AIRCOASTAL HELICOPTERS, INC.

WHILE PERFORMING 100/300 HOUR INSPECTION, FOUND LOW COMPRESSION CYLINDER NR 5. EXHAUST VALVE FOUND TO BE VERY TIGHT IN VALVE GUIDE AND PERFORMED SB388C AND VALVE GUIDE REAMING PROCEDURE, INSPECTED VALVE AND STEM, NO DEFECTS FOUND EXCEPT VALVE GUIDE HAD CARBON BUILD UP. COMPRESSION RETURNED TO NORMAL FOR ENGINE WITH 398.0 HOURS SINCE O/H. COMPANY COOL DOWN POLICY FOR ALL RECIPROCATING ENGINES CHANGED TO FULL 5 MINUTES, ESPECIALLY REQUIRED DUE TO VERY HIGH OAT OVER 95 DEGREES F THIS SUMMER.

PILOT FOUND RT SIDE OF NEW MUFFLER CRACKED OVER 50 PERCENT OF DIAMETER WHERE EXHAUST COLLECTOR ENTERED THE MUFFLER SECTION. THIS ACFT WAS 2200 HR O/H WITH NEW MFG FACTORY KIT COMPLETED 2/1/2013 BY AUTHORIZED MFG SERVICE FACILITY. NO KNOWN REASON FOR THIS CRACK TO OCCUR. WARRANTY MUFFLER BEING SHIPPED. INSTALLED SERVICEABLE EXHAUST SYS WITH TSN: 1808.5 UNTIL NEW PART ARRIVES.

DURING SEARCH FOR POSSIBLE REFRIGERANT LEAKS ON NEW ACFT, CHECKED WIRING TO FREEZE SWITCH BEHIND EVAPORATOR TO AFT CABIN WALL, AND FOUND THE WIRE WAS RUBBING ON THE FREEZE SWITCH CAPILLARY TUBE, WITH NO DAMAGE TO EITHER COMPONENT AT THIS TIME. INSTALLED SPIRAL WRAP AROUND 2 WIRES TO FREEZE SWITCH TO PREVENT WIRING FAILURE. INSTALLED SPRIAL WRAP ANTI-CHAFE TO WIRING ON REPAIRED PART TO PREVENT RE-OCURANCE. NOTIFIED MFG PRODUCT SUPPORT OF PROBLEM AND WAS TOLD A SERVICE BULLETIN WOULD BE ISSUED.

FOUND WIRING TO FREEZE SWITCH HAD CHAFED THROUGH THE CAPILLARY TUBE TEMP SENSOR RELEASING ALL ITS REFRIGERANT, CAUSING SWITCH TO OPEN AND NOT ALLOW COMPRESSOR TO RUN. SWITCH NOT FIELD REPLACEABLE, HAD TO SENT TO FACTORY FOR REPAIRS. INSTALLED SPIRAL WRAP ANTI-CHAFE TO WIRING ON REPAIRED PART TO PREVENT REOCCURRENCE. NOTIFIED MFG PRODUCT SUPPORT OF PROBLEM AND WAS TOLD A SERVICE BULLETIN WOULD BE ISSUED. (K)

FOUND WIRING TO FREEZE SWITCH HAD CHAFED THROUGH THE CAPILLARY TUBE TEMP SENSOR RELEASING ALL IT'S REFRIGERANT, CAUSING SWITCH TO OPEN AND NOT ALLOW COMPRESSOR TO RUN. SWITCH NOT FIELD REPLACEABLE, HAD TO SEND TO FACTORY FOR REPAIRS. INSTALLED SPIRAL WRAP ANTI-CHAFE TO WIRING ON REPAIRED PART TO PREVENT REOCCURRENCE. NOTIFIED PRODUCT SUPPORT OF PROBLEM AND WAS TOLD A SB WOULD BE ISSUED.

§135.415(A)(16) EMERGENCY ACTIONS EXC ENGINE SHUTDOWN THIS IS NOT A CHARTER AIRCRAFT. IN LEVEL FLIGHT DURING VFR CONDITIONS, DURING CROSS COUNTRY FLIGHT TRAINING WHILE IN LEVEL FLIGHT, A SUDDEN VIRATION AND NOISE WAS HEARD FROM ENGINE AREA. INSTRUCTOR AND STUDENT MADE PRECAUTIONARY POWERED LANDING TO SUITABLE SITE. FOUND AFT MAIN ENGINE TO TRANSMISSION DRIVE SYSTEM BELT HAD DISINTEGRATED, CAUSING FORWARD BELT TO SKIP A GROOVE FORWARD SO ONLY ONE OF FOUR DRIVE BELT SECTIONS WAS POWERING ROTOR DRIVE SYSTEM. DISSASEMBLY, INSPECTION OF SYSTEMS IN AREA, AND NEW PART REPLACEMENT TO BE PERFORMED.

