CONSTRUCTION HELICOPTERS, LLC

Operated by CONSTRUCTION HELICOPTERS INC (per NTSB report)

DURING FLIGHT HAD LOW TRANSMISSION PRESSURE AND ELS SYSTEM KICKED ON. FOUND MGB LINER MATERIAL IN CHIP DETECTOR SCREEN OF MGB.

DURING FLIGHT HAD LOW TRANSMISSION PRESSURE AND ELS SYSTEM KICKED ON. FOUND MGB LINER MATERIAL IN CHIP DETECTOR SCREEN OF MGB.

TORQUE SENSOR ASSEMBLY [PN: 3101726-3, SN: P-8423, TSO: 3,059.5] HEXAGON PLAIN NUT [PN: 867349-1] BACKED OFF DURING FLIGHT.

DURING DESCENT, ENGINE FLAMED OUT @ 7000 FT MSL. THROTTLES @ FLIGHT IDLE, ENGINE NTS SURGING, EGT 428, RPM DROPPED TO 38%, INITIATED FEATHER OF ENGINE. SINGLE ENGINE LANDING UNEVENTFUL. CAUSE TBD.

DURING DESCENT, #2 ENGINE FLAMED OUT @ 7000 FOOT MSL, THROTTLES @ F.I. ENGINE NTS SURGING, EGT 428, RPM 38%, FEATHERED ENGINE. SINGLE ENGINE LDG UNEVENTFUL. CAUSE TBD

#1 ENGINE FIRE LIGHT ILLUMINATED IN FLIGHT. R&R'D ENGINE FIRE LOOP CABLE.

WHILE INVESTIGATING HORIZONTAL FITTINGS ON FUSELAGE SIDE DUE TO CRACKS IN FITTINGS, FOUND MATING FITTINGS ATTACHED TO HORIZONTAL STABILIZERS CRACKED AS WELL WHEN INSPECTED POST STABILIZER REMOVAL FROM EMPENNAGE. R/H STABILIZER AFT SPAR ATTACH FITTING P/N 212-31123-05.1 & L/H STABILIZER FWD SPAR ATTACH FITTING P/N 212-31122-03.1 FOUND TO BE CRACKED.

PERFORMED EDDY CURRENT INSPECTION OF ACCESSIBLE AREAS OF FRAME NO.29, 31, L/H, R/H UPPER & LOWER ATTACH FITTINGS (QTY:8) AND FRAME NO.29 SHOWS REJECTABLE INDICATIONS ON UPPER R/H FITTING & LWR L/H FITTING. 2 EA, P/N 212-24103-02.1

PERFORMED EDDY CURRENT INSPECTION OF ACCESSIBLE AREAS OF FRAME NO.29, 31, L/H, R/H UPPER & LOWER ATTACH FITTINGS (QTY:8) AND FRAME NO.31 SHOWS REJECTABLE INDICATIONS ON UPPER R/H FITTING. 1 EA, P/N 212-24154-02.2

PERFORMED EDDY CURRENT INSPECTION OF ACCESSIBLE AREAS OF FRAME NO.29, 31, L/H, R/H UPPER & LOWER ATTACH FITTINGS (QTY:8) AND FRAME NO.31 SHOWS REJECTABLE INDICATIONS ON LWR L/H FITTING. 1 EA, P/N A0473-0001

DURING A 1Y, 2Y, 4Y CPCP INSPECTION OF THE EMPENNAGE OF S/N 289 IT WAS FOUND 6 OUT OF 8 OF THE HORIZONTAL STABILIZER FITTINGS CRACKED. THE CRACKS WERE FOUND IN THE RADIUS OF ONE OF THE FITTINGS & FROM FASTNER TO FASTNER ON OTHERS.

