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Airworthiness Directives; Robinson Helicopter Company Helicopters

Robinson R44 Raven II · Airworthiness Directives

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Overview

This document is an Airworthiness Directive (AD) issued by the FAA for certain Robinson Helicopter Company models, specifically the R22, R44, and R66. The directive addresses safety concerns related to the tail rotor blade (TRB) tip caps, which have been reported to lose their caps due to corrosion. The AD mandates visual inspections of the TRB tip caps for signs of corrosion and requires the removal of affected TRBs from service within a specified timeframe. This AD is crucial for maintaining the safety and airworthiness of the affected helicopters, particularly for those operating in corrosive environments such as near saltwater. The document outlines compliance requirements and the necessary actions to mitigate the identified risks.

  • Effective date of the AD is April 2, 2024.
  • Visual inspections of TRB tip caps must be conducted within 10 hours of the AD's effective date and before each flight thereafter.
  • Affected TRBs must be removed from service within 10 months of the AD's effective date.
  • Corrosion must be addressed immediately if detected during inspections.
  • The AD affects Robinson R22, R44, and R66 helicopters with specific part-numbered TRBs.

Document

Source

Originally published by services.casa.gov.au. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.

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Document details

Type
Airworthiness Directives
Year
2024
Pages
11
File size
463 KB
Publisher
services.casa.gov.au
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1,002Robinson R44 Raven II registered worldwide · 0 active

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In this document

Compliance Requirements

The AD requires compliance within specific timeframes. Within 10 hours of the effective date, pilots must visually check each TRB tip cap area for signs of corrosion. Following this, inspections must occur at intervals not exceeding 100 hours TIS or during the next 100-hour or annual inspection. If corrosion is detected, it must be addressed before further flight.

Affected Models and Parts

This AD applies to Robinson Helicopter Company models R22, R22 Alpha, R22 Beta, R22 Mariner, R44, R44 II, and R66. Specifically, it targets TRBs with certain part numbers and serial numbers, including P/N A029–2, C029–3, and F029–1, with specified serial number limits.

Unsafe Condition

The FAA issued this AD due to reports of TRB tip caps detaching from helicopters, which can lead to severe vibrations and potential loss of control. The directive aims to prevent such incidents by ensuring regular inspections and maintenance of the TRB tip caps.

Cost of Compliance

The FAA estimates that compliance with this AD will affect approximately 2,701 helicopters in the U.S. The estimated labor cost for visually checking the TRBs is about $22 per helicopter per cycle, with additional costs for corrosion removal and TRB replacement if necessary.

Inspection Procedures

Pilots holding at least a private pilot certificate are authorized to perform the visual inspections of the TRB tip caps. The inspections focus on the bond line and surface of the tip caps for signs of corrosion, such as exposed bond lines or bubbled paint.

Safety notes

  • Failure to comply with this AD could result in increased vibrations and loss of control of the helicopter.
  • Corrosion on TRB tip caps can lead to severe safety hazards if not addressed promptly.

