ASPEN HELICOPTERS INC

HOSE ASSEMBLY CHAFING DAMAGE RESULTING IN LOSS OF FLUID.

UPON VISUAL INSPECTION OF FRICTION DAMPERS AND TRANSMISSION MOUNTS, FOUND LIFT LINK FITTING CRACK ON THE AFT LUG BUSHING AREA COVERING THE ENTIRE LATERAL (SIDE). TRANSMISSION MOUNTS WERE REMOVED AND INSPECTED FOUND PRESSURE REQUIRED TO DEFLECT MOUNT WAS BEYOND LIMITS ALLOWED.

DURING AN OAS INSPECTION A SMALL CRACK WAS FOUND ON THE TOP RIGHT HAND SIDE OF THE AFT FUSELAGE BULKHEAD P/N 206-032-308-003, NEXT TO THE TAILBOOM ATTACHMENT BOLT HOLE. AFTER FINDING THE CRACK ON THIS AIRCRAFT WE QUICKLY INSPECTED OUR A/C. IT ALSO HAS THE SAME CRACK IN THE EXACT SAME LOCATION.

DURING AN OAS INSPECTION A SMALL CRACK WAS FOUND ON THE TOP RIGHT SIDE OF THE AFT FUSELAGE BULKHEAD P/N 206-032-308-003, NEXT TO THE TAIL BOOM ATTACHMENT BOLT HOLE. THIS SAME CRACK WAS FOUND ON OUR OTHER A/C ON THE SAME DAY IN THE SAME LOCATION.

TAIL ROTOR BLADE DEVELOPED DEEP CORROSION PIT AT BLADE ROOT.

TAIL ROTOR BLADE DEVELOPED DEEP CORROSION PIT AT BLADE ROOT.

DURING ROUTINE MAINTENANCE, CONDUCTING AD2011-23-02 FOR CRACKS AND CORROSION, FOUND A VOID IN THE M/R BLADE AT ABOUT STATION 29.5 ON THE TOP SIDE OF THE BLADE DOUBLER. BLADE WAS REMOVED FROM SERVICE.

DURING FLIGHT, FUEL WAS FOUND LEAKING FROM ENGINE DRAIN. UPON FURTHER REVIEW IT WAS FOUND THAT FUEL WAS LEAKING THROUGH THE FUEL PUMP SEAL, WHEN ELECTRICAL FUEL PUMP WAS OPERATED ON THE GROUND THE SAME FUEL LEAK WAS DUPLICATED. SEAL WAS REPLACED. ACFT ENGINE AND FUEL PUMP WAS RETURNED BACK TO SERVICE.

WALKING THROUGH HANGER, NOTICE A FUEL STAIN ON THE HANGER FLOOR. FURTHER REVIEW FOUND ENGINE DRIVEN FUEL PUMP DRAIN LEAKING STATICALLY. PUMP WAS REMOVED, SEAL REPLACED BY PCE, PUMP WAS REINSTALLED. AIRCRAFT ENGINE AND FUEL PUMP WERE RETURNED BACK TO SERVICE.

PROPELLER BLADE ON PROPELLER ASSY PN HC-C2YR-2CUF/FC7666A-4 WAS DISCOVERED LOOSE ON PRE-FLIGHT INSPECTION. THIS PROPELLER HAD 240.2 HRS TSO, IT WAS OVERHAULED ON 28 MARCH 2011. THIS IS 2ND OF 2 PROPELLERS THAT HAVE DEVELOPED LOOSE PROPELLER BLADES AFTER BEING O/H BETWEEN MARCH 2011 AND MAY 2011. RECOMMEND STRICT ADHERENCE TO O/H ASSY STEP INSP QA POLICIES.

PROPELLER BLADE ON PROPELLER ASSY WAS DISCOVERED LOOSE ON PREFLIGHT INSPECTION. THIS PROPELLER HAD 47.6 HRS TSO, IT WAS OVERHAULED ON 12 MAY 2011. 1ST OF 2 PROPELLERS THAT HAVE DEVELOPED LOOSE PROPELLER BLADES AFTER BEING OVERHAULED.

DURING LANDING, RT POSITION ENGINE EXPERIENCED ROUGHNESS. FOUND CYLINDER NR 2 EXHAUST VALVE STUCK. VALVE GUIDE INSPECTIONS ARE DUE AT 1000 HOURS. ENGINE ONLY HAD 842.6 HRS. (K)

UPON COMPLYING WITH SB, VALVE GUIDE INSPECTION, FOUND LIFTER BODY PN 72877 BROKEN. VALVE GUIDE REVEALED NO SIGNS OF STICKING. (K)

DURING FLIGHT FITTING BECAME DETACHED CAUSING LOSS OF OIL. FOUND FITTING MADE OF ALUMINUM. NEW FITTING MADE OF STEEL. (K)

STARTER WILL NOT DISENGAE FROM FLYWHEEL. SAME MALFUNCTION AS MFG SB 559, BUT SB 559 DOES NOT APPLY TO THIS PN.

RECEIVED SWASHPLATE ASSY FROM VENDOR OVERHAUL SHOP. DURING INSTALLATION FOUND LEVER (PN 206-010-467-001) WAS INSTALLED UP-SIDE-DOWN. ALSO FOUND SHIMS (PN 206-010-463-005) WERE NET STACKED EVENLY. PROBABLE CAUSE: WORKMANSHIP AND QA PROBLEM.