DURING A 1Y, 2Y, 4Y CPCP INSPECTION OF THE EMPENNAGE OF S/N 289 IT WAS FOUND 6 OUT OF 8 OF THE HORIZONTAL STABILIZER FITTINGS CRACKED. THE CRACKS WERE FOUND IN THE RADIUS OF ONE OF THE FITTINGS & FROM FASTNER TO FASTNER ON OTHERS.

DURING A 1Y, 2Y, 4Y CPCP INSPECTION OF THE EMPENNAGE OF S/N 289 IT WAS FOUND 6 OUT OF 8 OF THE HORIZONTAL STABILIZER FITTINGS CRACKED. THE CRACKS WERE FOUND IN THE RADIUS OF ONE OF THE FITTINGS & FROM FASTNER TO FASTNER ON OTHERS.

DURING CRUISE FLIGHT, 50 MILES FROM HK01, #1 ENGINE FAILED. CREW PERFORMED APPROPRIATE EMERGENCY PROCEDURE, ANALYZED PERFORMANCE OF AIRCRAFT WITH ONE ENGINE AND ENTERED DESCENT, APPROACH, AND LANDING PHASES FOR SINGLE ENGINE LANDING. AIR RESTART WAS ATTEMPTED WITH NO SUCCESS. AIRCRAFT WAS LANDED ON ONE ENGINE, NO DAMAGE OR INJURIES. INVESTIGATION REVEALED THE ACCESSORY GEAR BOX SUFFERED INTERNAL FAILURE AND FUEL PUMP / FUEL CONTROL INPUT DRIVE WAS INOPERATIVE. NO OTHER DAMAGE OR MECHANICAL FAILURES WERE NOTED. ENGINE WILL BE SENT TO OVERHAUL FACILITY.

ENCOUNTERED SMOKE IN THE COCKPIT WITH ACCOMPANYING DC GEN AND RECTIFIER WARNING LIGHTS ILLUMINATED. IDENTIFIED TRANSFORMER RECTIFIER WINDINGS HAD OVERHEATED AND SMOKE RESIDUE ON THE CASE OF THE UNIT. NO NOTED FIRE OR ANY OTHER WIRE DAMAGE. THE EVENT TRANSPIRED DURING PILOT FLIGHT TRAINING WITH NO INJURIES OR INCIDENTS.

EXPERIENCED AN ELECTRICAL FAILURE THAT RESULTED IN 6 CIRCUIT BREAKERS TRIPPED AND ELECTRICAL CONNECTOR J3/P3 ON THE AVIONICS RELAY BOX TO SHOW MELTING ON ONE END OF THE CONNECTOR AND ASSOCIATED WIRES AT THE CONNECTOR LOCATION. FURTHER FINDINGS REVEALED THE #2 VERTICAL AND DIRECTIONAL GYROS IN THIS CIRCUIT TO BE INOPERATIVE AND DETERMINED TO BE THE CAUSE OF THE EVENT. THE PILOT DIDN'T NOTE ANY SMOKE,BUT DID SMELL AN ELECTRICAL ODER. NOTICED THE SIX CIRCUIT BREAKERS (#1 GAD, #2 GAD, GYRO COMP 1 26VOB, GYRO COMP 1 115VOB, GYRO COMP 2 26VOB, GYRO COMP 2 115VO) WERE OPENED.

CARRYING AN EXTERNAL LOAD, A NR 2 ENGINE FIRE INDICATED. THE LOAD WAS SET BACK DOWN AND AIRCRAFT LANDED. INSPECTED THE NR 2 ENGINE AND NO EVIDENCE OF FIRE. DETERMINED FALSE INDICATION AND TROUBLESHOOTING REVEALED COULD NOT DUPLICATE THE INDICATION. SYSTEM WIRING AND COMPONENTS WERE CHECKED AND NO ANOMALIES WERE FOUND. NO PARTS WERE CHANGED.

MAIN ROTOR GEARBOX EMERGENCY OIL LINE WAS LOSING OIL CAUSING INDICATION OF LOW GEARBOX OIL PRESSURE. THIS WAS CAUSE FOR AN EMERGENCY LANDING.

