WPR17LA188

Maintenance personnel's inadequate routine maintenance on the helicopter engine, which led to low cylinder compression, improper magneto timing, and camshaft lobe wear, which subsequently resulted in degraded engine performance.

The commercial pilot and passenger departed in the helicopter on a personal flight to a nearby lake, but decided to change course during the flight to meet a friend at his home. They approached from the north with the intention of landing in the backyard. After entering an out of ground effect hover, the pilot received a low rotor rpm indication and the helicopter began to descend. The pilot was able to restore the rotor rpm to normal momentarily, but after completing a 360° right pedal turn to search for a suitable landing site, the helicopter started to sink again. The helicopter's right skid then impacted the ground, which resulted in a dynamic rollover and substantial damage to the fuselage. The property owner stated that he saw intermittent puffs of dark gray smoke coming from the tailpipe that turned into a steady stream after the helicopter completed the pedal turn.  According to maintenance logs, verification of engine-to-magneto timing, a differential compression check, and confirmation of valve movement using a relevant service bulletin were completed during the most recent 100-hour inspection (about 104 flight hours before the accident); however, postaccident examination found that the magnetos were improperly timed by 10o, cylinder compression was low, and a camshaft lobe was severely worn and spalled, which would have inhibited two intake valves from operating normally during the accident flight and resulted in a reduction in the effectiveness of two cylinders. These anomalies resulted in a reduction in the engine's available power, and the absence of this power precluded the helicopter from maintaining an out of ground effect hover. The presence of dark smoke from an operating engine can be the result of an excessively rich mixture; however, the origin of the dark gray smoke in this case could not be determined. A flight instructor who regularly flew the helicopter stated that, despite his repeated reports of degraded engine performance, one of the multiple mechanics responsible for servicing the helicopter justified the performance issues as the result of age, as the engine was nearing its next major overhaul. This likely encouraged the instructors who flew the helicopter to dismiss the problem as well and to "manage" the lack of power instead. Additionally, the mechanic responsible for the helicopter's most recent inspection stated that he did not comply with the manufacturer's service bulletin to inspect the valves for adequate movement, which likely would have prompted an inspection of the camshaft and discovery of the lobe wear.