INSTRUCTOR MADE UNSCHEDULED LANDING IN SAFE AREA AFTER EXCESSIVE NOISE AND VIBRATION FROM ENGINE AREA. FOUND AFT MAIN DRIVE BELT HAD FAILED COMPLETELY AND HAD PUSHED THE FORWARD BELT FORWARD WHERE ONLY ONE SECTION WAS STILL POWERING ROTOR DRIVE SYSTEM. ADDITIONAL DAMAGE TO ENGINE COOLING FAN SHROUD BY ENGINE OIL COOLER. ALL BELTS AND FAN SHROUD TO BE REPLACED. ONE ANTENNA CONNECTOR TO BE RELACED. THIS IS NOT A CHARTER AIRCRAFT.

ENGINE OIL LEAK FROM OIL FILTER HOUSING CAP FOUND TO BE CAUSED BY SEVERE CORROSION AROUND CAP RETAINER STUD BASES, WITH MISSING METAL MIGRATED TO O-RING SEAL AREA. INSTALLED TSO: 0.0 PN 23035102 HOUSING ASSEMBLY. RUNUP LEAK CHECKS FOUND PROBLEM RESOLVED. SUGGEST CLOSER INSPECTION THIS AREA ON AGING AIRCRAFT ENGINES DURING SCHEDULED MAINTENANCE.

GROUND CREW CLOTH SAFARI HAD BLEW OFF IN HIGH WIND AND WENT THROUGH MAIN ROTOR. NO VIBRATIONS OR APPARENT DAMAGE FELT IN AIRCRAFT, WAS SMOOTH RETURNING TO AIRPORT. FOUND DENT TOP AND BOTTOM AT STA 141 TO 145, IB OF OB TRIM TABS. OTHER AIRCRAFT SENT TO MOVE GROUND CREW, BLADE REMOVED AND SENT FOR EVALUATION FOR PATCH. FACTORY ENGINEERING CONDEMED BLADE FOR TOP DENT TOO DEEP FOR REPAIR. (K)

TAIL ROTOR BLADE, SENT TR BLADES INSPECTION, BLADE FAILED SKIN THICKNESS TEST WAS .0064 ON UPPER SURFACE, NOT REPAIRABLE. WARRANTY CLAIM.

NOTICE HIT TOT ON A NORMALLY COOL RUNNING TURBINE, OVER A PERIOD OF A FEW FLIGHTS TOT CLIMBED MORE. PERFORMED NORMAL BARFIELD TOT TESTING AND BLEED VALVE CLOSURE TESTS, THEN DID THE HAND FEEL TEST DURING START AND IDLE AND FOUND AIR LEAKAGE AT LEFT AFT AIR TUBE AREA. FOUND CRACK IN REINFORCED AIMPIT AREA OF COMBUSTION CASE. NO DAMAGE TO LINER AND GOOD PATTERN FROM FUEL NOZZLE. ORDERED COMBUSTION CASE FOR REPLACEMENT.

INSTALLED 2 NEW BLADES WITH HIGH VISIBILITY PAINT FROM MFG. ABLE TO PERFORM SPAN AND LATERAL BALANCE TO LESS THAN .02IPS. UNABLE TO REDUCE VERTICAL VIBRATION TO ACCEPTABLE LEVELS IN HOVER TO 120 MPH. INSTALLED ANOTHER WARRANTY BLADE AND WAS ABLE TO TRACK TO MORE ACCEPTABLE VERTICAL VIBRATION LEVELS.

ORDERED NEW FLOAT BAGS FROM FLOATS AND FUEL CELLS, ONE MFG DATE MAY 2003, OTHER FEB 2004, BOTH MANUFACTURED WITH AFT BELT AND BUCKLE ASSEMBLIES INSTALLED UPSIDE DOWN. HAD TO SEND FOR REPAIRS TO NEW BAGS.