THE SIC NOTICED THE ENGINE INSTRUMENT INDICATIONS WERE DISPLAYING IRREGULAR INDICATIONS WHILE OVER A LAKE FILLING A WATER BUCKET. NR 2 ENGINE ROLLED BACK TO IDLE AND WOULD NOT ACCELERATE. TRANSMISSION INDICATIONS WERE NORMAL APART FROM A TORQUE SPLIT. NOSED ACFT OVER AND ESTABLISHED SINGLE ENGINE FLIGHT TO THE NEAREST AIRPORT AND EXECUTED A RUN ON LANDING. AFTER SHUTDOWN MAINTENANCE INSPECTED NR 2 ENGINE AND FOUND COMPRESSOR DAMAGE. UPON FURTHER INSPECTION OF THE AREA IT WAS DISCOVERED A NUT WAS MISSING FROM THE NR 2 ENGINE INLET SCREEN. MISSING NUT WAS REPLACED WITH NEW HARDWARE AT THE INLET SCREEN. NR 2 ENGINE WAS R & R WITH SERVICEABLE ENGINE. AIRCRAFT WAS RETURNED TO SERVICE ON 8/30/2016 AFTER ENGINE RUNS AND CHECK FLIGHT. NO FURTHER DEFECTS NOTED.

WHEN REMOVING BEAM, LT AND RT SIDES, IT WAS FOUND THAT BOTH OTBD BEARINGS WERE SEVERELY CORRODED. RT BEARING WAS SEIZED WITH NO VISIBLE INDICATIONS OF SEIZURE AND LT 1 WAS STIFF WITH RUST COMING OUT OF BEARING SEALS.

DURING REMOVAL OF MAIN ROTOR GEARBOX, THE FWD AND REAR MGB MOUNT BOLTS AND SLEEVE BUSHINGS WERE REMOVED. 3 OF THE 4 SLEEVE BUSHINGS WERE FOUND TO BE COMPLETELY BROKEN, WITH THE 4TH CRACKED APPROXIMATELY 75 PERCENT OF THE CIRCUMFERENCE OF THE BUSHING IN THE SAME LOCATION AS THE OTHER BROKEN BUSHINGS.

ON DEPARTURE, SMOKE NOTICED IN THE COCKPIT. DECLARED EMER & RETURNED. R & R LT LANDING LIGHT IAW MM 33-40-10.

DURING APPROACH, THE FLIGHT CREW SMELLED & OBSERVED A PUFF OF SMOKE THAT CAME FROM THE BOTTOM LT SIDE OF THE INSTRUMENT PANEL. NO ACTION WAS TAKEN AS LANDING WAS IMMINENT & A NORMAL LANDING WAS PERFORMED WITHOUT INCIDENT.

WHEN RAISING LANDING GEAR, IT LOCKED THEN UNLOCKED WITH A NOTICEABLE SHUTTER AND THE UNLOCK LIGHT BLINKED. DID THIS TWICE WITH SAME RESULT. ACFT RETURNED TO BASE WITH OUT FURTHER INCIDENT.

CRACK FOUND BETWEEN TWO FASTENERS ON FORGED OVERHEAD FRAME JUST AFT OF THE APU ACCUMULATOR PRESSURE GAUGE. BS 422, BL 3. MACHINED FITTING FABRICATED AND INSTALLED PER SIKORSKY ENGINEERING DOCUMENT DRB 2015-SA-92-104A.

AT CRUISE FLIGHT DURING NIGHT VISION GOGGLE TRAINING THERE WAS AN ORDER OF SMOKE IN THE FLIGHT DECK. THE COPILOTS SIDE OF THE OVERHEAD PANEL WAS HOT TO THE TOUCH IN THE VICINITY OF THE LIGHT SWITCHES & RHEOSTATS. FLIGHT DECK LIGHTING WAS EXTINGUISHED & THE OVERHEAD PANEL DECREASED IN TEMPERATURE. THE DECISION WAS MADE TO RETURN TO AIRPORT & A NORMAL LANDING WAS ACCOMPLISHED WITHOUT FURTHER INCIDENT. REPAIRED POST LIGHT ON MONITOR PANEL, COPILOT SIDE IAW DWG C212-289-012.

