Eagle Helicopters, Inc.

DURING ROUTINE WINTER MAINTENANCE, AN INSPECTION OF THE LANDING GEAR CROSSTUBES WERE ACCOMPLISHED IAW THE MFG 300 HOUR INSPECTION. ONE OF THE SADDLES FOR THE ATTACHMENT OF SKID GEAR TO THE FUSELAGE WAS FOUND DEBONDED ON THE CROSSTUBE. ICA INSTRUCTIONS CALL FOR REMOVING THE SADDLE AND REBONDING AND RECLAMPING THE SADDLE TO THE CROSSTUBE. THE SADDLE WAS REMOVED AND A CRACK WAS FOUND IN THE CROSSTUBE IN THE AREA OF THE OF THE INBD CLAMP. THE CRACK PROGRESSED FROM THE TOP OF THE CROSSTUBE DOWNWARD AND WAS NOT VISIBLE AS IT PROGRESSED UNDERNEATH THE ATTACHMENT CLAMP. THE 2 YEAR INSPECTION CALLS OUT REMOVING THE CLAMPS FOR INSPECTION OF THE CROSSTUBE AND REINSTALLATION OF THE CLAMPS. THE CRACK WOULD HAVE BEEN VISIBLE AT THIS TIME. THE 2 YEAR INSPECTION WAS CARRIED OUT FEBRUARY OF 2015 AND NO DISCREPANCIES WERE NOTED AT THE TIME. THE CRACK WAS ONLY DISCOVERED DUE TO THE FACT THE SADDLE HAD COME LOOSE AND REQUIRED REBONDING.

DURING CRUISE CHECK, THE HYDRAULIC PRESSURE ON THE NR 1 SIDE FELL TO 0. FUEL PRESSURE AND OIL PRESSURE ON NR 2 SIDE PEGGED OUT. RETURNED TO DEPARTURE.

NR 2 ENGINE SHUT DOWN IN-FLIGHT. PILOT MADE NORMAL LANDING. INVESTIGATED PROBLEM. PULL FUEL PUMP OFF. FOUND INTERNAL SPLINES OF PUMP GROUND OFF. SPLINES MISSING DUE TO ABNORMAL WEAR ON SPLINES. INSTALLED NEW PUMP. GROUND RAN ENGINE. ENGINE FUNCTIONED PROPERLY. (X)

FOLLOWING DISASSEMBLY OF ENGINE FOR METAL CONTAMINATION, DISCOVERED 2 EACH OF THE LOCKCUPS HAD FAILED. CUPS CRACKED AND SPLIT AT THE LOCKING TANGS WHICH ENGAGE THE PLANETARY GEARSHAFTS. THE RETAINING NUTS WHICH THE LOCKCUPS RETAIN, REMAINED IN PLACE AND THE PIECES OF THE LOCKCUPS WERE FOUND IN THE SCAVENGE SCREEN OF THE ACCESSORY DRIVE GEARBOX AND LAYING IN THE OUTPUT REDUCTION GEARBOX.

OIL PUMP SEIZED ON START-UP. NO SHEAR SHAFT WAS INCORPORATED IN OIL PUMP. SEIZURE CAUSED DAMAGE TO PUMP DRIVE RING GEAR TEETH INSIDE TRANSMISSION ASSY AS WELL AS OIL PUMP ASSY. IF SHEAR SHAFT WAS INCORPORATED IN OIL PUMP, ONLY PUMP WOULD HAVE NEEDED CHARGING IN THIS CASE, NOT PUMP AND TRANSMISSION.

OIL PUMP SEIZED ON START-UP. NO SHEAR SHAFT WAS INCORPORATED IN OIL PUMP. SEIZURE CAUSED DAMAGE TO PUMP DRIVE RING GEAR TEETH INSIDE TRANSMISSION ASSY AS WELL AS OIL PUMP ASSY. IF SHEAR SHAFT WAS INCORPORATED IN OIL PUMP, ONLY PUMP WOULD HAVE NEEDED CHARGING IN THIS CASE, NOT PUMP AND TRANSMISSION.

WHILE CARRYING OUT OPERATIONS ON THE AFTERNOON OF 10-23-97, PILOT REPORTED INCREASE OF VIBRATION WHILE IN-FLIGHT RETURNING TO LANDING SITE. AIRCRAFT WAS SHUT DOWN. ON EXAMINATION OF TAIL ROTOR, INSIDE PART OF TIP WAS FOUND MISSING. NO OTHER DAMAGE WAS APPARENT AND SUBSEQUENT TAIL ROTOR REPLACMENT AND BALANCING CURED PROBLEM. (X)

WHILE PERFORMING POST-FLIGHT INSPECTION, MECHANIC SAW WHAT APPEARED TO BE A CRACK IN THE UPPER SURFACE OF M/R BLADE SKIN. UPON FURTHER INSPECTION, FOUND THE SKIN WAS CRACKED AS WELL AS A VOID HAD APPEARED UNDER THE AREA OF THE CRACK.

RIGHT HAND/UPPER EDGE CRACKED. CRACKED CAUSED BY SHARP CORNERS ON TAIL BOOM PADS ATTACHED BETWEEN TAILBOOM AND FRAME. C/W TB 206L-94-169 AT THIS TIME CALLS FOR NEW PADS MADE WITH RADIUS CORNERS.