Maintenance Error Leads to Helicopter Loss of Control in KwaZulu-Natal

Casualties unknown • Open grass area at Light Flight Aerodrome, ZA

A Rotorway Executive 162F helicopter sustained substantial damage after a pilot's recent maintenance on the swashplate assembly caused a sudden loss of control during a hover check.

What happened

On 10 February 2022, a Rotorway Executive 162F helicopter, registration ZU-LIZ, was involved in an accident at Light Flight Aerodrome in Cato Ridge, KwaZulu-Natal. Prior to the flight, the pilot, who also built the aircraft, performed maintenance to address engine fuel injector issues and to tighten the slider ball collar bearing on the swashplate assembly due to observed play.

Following the maintenance, the pilot conducted a power check and an evaluation flight, maintaining a low hover at approximately 6 to 10 feet above the ground for 30 minutes. While the engine performance appeared stable, the pilot eventually noticed a slight leftward drift. During an attempt to taxi back to the hangar, the aircraft became increasingly difficult to control. As the pilot lowered the collective pitch to land, the cyclic control pulled violently to the left. The left skid struck the ground while the right skid remained airborne, causing the aircraft to yaw 170 degrees. The impact broke the left skid, leading the helicopter to roll over onto its side. The pilot escaped the wreckage without injury, though the aircraft suffered substantial damage.

The investigation

The SACAA AIID investigation established that the pilot had performed the maintenance work himself. While the pilot was the builder of the aircraft, he did not hold an Approved Person Certificate or an Aircraft Maintenance Engineer qualification. The investigation reviewed the maintenance logs, which confirmed the cleaning of fuel injectors and the adjustment of the swashplate collar bearing.

Findings

  • The loss of control was triggered by the tightening of the slider ball adjustment collar, which became too tight to operate correctly under the heat and prolonged duration of the hover.
  • The pilot performed maintenance tasks that were not in compliance with the required qualifications under the Civil Aviation Regulations.
  • The pilot/owner was not an authorized person to carry out such maintenance without a dual check by a qualified professional.
  • The aircraft was operating under a private flight provision (Part 94) and was otherwise in a stable weight and balance configuration.

Probable cause

The pilot's maintenance on the swashplate adjustment collar caused the component to bind under thermal expansion during a prolonged hover, resulting in a sudden, uncontrollable leftward cyclic pull and subsequent rollover.

Frequently asked questions

What happened in the 2022-02-10 Rotorway Executive 162F accident near Open grass area at Light Flight Aerodrome, ZA?

A Rotorway Executive 162F helicopter sustained substantial damage after a pilot's recent maintenance on the swashplate assembly caused a sudden loss of control during a hover check.

What aircraft was involved and where did it happen?

The accident on 2022-02-10 involved a Rotorway Executive 162F, registration ZU-LIZ, at Open grass area at Light Flight Aerodrome, ZA.

What was the probable cause of the accident?

The pilot's maintenance on the swashplate adjustment collar caused the component to bind under thermal expansion during a prolonged hover, resulting in a sudden, uncontrollable leftward cyclic pull and subsequent rollover.

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