The recorded weather was captured from a weather station at AUN, located approximately 13.5 nm north of the accident site. The 1855 recorded weather observation at AUN included wind from 250° magnetic, wind calm, visibility 10 statute miles, clear skies, temperature 32° C, dew point 26° C, and an altimeter setting of 29.86 inches of mercury. According to the pilot, he had accumulated a total of 3,985 total flight hours and 66.5 hours in the helicopter make and model. The pilot estimated that he flew about 3 total hours in the helicopter make and model within the 90 days that preceded the accident. He further estimated that he amassed about 500 total flight hours in Robinson R-22s, but did not accrue any flight experience in the R-22 in the last 90 days. Airframe and Tailcone Damage Scuff marks were observed on both the nose and belly of the helicopter and longitudinal scoring was observed on both the chin and helicopter belly. The left side of the roof and left door frames sustained impact damage along with the forward edge of the main fuel tank and the left windshield was shattered. A small dent was observed in tailcone bay no. 4 on the left side and another small dent on the upper surface of tailcone bay no. 5 forward of the strobe light. The strobe light lens was shattered and the left side navigation antenna was damaged. The mid-span section of the upper vertical stabilizer displayed leading edge damage and trailing edge damage was observed on the horizontal stabilizer. The tail skid was bent upward with core scoring on the lower surface and the tail rotor guard was broken at the stabilizer, which occurred during the recovery process as photographs taken at the accident site show the tail skid in its original position and the tail rotor guard unbroken. Flight Controls Cyclic control movement was confirmed from the cockpit to the main rotor blades and collective control was verified from the collective to the main rotor blades through the swashplate. A main rotor blade pitch change link was broken, but the fracture surface was consistent with overload separation. All three main rotor servos operated smoothly when the cyclic and collective were actuated by hand. The anti-torque pedals were smooth and continuous from the cockpit to the tail rotor. Drive System Both the main rotor and tail rotor drive/output shafts rotated smoothly and oil was present in the gearboxes. The V belts were in good condition and in place on both sheaves. Continuity of the main rotor and tail rotor drive systems were confirmed from the lower sheave to the main rotor blades through the main rotor drive shaft and from the upper sheave to the tail rotor blades through its respective drive shaft. Main Rotor and Tail Rotor Blades One main rotor blade displayed upward bowing near the tip, chordwise creasing throughout the blade span, and was bent opposite the direction of rotation. Additionally, tree residue was observed along the leading edge. The other main rotor blade exhibited upward bowing and was bent opposite the direction of rotation. Chordwise creasing was observed throughout the span of the blade. A 5 foot section of afterbody was separated from the blade spar about mid-span and tree residue was observed on leading edge and lower surface. Both tail rotor blades remained attached to the hub. One tail rotor blade displayed multiple dents near the leading edge on the outboard skin and coarse scuff marks along the trailing edge. Tree residue was observed on both the inboard and outboard skins on both tail rotor blades. Fuel System The main fuel tank and auxiliary fuel tank did not display any breaches or show any leaks. Both fuel caps were secure and the vent tubes were clear. The gascolator screen displayed trace amounts of debris and the fuel exhibited an odor and color consistent with 100 LL aviation grade gasoline. The key was turned to the prime position to test the auxiliary fuel pump, which did not engage during the attempt. Engine Rotational continuity was established throughout each of the six cylinders, when the crankshaft was rotated by hand using the engine-cooling fan, which showed light compression on all six cylinders. The ignition harness leads were removed from the spark plugs, most of the leads showed indications of arcing. The ignition lead wires to the cylinder no. 3 and 5 spark plugs were loose and the rim of the upper plug to cylinder no. 1 displayed corrosion. The spark plugs displayed excessive contamination, which consisted of pliable carbon deposits and other debris that caused electrode bridging. When compared to the Champion Aerospace Aviation Service Manual, the plugs were similar to the manual's classification of "severely fouled" plugs. The bottom spark plugs to cylinder nos. 1, 3, and 5 displayed oil fouling, consistent with the helicopter's resting position on its side at the accident site. A magneto synchronizer was used to measure the magneto timing, which revealed a timing of 10° before top dead center. According to the engine manufacturer, the magnetos should be timed to 20° before top dead center. Engine Test The spark plugs were re-installed, a quart of piston engine oil was added and the helicopter was moved to an open area for an engine run. Initially, the engine was started normally and idled at 64% for about 2 minutes until the oil temperature was in the green range. During this time the engine ran rough and gray smoke streamed from the tailpipe. After the warm-up was complete, the rpm was increased to 100% and the engine continued to run rough. The rpm was then reduced to 75% and a magneto check was completed; the rpm level dropped to 61% when the ignition was turned to the left magneto and 55% when switched to the right magneto. After the engine run, when comparing cylinder temperatures by hand, the temperature of cylinder no. 5 was cooler than the other cylinders. Additionally, the cylinder no. 3 intake pipe was found loose. The lower spark plugs were then removed and a compression test was performed on each individual cylinder at 80 psi. The results were as follows: no. 1; 28 psi, no. 2; 34 psi, no. 3; 52 psi, no. 4; 38 psi, no. 5; 36 psi, no. 6; 54 psi. During each cylinder compression test, air could be heard leaking from the exhaust. A second engine run yielded similar results as the first test despite introducing clean spark plugs. Valve Movement The NTSB IIC examined the intake valve movement with the accident pilot at the owner's hangar. Initially, the pilot used the starter to turn the engine, while the NTSB IIC observed the intake valves, which confirmed that both intake valves for cylinder nos. 5 and 6 extended only about one-third the total travel of the other intake valves in the open position. A subsequent visual inspection of the camshaft revealed that the intake valve cam lobe to cylinder nos. 5 and 6 exhibited severe wear and spalling (see photograph 1). Photograph 1: Intake Camlobe for Cylinder Nos. 5 & 6 According to FAA records, the helicopter was manufactured in 2006 and registered to A M Helicopter Services on May 20, 2008. The helicopter was powered by a Lycoming IO-540-AE1A5, a direct drive, air cooled, 260 hp engine. A review of the logbooks revealed that the helicopter's most recent 100 hour airframe inspection was completed on May 21, 2017 at an accumulated time of 1,991.3 flight hours. At the time of the accident, the helicopter had accumulated a total of 2,095 flight hours. The engine's most recent 100-hour inspection was performed by IA Maintenance, a service facility in Woods Cross, Utah. In this entry, the mechanic recorded that he performed a differential compression check, cleaned, gapped, and tested the spark plugs, inspected the magneto and tachometer points and checked engine to magneto timing. Additionally, the mechanic noted that he complied with Lycoming Service Bulletin 301B. With the excepti