Incorrect maintenance procedures and inadequate inspections contributed to the helicopter crash in a township cornfield on Sept. 15, 2012, that claimed the life of a 65-year-old pilot, accordin
By Jennifer Kohlhepp, Staff Writer
WEST WINDSOR — Incorrect maintenance procedures and inadequate inspections contributed to the helicopter crash in a township cornfield on Sept. 15, 2012, that claimed the life of a 65-year-old pilot, according to the National Transportation Safety Board.
Investigators also determined that the upper rod end disconnected from the servo due to severely worn threads, which resulted in the pilot’s loss of control and the separation of a main rotor blade during flight, according to the probable cause summary the safety board approved on Dec. 2.Former New York City police officer Michael Scarfia of Staten Island piloted the flight that originated from Princeton Airport and was destined for Atlantic City International Airport.
Earlier that day he had completed a roundtrip flight to New York in the helicopter. At the conclusion of that flight, the helicopter was refueled and then departed for Atlantic City. The helicopter was in radio and radar contact with McGuire Approach Control until noon and no distress calls were received, according to the safety board.
”Witnesses near the area of the accident site reported hearing a banging, explosion, or engine rev noise, followed by a piece separating from the helicopter and the helicopter spiraling nose down toward the ground,” the safety board stated in the narrative of the flight.
The helicopter came to rest upright in a cornfield. A post-crash fire consumed a majority of the cockpit and cabin. Both forward cabin doors were found about 50 yards from the main wreckage. The entire yellow main rotor blade and sleeve assembly had separated from the rotorhead and was recovered 270 yards southeast of the main wreckage, according to the board.
A 100-hour maintenance inspection of the accident helicopter had been completed on the morning of the accident and a 600-hour inspection of the accident helicopter was completed about three months prior to the accident. Neither inspection detected the worn threads on the servo, according to the board.
Investigators also determined that the operator used Mastinox, a corrosion-inhibiting compound, during installation of the upper rod ends to the servos. The helicopter manufacturer’s maintenance manual did not prescribe for the use of Mastinox and stated only grease should be used, according to the board.
Investigators also determined that the helicopter manufacturer provided insufficient inspection criteria.
”Review of the helicopter manufacturer’s checklists and maintenance manuals revealed some guidance for servo inspections,” the board summary of probable cause stated. “The daily operating check (after the last flight of the day) included an instruction to check the main rotor servos for security and absence of leaks. The 600-hour inspection called for checking the radial play of the end bearings; however, there were no instructions to specifically check the threads of the servo end fitting or the torque of the rod end nut.”