGHT. MAINTENANCE FOUND 4 FLAKES ON UPPER AND LOWER PLUGS WITHIN PARAMETERS. PERFORMED AN OIL SYSTEM DRAIN, FLUSH AND FILTER CLEAN AND CHANGE AND GROUND RUN. CHIP PLUGS WERE CLEAN UPON REINSPECTION. AIRCRAFT WAS RETURNED TO SERVICE.

Part: BLADE — CRACKED (MAIN ROTOR) · airframe 16,455 hrs · 52,917 cycles

THE BOTTOM SKIN OF THE MAIN ROTOR BLADE HAS A 4 1/2 INCH CRACK STATING AT THE TRAILING EDGE AND PERPENDICULAR TO SPAN 57 1/4 INCHES IN FOR BLADE TIP.

Part: CHIP DETECTOR — SHORTED (MAIN GEARBOX) · airframe 15,774 hrs · 45,248 cycles

DURING A PREFLIGHT INSPECTION THE PILOT NOTICE A MAIN ROTOR GEARBOX DIMMLY ILLUMINATED CHIP LIGHT. MAINTENANNCE DISCOVERED AND INTERNAL SHORT IN THE CHIP DETECTOR AND REPLACED WITH SERVICABLE.

Part: GEARBOX — MAKING METAL (MAIN ROTOR) · airframe 15,807 hrs · 50,591 cycles

DURING A POST MAINTENANCE OPERATIONAL CHECK FLIGHT THE MAIN ROTOR GEARBOX CHIP LIGHT ILLUMINATED. A PIECE OF METAL WAS FOUND ON THE CHIP PLUG. THE TRANSMISSION WAS REMOVED AND A SERVICABLE TRANSMISSION WAS INSTALLED.

Part: CHIP DETECTOR — CONTAMINATED (GEARBOX) · airframe 18,015 hrs · 29,253 cycles

PILOT REPORTED AND ENGINE CHIP LIGHT AND PERFORMED AN UNSCHEDULED LANDING. MAINTENANCE FOUND 1 SLIVER ON THE UPPER GEARBOX CHIP PLUG. THE PLUG WAS CLEANED AND A PENALTY ENGINE RUN WAS PERFORMED IN REFERENCE TO THE ENGINE OMM. THE PLUGS WERE FOUND CLEAN AND THE AIRCRAFT WAS PLACED BACK IN SERVICE.

Part: BLADDER — LEAKING (FUEL CELL) · airframe 14,930 hrs · 42,114 cycles

DURING 100 HOUR MAINTENANCE INSPECTION, A SMALL FUEL LEAK WAS DISCOVERED ON THE BOTTOM OF THE RIGHT FUEL BLADDER. BLADDER WAS REMOVED AND REPLACED

Part: ENGINE — MAKING METAL (ZONE 100) · airframe 17,432 hrs · 27,205 cycles

DURING CRUISE FLIGHT AND ENGINE CHIP LIGHT INDICATION OCCURRED. THE PILOT PERFORMED A PRECAUTIONARY LANDING. MAINTENANCE DISCOVERED METAL FLAKES ON UPPER AND LOWER ENGINE CHIP PLUG. PER MAINTENANCE MANUAL INSTRUCTION IT WAS DETERMINED THAT THE ENGINE ASSEMBLY REQUIRED REMOVAL FROM THE AIRFRAME FOR ANALYSIS.

Part: BLADE — DELAMINATED (TAIL ROTOR) · airframe 18,127 hrs · 29,445 cycles

DURING A POST FLIGHT INSPECTION BY AN AIRCRAFT MECHANIC TAIL ROTOR LEADING EDGE DELAMINATION WAS FOUND. BOTH TAIL BLADES WERE REMOVED FROM THE AIRCRAFT AND REPLACED WITH NEW.

Part: GEARBOX — FALSE INDICATION (MAIN ROTOR) · airframe 19,406 hrs · 22,355 cycles

PILOT EXPERIENCED A MAIN ROTOR GEARBOX CHIP LIGHT ENROUTE TO THE AIRPORT. MAINTENANCE EXAMINED THE SYSTEM CHIP DETECTORS AND ELECTRICAL SYSTEM AND FOUND NO CHIP OR ABNOMALIES. AN OPERATIONAL TEST FLIGHT WAS PERFORMED AND FOUND SATISFACTORY. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: HOUSING — WORN (MAIN ROTOR HUB) · airframe 17,213 hrs · 26,413 cycles

EXTREME PLAY FOUND BETWEEN MAIN ROTOR PITCH HOUSING AND PITCH BEARING HOUSING. THE UPPER BOLT STILL HAD TORQUE STRIP APPLIED BETWEEN NUT WASHER AND BOLT BUT WAS LOOSE IN PIECES DUE TO THE WEAR. THE UPPER BOLTS ON TWO OTHER PITCH HOUSINGS WERE FOUND TO BE UNDER TORQUED BUT TORQUE STRIPED.