Full document text

2/27/24, 8:52 AM about:blank about:blank 1/8 [Federal Register, Volume 89 Number 39 (Tuesday, February 27, 2024)] [Rules and Regulations] [Pages 14377-14379] From the Federal Register Online via the Government Publishing Office [www.gpo.gov] [FR Doc No: 2024-03920] DEPARTMENT OF TRANSPORTATION Federal Aviation Administration 14 CFR Part 39 [Docket No. FAA–2023–2232; Project Identifier AD–2023–00943–R; Amendment 39– 22681; AD 2024–04–02] RIN 2120–AA64 Airworthiness Directives; Robinson Helicopter Company Helicopters AGENCY: Federal Aviation Administration (FAA), DOT. ACTION: Final rule. SUMMARY: The FAA is adopting a new airworthiness directive (AD) for certain Robinson Helicopter Company Model R22, R22 Alpha, R22 Beta, R22 Mariner, R44, R44 II, and R66 helicopters. This AD was prompted by reports of helicopters losing a tail rotor blade (TRB) tip cap. This AD requires visually checking and inspecting certain part-numbered and serial-numbered TRB tip caps for evidence of corrosion and, depending on the results, removing the corrosion. This AD also requires removing all affected TRBs from service and prohibits installing them on any helicopter. The FAA is issuing this AD to address the unsafe condition on these products. DATES: This AD is effective April 2, 2024. ADDRESSES: AD Docket: You may examine the AD docket at regulations.gov under Docket No. FAA–2023–2232; or in person at Docket Operations between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD docket contains this final rule, any comments received, and other information. The 2/27/24, 8:52 AM about:blank about:blank 2/8 address for Docket Operations is U.S. Department of Transportation, Docket Operations, M–30, West Building Ground Floor, Room W12–140, 1200 New Jersey Avenue SE, Washington, DC 20590. Related Service Information: • For service information identified in this final rule, contact Robinson Helicopter Company, Technical Support Department, 2901 Airport Drive, Torrance, CA 90505; phone (310) 539–0508; fax (310) 539– 5198; email ts1@robinsonheli.com; or website robinsonheli.com. You may view this service information at the FAA, Office of the Regional Counsel, Southwest Region, 10101 Hillwood Parkway, Room 6N–321, Fort Worth, TX 76177. For information on the availability of this material at the FAA, call (817) 222–5110. FOR FURTHER INFORMATION CONTACT: James Guo, Aviation Safety Engineer, FAA, 3960 Paramount Boulevard, Lakewood, CA 90712; phone: (562) 627–5357; email: james.guo@faa.gov. SUPPLEMENTARY INFORMATION: Background The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 CFR part 39 by adding an AD that would apply to certain Robinson Helicopter Company Model R22, R22 Alpha, R22 Beta, R22 Mariner, R44, R44 II, and R66 helicopters. The NPRM published in the Federal Register on December 6, 2023 (88 FR 84761). The NPRM was prompted by three reports of TRB tip caps coming loose due to corrosion at the bond on Robinson Helicopter Company Model R44 helicopters. Due to the similarity of the TRB tip caps on Robinson Helicopter Company Model R22, R22 Alpha, R22 Beta, R22 Mariner, R44 II, and R66 helicopters, those model helicopters are also affected by this issue. According to Robinson Helicopter Company, it has also seen TRBs that have corroded to an unserviceable condition, including severe leading edge pitting and degradation of the bond at the tip cap. Robinson Helicopter Company advises that helicopters operating near saltwater are particularly susceptible to corrosion, especially if stored outdoors. Affected TRBs were factory-installed or shipped as spares prior to November 2022. The three reports include a TRB tip cap departing its helicopter. The separate incidents occurred during a run-up check, after landing, and during a landing on different helicopters. In the NPRM, the FAA proposed to require repetitively checking and inspecting the tips caps of TRB part number (P/N) A029–2 with TRB serial numbers (S/N) up to 11279 inclusive (P/N A029–2 REV A through U inclusive), TRB P/N C029–3 with TRB S/N up to 14329 inclusive (P/N C029–3 REV A through Q inclusive), and TRB P/N F029–1 with TRB S/N up to 3099 inclusive (P/N F029–1 REV A through F inclusive) for evidence of corrosion, removing corrosion, and eventual removal of those TRBs from service. The owner/operator (pilot) holding at least a private pilot certificate may accomplish the check of the TRB tip caps and must enter compliance with the applicable paragraph of this AD into the helicopter maintenance records in accordance with 14 CFR 43.9(a) and 91.417(a)(2) (v). The pilot may perform this action because it only involves visually checking the TRB tip caps for an exposed tip cap bond line or bubbled paint. This action could be performed equally well by a pilot or a mechanic. This is an exception to the FAA's standard maintenance regulations. ▪ 2/27/24, 8:52 AM about:blank about:blank 3/8 A debonded TRB tip cap can cause severe vibration and possible failure of the tail rotor gearbox housing. This condition, if not addressed, could result in increased vibrations, reduced controllability, and subsequent loss of control of the helicopter. The FAA is issuing this AD to address the unsafe condition on these products. Discussion of Final Airworthiness Directive Comments The FAA received no comments on the NPRM or on the determination of the costs. Conclusion The FAA reviewed the relevant data and determined that air safety requires adopting this AD as proposed. Accordingly, the FAA is issuing this AD to address the unsafe condition on these products. Except for minor editorial changes, this AD is adopted as proposed in the NPRM. Related Service Information The FAA reviewed Robinson Helicopter Company R22 Service Bulletin SB–120, R44 Service Bulletin SB–112, and R66 Service Bulletin SB–41, each dated December 22, 2022 (SB–120, SB–112, and SB–

