Service difficulty report · Cover Plate · Hughes 369FF

Difficulty date
May 11, 2016
Submitted
May 13, 2016
Operation
General aviation
Filed by
H44R404H
Helicopter Flight Services Inc
Aircraft
N532EZ
Make and model
Hughes 369FF
Aircraft serial
0146FF
Aircraft time
1,755 hours, 14,090 cycles
Engine
Allsn 250C30
Engine time
1,755 hours, 1,982 cycles
Part
Cover Plate
Part number
6855319
Condition
Worn
Location
Engine Gearbox
Part time
1,755 hours, 1,982 cycles
Stage of operation
IN
How discovered
V
Nature of condition
O
Precautionary procedure
K

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

What was found

DURING REPLACEMENT OF THE OVER RUNNING CLUTCH, A SPECIAL TOOL IS REQUIRED TO TORQUE THE INTERNAL WRENCHED RETENTION NUT INSIDE THE PTO SHAFT OF THE ENGINE. WHEN THE TOOL WAS WITHDRAWN PART OF IT REMAINED STUCK IN THE NUT, THE TECH DID NOT REALIZE THAT THIS HAD OCCURRED AND PROCEEDED TO INSTALL THE DUST SHIELD ON THE ENGINE GEARBOX. OVER TIME THE PART OF THE TOOL STUCK IN THE NUT BECAME UNSTUCK AND BECAUSE THE ENGINE SITS AT ANGLE IN THE ACFT. IT SLID DOWN THE INSIDE OF THE OVER RUNNING CLUTCH RETENTION COLLAR AND RESTED AGAINST THE DUST SHIELD. AS THE ENGINE WAS RUNNING THE TOOL RESTING AGAINST THE DUST SHIELD WORE THE THIN METAL OF THE SHIELD TO THE POINT THAT IT WORE THROUGH AND CAME TO REST ON THE ENGINE DOOR. THIS WAS DISCOVERED BY THE PILOT DURING HIS NORMAL PREFLIGHT. IN CONCLUSION, THE TOOL USED AT THE TIME WAS NOT THE COMMERCIALLY AVAILABLE TOOL RECOMMENDED BY THE ACFT MFG. ALTHOUGH THE TOOL USED DID FUNCTION AS INTENDED BY THE ACFT MFG IT USED SEPARATE INDIVIDUAL PIECES. THE COMMERCIALLY AVAILABLE TOOL IS CURRENTLY BEING PURCHASED AND WILL BE USED EXCLUSIVELY FROM NOW ON. THE ESTABLISHED PROCEDURES OF THE REPAIR STATION WERE NOT FOLLOWED, AN INSPECTOR DID LOOK OVER THE WORK UPON COMPLETION THE DUST SHIELD WAS ALREADY INSTALLED AT THE TIME OF INSPECTION. THE REPAIR STATIONS PROCEDURE REQUIRES THAT AN INSPECTOR CLEAR AN AREA BEFORE IT IS CLOSED. THE TECH AND INSPECTOR HAVE BEEN COUNSELED AS TO THIS REQUIREMENT.

More about the Hughes 369FF