TRANSMISSION CHIP LIGHT CAME ON ON LANDING. FOUND TANG FROM ACCESSORY DRIVE LOCK WASHER ON CHIP DETECTOR. VERIFIED ON TRANSMISSION DISASSEMBLY. ALL TRANSMISSION BEARINGS REPLACED 1/9/1998 . OTHER WASHER TANG NOT IN NUT SLOT AND BENT SUGGESTING IMPROPER INSTALLATION. UNFORTUNATELY FOUND SUN GEAR 206-040-122-3 AND SHAFT 206-040-003 SPLINE AREAS WORN EXCESSIVE CAUSING MINOR REPAIR TO BECOME EXPENSIVE. SUN GEAR ONE UPPER TOOTH HARDNESS COATING CHIPPED OFF, NO DAMAGE TO PLANETARY OR ANY OTHER COMPONENTS, NO METAL FLAKES ON OIL FILTER OR IN GEAR CASE.

VOLTAGE REGULATOR FAILED ON TAKEOFF, CAUSED BOTH COMM RADIOS TO FAIL WITH SMOKE OBSERVED FROM COLLINS 251 COMM RADIO. REPLACED REGULATOR, SERVICED GILL BATTERY AND OVERFLOW BOTTLE, ADJUSTED REG TO 27.5 VDC, BORROWED RADIOS TO USE WHILE COMM ARE REPAIR, NO OTHER DAMAGE FOUND.

VOLTAGE REGULATOR FAILED ON TAKE OFF, CAUSED BOTH COMM RADIOS TO FAIL WITH SMOKE OBSERVED FROM COLLINS 251 COMM RADIO. REPLACED REGULATOR, SERVICED GILL BATTERY & OVERFLOW BOTTLE, ADJUSTED REG TO 27.5 VDC, BORROWED RADIOS TO USE WHILE COMM ARE REPAIR, NO OTHER DAMAGE FOUND.

HIGH SKID GEAR TUBE DISSIMILAR METAL CORROSION CRACK FOUND STARTING WITH SKID SHOE INSERT NUT UNDER AFT CROSSTUBE TITTING, ONLY 3 YEARS OLD, CRACK MAY HAVE BEEN MISSED FOR A WHILE ON INSPECTIONS.

SKID GEAR LANDING TUBE FOUND DISSIMILAR METAL CORROSION CRACK STARTING WITH SKID SHOE INSERT NUT AFT CROSSTUBE FITTING, NON-REPAIRABLE AREA. TUBE ONLY 3 YEARS OLD, CRACK MAY HAVE BEEN MISSED ON PAST INSPECTORS.

FOUND STIFFNER CRACKED DURING INSPECTION - CRACK ORIGINATED IN LOWEST HI-LOCK FASTNER POSITION 2.875

FOUND STIFFNER CRACKED DURING INSPECTION - CRACK ORIGINATED IN LOWEST HI-LOCK FASTENER POSITION 2.875 INCH BELOW TOP OF PART. ALSO SPLICED NEW WEB (PN 206031106349S) DUE TO CRACK IN WEB FROM SAME LOCATION. REPLACED STIFFNER. ALL WORK IAW SRM.

REMOVED BOTH HORIZONTAL STABILIZERS THAT HAD BEEN LAST INSTALLED OVER 5 YEARS AGO. FOUND EXCESSIVE CORROSION IN SPAR CLAMP AREA ON RIB CLOSEST TO TAILBOOM. REQUIRES TOTAL RIBE REPLACEMENT OF $1966 RIB. INSPECTED OTHER RIB ALSO HAD CORROSION & PIECE MISSING SO REPLACED 206-020-123-047S RIB ON THAT SIDE ALSO. THIS IS SECOND REPORT IN LESS THAN YEAR ON SAME PARTS. SUGGEST BELL HELICOPTER INSERT A 3 YEAR INSPECTION IN MAINTENANCE MANUAL, ESPECIALLY WHEN AIRCRAFT IN CORROSIVE ENVIRONMENT LIKE THE STATE OF FLORIDA.

ACTUATOR FAILED AFTER FEBRUARY 2001 OVERHAUL. NO ALODINE OR OTHER CORROSION PROTECTION ON INSIDE OF CASE.INTERNAL CORROSION CAUSED FAILURE.

STUD PULLED OUT WITH LESS THAN 50 INCH POUND ON TORQUE WRENCH WHEN INSTALLING FW UNIT IN ENGINE - HIDDEN DAMAGE NOT FOUND BY BELL CSF OVERHAUL FACILITY. NEW HOUSING SENT BY CSF.

AIRCRAFT WAS FLYING LOW SPEED OVER A CORN FIELD AT NIGHT FOR FROST PREVENTION. ON RETURN LEG TO AIRPORT FOR REFUELING. AT 11:30 PM AIRCRAFT DEVELOPED SEVERE MAIN ROTOR VIBRATION. UPON SHUTDOWN, FOUND CRACK IN BLADE AREA.