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41). This service information specifies procedures for revising the Pilot's Operating Handbook of affected helicopters by inserting the included “Special Tail Rotor Tip Preflight Inspection” page and briefing all pilots and maintenance personnel regarding those inspection procedures. This service information also specifies procedures for replacing, and returning or sending photos of affected TRBs to Robinson Helicopter Company. The FAA also reviewed Robinson Helicopter Company R22 Service Letter SL–93, R44 Service Letter SL–82, and R66 Service Letter SL–40, each dated June 30, 2021 (co-published as one document) (SL–93, SL–82, and SL–40). This service information specifies procedures for removing corrosion from TRBs, applying protectant, balancing TRBs after corrosion removal or painting, chemical cleaning TRBs, and tap testing the TRB tip cap area. Differences Between This AD and the Service Information The effectivity of Robinson Helicopter Company SB–120, SB–112, and SB–41 identify the helicopter S/Ns that the affected TRBs were factory-installed on and the shipping dates of affected TRB spares, whereas this AD applies to the specified model helicopters with certain part-numbered and serial- numbered TRBs installed. Robinson Helicopter Company SB–120, SB–112, and SB–41 specify revising the Pilot's Operating Handbook of affected helicopters and briefing all pilots and maintenance personnel regarding the inspection requirements, whereas this AD does not require those actions. Robinson Helicopter Company SB–120, SB–112, and SB–41 do not specify any visual inspections accomplished by a mechanic, whereas this AD requires repetitive visual inspections of the TRBs by persons authorized under 14 CFR 43.3. Robinson Helicopter Company SB–120, SB–112, and SB–41 specify replacing, and returning or sending photos of affected TRBs by December 31, 2024, whereas this AD requires removing affected TRBs from service within 10 months. 2/27/24, 8:52 AM about:blank about:blank 4/8 SL–93, SL–82, and SL–40 specify procedures for chemical cleaning TRBs, tap testing the TRB tip care area, applying protectant, and balancing TRBs after corrosion removal or painting, whereas this AD does not require those actions. Costs of Compliance The FAA estimates that this AD affects 2,701 helicopters of U.S. registry. The FAA estimates the following costs to comply with this AD. Labor costs are estimated at $85 per work-hour. Visually checking or inspecting the TRBs (up to two affected TRBs per helicopter) will take approximately 0.25 work-hour for an estimated cost of up to $22 per helicopter per cycle, for a U.S fleet cost of up to $59,422 per cycle. If required, removing any corrosion will take approximately 2 work-hours and the parts will cost approximately $100 for an estimated cost of $270 per TRB. Replacing a TRB will take approximately 3.5 work-hours and the parts will cost up to approximately $3,600 for an estimated cost of up to $3,898 per TRB. The FAA has included all known costs in its cost estimate. According to the manufacturer, however, some of the costs of this AD may be covered under warranty, thereby reducing the cost impact on affected operators. Authority for This Rulemaking Title 49 of the United States Code specifies the FAA's authority to issue rules on aviation safety. Subtitle I, section 106, describes the authority of the FAA Administrator. Subtitle VII: Aviation Programs, describes in more detail the scope of the Agency's authority. The FAA is issuing this rulemaking under the authority described in Subtitle VII, Part A, Subpart III, Section 44701: General requirements. Under that section, Congress charges the FAA with promoting safe flight of civil aircraft in air commerce by prescribing regulations for practices, methods, and procedures the Administrator finds necessary for safety in air commerce. This regulation is within the scope of that authority because it addresses an unsafe condition that is likely to exist or develop on products identified in this rulemaking action. Regulatory Findings This AD will not have federalism implications under Executive Order 13132. This AD will not have a substantial direct effect on the States, on the relationship between the national government and the States, or on the distribution of power and responsibilities