Service difficulty report · Relay · Bell 205A1

Difficulty date
June 16, 2026
Submitted
June 20, 2026
Operation
Air carrier
Aircraft
N3804C
Make and model
Bell 205A1
Aircraft serial
30314
Aircraft time
18,261 hours
Part
Relay
Part number
6041H229
Condition
Failed
Location
Zone 100
Stage of operation
NR
How discovered
O
Nature of condition
B
Precautionary procedure
B, A

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

ENROUTE TO A DIP SITE FOR ANOTHER BUCKET OF WATER THE PILOT SMELLED ELECTRICAL SMOKE IN THE CABIN OF THE AIRCRAFT. ODOR WAS IMMEDIATELY FOLLOWED BY SMOKE COMING FROM UNDER THE CENTER CONSOLE WHICH FILLED THE HELICOPTER CABIN. THE PILOT CALLED IN A MAYDAY OVER THE RADIO AND BEGAN FLYING TO AN OPEN FIELD NORTHWEST OF BUCKWITH RESERVOIR TO MAKE AN EMERGENCY LANDING. AIR ATTACK HALTED AIR OPERATIONS AND FOLLOWED THE AIRCRAFT TO THE EMERGENCY LANDING SITE. ANOTHER HELICOPTER AND LARGE AIR TANKER ON THE INCIDENT ALSO FOLLOWED TO ENSURE THEY COULD PROVIDE HELP IF NEEDED. THE PILOT SHUT OFF THE THREE BATTERY SWITCHES ENROUTE TO THE LANDING SITE WHICH IMMEDIATELY CAUSED THE SMOKE TO SUBSIDE. WHILE THIS WAS OCCURRING AIR ATTACK INFORMED THE GROUND RESOURCES AND THE MANAGER OF THE HELICOPTER OVER THE VHF AIR TO GROUND INCIDENT FREQUENCY. THE CREW CAPTAIN THAT WAS MANAGING ONE OF THE DIP SITES MADE HIS WAY TO THE EMERGENCY LANDING SITE. NOTIFICATIONS WERE MADE FOLLOWING THE MISHAP RESPONSE PLAN AND ALL NECESSARY PERSONNEL WERE INFORMED OF THE UNFOLDING SITUATION. THE PILOT WAS ABLE TO SAFELY PUT THE AIRCRAFT ON THE GROUND WITH NO INJURY OR FURTHER DAMAGE TO THE AIRCRAFT. THE DISTRICT CHIEF FOR THE AREA ARRIVED AT THE EMERGENCY LANDING SITE FIRST AND CONFIRMED THE LATITUDE AND LONGITUDE AS WELL AS CONFIRMED THAT THE PILOT WAS OKAY. NO FURTHER DAMAGE TO THE AIRCRAFT WAS CAUSED WHILE LANDING. THE MANAGER WAS ALSO ABLE TO REACH THE PILOT VIA CELL PHONE AND CONFIRMED THAT THE PILOT WAS OKAY. THE CREW CAPTAIN ARRIVED AT THE EMERGENCY LANDING SITE SHORTLY AFTER AND ENSURED THAT THE MECHANIC WAS ENROUTE. THE MANAGER INFORMED THE REGION AIRCRAFT MAINTENANCE INSPECTOR ABOUT THE INCIDENT WITH THE PLAN TO FOLLOW UP ONCE A RESOLUTION WAS REACHED. THROUGHOUT THE INCIDENT THE HELICOPTER OPERATIONS SPECIALIST WAS INFORMED WITH UPDATES AND DETAILS. THE MECHANIC ARRIVED AT THE LANDING SITE AND BEGAN DIAGNOSING THE HELICOPTER WITH THE PILOT. IT WAS FOUND THAT A BATTERY RELAY HAD FAILED AND BURNED THROUGH THE RELAY. UPON FINDING THE FAILED RELAY THE MECHANIC LOOKED THROUGH THE WIRING HARNESS TO ENSURE DAMAGE HADN’T SPREAD THROUGH THE ADJOINING WIRE HARNESS. ONCE THE ISSUE WAS DISCOVERED, A REPLACEMENT RELAY WAS ON HAND IN THE MECHANIC TRAILER. THE MECHANIC INSTALLED THE NEW RELAY AND COMPLETED THE REQUIRED DOCUMENTATION FOR THE REPAIR. THE HELICOPTER WAS TESTED WITH THE NEW PART, ENSURING THAT THE CIRCUITS ATTACHED TO THE RELAY BUSS WERE WORKING APPROPRIATELY AND NO CASCADING FAILURES HAD OCCURRED AS A RESULT OF THE FAILED RELAY.

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