STRONG ODOR OF BURNING PLASTIC DURING FLIGHT. INSPECTED LT & RT AVIONICS CABINETS, CO-PILOT, CENTER & PILOT CIRCUIT BREAKER PANEL WIRING, LT CONTROL TUBE/WIRING HARNESS COMPARTMENT. GROUND RAN ACFT WITH HEATERS & AIR CONDITIONING SYSTEMS ON AND OFF. COULD NOT DUPLICATE ODOR. ACFT RETURNED TO SERVICE.

DURING INSPECTION FOUND NR 6 LT & NR 6 RT FRAMES DAMAGED. LOCALLY FABRICATED FRAMES. WORK PERFORMED IAW DWG 14019-2013 & 14019-2014 INSTRUCTIONS.

DURING INSPECTION FOUND NR 11 LT & NR 11 RT FRAMES DAMAGED. LOCALLY FABRICATED FRAMES. WORK PERFORMED IAW DWG 14019-2018 & 14019-2019 INSTRUCTIONS.

DURING NDT OF LT ENG MOUNT FITTING INSPECTION, FOUND AFT UPPER LT ENG MOUNT FITTING TO BE CORRODED. REMOVED UPPER ENG MOUNT FITTING PN 212-13116-01.2 & SENT OUT TO BE LOCALLY FABRICATED. WORK DONE IAW DWG 14019-2026.

FOUND CRACK INDICATION ON NR 1 ENG UPPER MOUNT FITTING ON LT WING FWD SPAR NEAR GROUNDING LUG. FURTHER INSPECTION FOUND TO BE LEVEL 2 CORROSION. PART TO BE REPLACED WITH SERVICEABLE.

CRACK FOUND AT STATION 3950 RT SIDE OF FUSELAGE. LOCALLY MANUFACTURED FILLER USING .032 X 2024-T3 & DOUBLER USING .040 X 2024-T3. ALL WORK DONE FOLLOWING DWG 14019-2049 REV V1. NO FURTHER ACTION REQUIRED AT THIS TIME.

CRACK FOUND AT STATION 3950 LT SIDE OF FUSELAGE. LOCALLY MANUFACTURED FILLER USING .032 X 2024-T3 & DOUBLER USING .040 X 2024-T3. ALL WORK DONE FOLLOWING DWG 14019-2049 REV V1. NO FURTHER ACTION REQUIRED AT THIS TIME.

DURING REMOVAL OF HORIZONTAL STABILIZER FOUND LT UPPER MOUNT BAR CORRODED. LOCALLY MANUFACTURED IAW EO 14019-2027 REV 1R. NO FURTHER ACTION REQUIRED AT THIS TIME.

DURING REMOVAL OF HORIZONTAL STABILIZER FOUND LT LOWER MOUNT BAR CORRODED. LOCALLY MANUFACTURED IAW EO 14019-2028 REV 1R. NO FURTHER ACTION REQUIRED AT THIS TIME.

DURING INSPECTION FOUND RT HORIZONTAL STABILIZER UPPER OTBD SKIN TO HAVE A DENT BEYOND LIMITS. FABRICATED SECTION OF SKIN USING ORIGINAL SKIN AS SAMPLE. MATERIAL USED .025 X 2024-T3 LOT 267230. ALL WORK DONE IAW EO 14019-300, REV V8 PAR 8 112. NO FURTHER ACTION REQUIRED AT THIS TIME.

LEFT SEAT TRACK SUPPORT HAT CHANNEL & SEAT TRACK FROM FS 3150 TO 3950 FOUND CORRODED BEYOND LIMITS & IN NEED OF REPLACEMENT.

