Heli-Jet Corp

PILOT REPORTED BURNED PLASTIC ODOR FROM ENGINE COMPARTMENT. MECHANIC INSPECTED ENGINE COMPARTMENT AND FOUND A BURNED AREA ON THE STARTER/GENERATOR CONNECTOR PLUG BACKSHELL. REPLACED THE STARTER AND THE HARNESS FROM THE STARTER/GENERATOR TO THE ENGINE DECK. GROUND RAN ACFT AND CHECKED ELECTRICAL SYSTEM. NO FURTHER DISCREPANCIES NOTED. ACFT RETURNED TO SERVICE.

LANDED, PROCEEDED WITH NORMAL SHUTDOWN PROCEDURES. DURING TWO-MINUTE SHUTDOWN, NOTICED GENERATOR CYCLING ON AND OFF, FIRE LIGHT ILLUMINATED MOMENTARILY THEN WENT OUT. FIRE LIGHT CAME ON AGAIN WITH MORE GENERATOR CYCLING. EXITED HELICOPTER WITH ENGINE AT FLIGHT IDLE AND LOOKED IN ENGINE COMPARTMENT. SAW 8 INCH FLAMES FROM GENERATOR CONNECTOR PLUG IN ENGINE DECK. SHUT DOWN ENGINE IMMEDIATELY. GOT HAND HELD EXTINGUISHER, OPENED ENGINE COWL AND EXTINGUISHED FIRE. SAW SMOKE COMING FROM OTHER AREAS OF THE HELICOPTER. OPENED OTHER ACCESS PANELS AND LOOKED FOR MORE FIRE. SHOT EXTINGUISHER INTO THE SIGHT HOLE IN RIGHT SIDE OF AIRCRAFT, UNDER ENGINE DECK, TO HIT BOTTOM SIDE OF GENERATOR CONNECTOR PLUG.

MEDIUM FREQ VIBRATION IN THE AIRFRAME. REPLACED BEARINGS IN THE FAN

DURING OPERATION, PILOT EXPERIENCED AN ENGINE CHIP. OIL SYSTEM PRELIMINARY INVESTIGATION SUGGESTED NR 2 BEARING FAILURE

PITCH LINK FAILED WHILE IN HOVER FLIGHT. PILOT EXECUTED HOVERING AUTOROTATION SUCCESSFULLY. TAIL ROTOR ASSY COMPLETE, 90 DEGREE GEARBOX, AND 42 DEGREE GEARBOX WERE REPLACED AS A PRECAUTION, FOR INSPECTION.

IT WAS NOTED DURING OPERATION, ENGINE EGT WAS OBSERVED TO BE ABOVE NORMAL. UPON TEARDOWN OF HOT SECTION, THE FIRST STAGE TURBINE NOZZLE OUTER SHROUD WAS FOUND SEVERELY CRACKED. (X)

PILOT REPORTED LOSS OF OIL PRESSURE IN-FLIGHT. THE FLIGHT WAS TERMINATED IMMEDIATELY AND THE ENGINE WAS SHUT DOWN. UPON INVESTIGATION, THE ENGINE OIL PUMP DRIVESHAFT WAS FOUND BROKEN. WHEN PUMP WAS REMOVED, A PIECE OF GEAR TOOTH FELL FROM PUMP OIL PASSAGE. GEAR PIECE IS FOREIGN TO THE OIL PUMP. AT THIS TIME, IT IS NOT KNOWN WHERE THE GEAR TOOTH CAME FROM.