Part: ENGINE — MAKING METAL (ZONE 200) · airframe 18,770 hrs · 21,470 cycles

PILOT REPORTED AN ENGINE CHIP LIGHT. MAINTENANCE FOUND A SMALL PIECE OF CARBON (LESS THAN.5MM) ON REAR BEARING CHIP PLUG. PERFORMED LEVEL "B" CHECKS IN REF TO ENGINE MANUAL. RETURNED AIRCRAFT TO SERVICE WITH CONDITION CHECKS.

Part: GEARBOX — EXCESS PLAY (MAIN ROTOR) · airframe 12,693 hrs · 35,040 cycles

DURING MAINTENANCE A MECHANIC DISCOVERED EXCESSIVE GEARPLAY IN THE MAIN ROTOR TRANSMISSION. THE UNIT WAS REMOVED FOR REPAIR

Part: COMPRESSOR — DAMAGED · airframe 12,693 hrs · 35,040 cycles

PILOT REPORTED TURBINE OUTLET TEMPERATURE INCREASE AT END OF FLIGHT. MAINTENANCE DISCOVERED COMPRESSOR BLADES DAMAGED BY UNKNOWN FOD.

Part: FUEL CONTROL — LEAKING (ENGINE) · airframe 12,390 hrs · 34,021 cycles

DURING A POST FLIGHT INSPECTION MAINTENANCE FOUND A SMALL FUEL LEAK AT THE OUT FITTING LOCATION ON THE ENGINE FUEL CONTROL UNIT. THE UNIT WAS REPLACED WITH A SERVICEABLE UNIT.

Part: BLADE — DELAMINATED (MAIN ROTOR) · airframe 15,993 hrs · 22,330 cycles

FOUND DELAMINATION ON MAIN ROTOR BLADE STAINLESS STEEL LEADING EDGE.

Part: BLADE — DENTED (MAIN ROTOR) · airframe 11,625 hrs · 3,385 cycles

DAMAGE WAS FOUND IN AREAS A AND H ON 4 OF THE 5 MAIN ROTOR BLADE BOTTOM SKINS APPROXIMATELY 6" FROM THE BLADE TIPS. MAINTENANCE DETERMINED IAW CSP HMI-2 MM THAT IT WAS REPAIRABLE DAMAGE AND NO SUDDEN STOPPAGE INSPECTION WAS REQUIRED. AFFECTED BLADES WERE REMOVED FOR REPAIR AND SERVICEABLE MAIN ROTOR BLADES INSTALLED.

Part: BLADE — DELAMINATED (M/R BLADE) · airframe 15,545 hrs · 37,060 cycles

DURING ROUTINE MAINTENANCE APROXIMATELY 1" INBD FROM THE TIP ON THE TOP OF THE MAIN ROTOR BLADE, PN 500P2100-105, SN 907B A .5" X .5" DELAMINATION WAS FOUND ON THE STAINLESS STEEL L/E OF THE BLADE. THE BLADE WAS REMOVED FROME THE ACFT AT THIS TIME.

Part: ENGINE — MAKING METAL · airframe 11,036 hrs · 34,694 cycles

PILOT GOT AN INTERMITTENT ENGINE CHIP LIGHT INDICATION AFTER TAKEOFF AND RETURNED FOR LANDING. MAINTENANCE FOUND LIGHT EXTINGUISHED BUT FOUND METAL ON UPPER AND LOWER ENGINE CHIP PLUGS. ENGINE WAS REMOVED FROM THE ACFT FOR FURTHER INSPECTION.

Part: BLADE — OUT OF BALANCE (MAIN ROTOR) · airframe 11,000 hrs · 4,856 cycles

DURING A MAINTENANCE GROUND RUN OPERATION A HIGH LATERAL VIBRATION WAS ENCOUNTERED AND THE ACFT WAS SHUTDOWN. IT WAS DISCOVERED THAT WATER HAD ENTERED THE BLADE DURING A HEAVY RAINFALL THE NIGHT BEFORE. ATTEMPTS TO REMOVE THE WATER WERE UNSUCCESSFUL AND THE BLADE WAS REMOVED FROM THE ACFT FOR EVALUATION.

Part: ENGINE — MAKING METAL · airframe 10,884 hrs · 34,142 cycles

ENGINE CHIP LIGHT ILLUMINATED DURING TOUR FLIGHT. THE PILOT LANDED ACFT AND CALLED MAINTENANCE. MAINTENACE FOUND METAL FLAKE MEASURING LESS THAN .03125 ON UPPER AND LOWER ENGINE CHIP PLUGS. AFTER CLEANING THE PLUGS A 30 MINUTE GROUND RUN WAS PERFORMED AND THE PLUGS WERE RECHECKED AND FOUND CLEAN. THE ACFT WAS RETURNED TO SERVICE.

Part: ENGINE — MAKING METAL · airframe 10,564 hrs · 27,948 cycles

DURING GROUND RUN AFTER THE FIRST START OF THE DAY THE ENGINE CHIP LIGHT ILLUMINATED. MAINTENANCE INSPECTED THE UPPER AND LOWER ENGINE PLUGS AND FOUND 1 SLIVER ON THE UPPER PLUG. A 30 MINUTE GOUND RUN WAS PERFORMED AND THE PLUGS WERE RECHECKED AND FOUND CLEAN. THE ACFT WAS RELEASED TO SERVICE.