RIGHT SEAT TRACK HAT CHANNEL SUPPORT & SEAT TRACK FROM FS 2400 TO 3950 FOUND CORRODED BEYOND LIMITS & IN NEED OF REPLACEMENT.

LEFT WING LOWER SURFACE IN AREA OF ENG EXHAUST TRAIL HAS CORROSION DAMAGE FROM ENG EXHAUST PRODUCT. MILITARY TECHNICAL INSTRUCTION 17 TO BE PERFORMED, REPAIR OF EXHAUST AREA THROUGH SKIN REPLACEMENT & DOUBLER PATCH.

RIGHT WING LOWER SURFACE IN AREA OF ENG EXHAUST TRAIL HAS CORROSION DAMAGE FROM ENG EXHAUST PRODUCT. MILITARY TECHNICAL INSTRUCTION 17 TO BE PERFORMED REPAIR OF EXHAUST AREA THROUGH SKIN REPLACEMENT & DOUBLER PATCH.

TOP INNER RIB OF LT HORIZONTAL STABILIZER AT INBD ATTACH FITTING FOUND CORRODED BEYOND LIMITS. REPLACED INNER RIB AS REQUIRED.

DURING WINDSHIELD REMOVAL AT HEAVY CHECK CORROSION FOUND ON THE COPILOT’S WINDSHIELD FRAME LOWER SECTION. REPAIRED IAW EO 12032-2036 SUPPORTED BY FAA FORM 8110-3.

DURING WINDSHIELD REMOVAL AT HEAVY CHECK CORROSION FOUND ON THE COPILOT'S WINDSHIELD FRAME LOWER SECTION. REPAIRED IAW EO 12032-2036 SUPPORTED BY FAA FORM 8110-3.

DURING WINDSHIELD REMOVAL AT HEAVY CHECK CORROSION FOUND ON THE COPILOT'S WINDSHIELD FRAME INBD VERTICAL SECTION. REPAIRED IAW EO 12032-2036 SUPPORTED BY FAA FORM 8110-3.

DURING WINDSHIELD REMOVAL AT HEAVY CHECK CORROSION FOUND ON THE COPILOT'S WINDSHIELD FRAME INBD VERTICAL SECTION. REPAIRED IAW EO 12032-2036 SUPPORTED BY FAA FORM 8110-3.

PILOT HEARD A LOUD BANG AND NOTICED A SEVERE VIBRATION IMMEDIATELY. PILOT SET EXTERNAL LOAD ON ROOF CURB, RELEASED LONGLINE/RIGGING AND MADE AN UNEVENTFUL EMERGENCY LANDING IN PARKING LOT AT JOB SITE. AUX HYD PRESSURE WENT TO ZERO BEFORE ACFT WAS SHUTDOWN. MECHANIC FOUND OIL COOLER BLOWER BELTS MISSING ALONG WITH AUX HYD LINES SEVERED AT PUMP. ADDITIONAL DAMAGE TO ANGLE GEARBOX AREA INCLUDED: BROKEN COLLECTIVE BIAS CABLE, SCORED MAIN DRIVESHAFT AND COUPLING, DAMAGES SHEET METAL AND BRAKE LINES. ALL DAMAGE CAUSED BY BELTS COMING APART AND THRASHING AROUND IN COMPARTMENT. FURTHER INVESTIGATION INDICATES BELT TENSIONER PULLEY BRG FAILED CAUSING BELTS TO COME APART. OIL COOLER BLOWER (INCLUDING TENSIONER PULLEY), COLLECTIVE BIAS CABLE, MAIN DRIVESHAFT AND COUPLING, BRAKE LINES, AUX HYD LINES, BLOWER BELTS AND AUX HYD PUMP REPLACED. ACFT RETURNED TO SERVICE AFTER GROUND RUNS AND LEAK CHECKS WERE COMPLETED.