among the various levels of government. For the reasons discussed above, I certify that this AD: (1) Is not a “significant regulatory action” under Executive Order 12866, (2) Will not affect intrastate aviation in Alaska, and (3) Will not have a significant economic impact, positive or negative, on a substantial number of small entities under the criteria of the Regulatory Flexibility Act. List of Subjects in 14 CFR Part 39 2/27/24, 8:52 AM about:blank about:blank 5/8 § 39.13 [Amended] Air transportation Aircraft Aviation safety Incorporation by reference Safety The Amendment Accordingly, under the authority delegated to me by the Administrator, the FAA amends 14 CFR part 39 as follows: PART 39—AIRWORTHINESS DIRECTIVES The authority citation for part 39 continues to read as follows: Authority: 49 U.S.C. 106(g), 40113, 44701. The FAA amends § 39.13 by adding the following new airworthiness directive: 2024–04–02 Robinson Helicopter Company: Amendment 39–22681; Docket No. FAA– 2023–2232; Project Identifier AD–2023–00943–R. (a) Effective Date This airworthiness directive (AD) is effective April 2, 2024. (b) Affected ADs None. (c) Applicability This AD applies to the Robinson Helicopter Company helicopters, certificated in any category, identified in paragraphs (c)(1) through (3) of this AD. (1) Model R22, R22 Alpha, R22 Beta, and R22 Mariner helicopters with tail rotor blade (TRB) part number (P/N) A029–2 with TRB serial numbers (S/N) up to 11279 inclusive (P/N A029–2 REV A through U inclusive), installed; (2) Model R44 and R44 II helicopters with TRB P/N C029–3 with TRB S/N up to 14329 inclusive (P/N C029–3 REV A through Q inclusive), installed; and (3) Model R66 helicopters with TRB P/N F029–1 with TRB S/N up to 3099 inclusive (P/N F029–1 REV A through F inclusive), installed. (d) Subject Joint Aircraft System Component (JASC) Code 6410, Tail Rotor Blades. ▪ ▪ ▪ ▪ ▪ 1. 2. 2/27/24, 8:52 AM about:blank about:blank 6/8 (e) Unsafe Condition This AD was prompted by reports of helicopters losing a TRB tip cap. The FAA is issuing this AD to detect and prevent TRB tip cap failures. The unsafe condition, if not addressed, could result in increased vibrations, reduced controllability, and subsequent loss of control of the helicopter. (f) Compliance Comply with this AD within the compliance times specified, unless already done. (g) Required Actions (1) Within 10 hours time-in-service (TIS) after the effective date of this AD and thereafter before the first flight of each day, visually check each TRB tip cap area (at and adjacent to the tip cap bond line on each surface and edge of the TRB) for an exposed tip cap bond line or bubbled paint, as depicted in Figure 1 to paragraph (g)(1) of this AD. These items may indicate evidence of corrosion. The owner/operator (pilot) holding at least a private pilot certificate may accomplish this TRB tip cap check and must enter compliance with this paragraph of the AD into the helicopter maintenance records in accordance with 14 CFR 43.9(a) and 91.417(a)(2)(v). The record must be maintained as required by 14 CFR 91.417, 121.380, or 135.439. Figure 1 to Paragraph (g)(1)—TRB Tip Cap Check/Inspection (2) Within 100 hours TIS or during the next 100 hour or annual inspection after the effective date of this AD, whichever occurs first, and thereafter at intervals not to exceed 100 hours TIS or during the next 100 hour or annual inspection, whichever occurs first, visually inspect each TRB tip cap area (at and adjacent to the tip cap bond line on each surface and edge of the TRB) for evidence of corrosion, which may be indicated by an exposed tip cap bond line or bubbled paint, as depicted in Figure 1 to paragraph (g)(1) of this AD. (3) As a result of the actions required by either paragraph (g)(1) or (2) of this AD, if there is evidence of corrosion, an exposed tip cap bond line, or bubbled paint, before further flight, remove all of the 2/27/24, 8:52 AM about:blank about:blank 7/8 corrosion. Note 1 to paragraph (g)(3): Robinson Helicopter Company R22 Service Letter SL–93, R44 Service Letter SL–82, and R66 Service Letter SL–40, each dated June 30, 2021 (co-published as one document), provide information regarding removing corrosion from TRBs. (4) Within 10 months of the effective date of this AD, remove all TRBs identified in paragraph (c) of this AD from service. (5) As of 10 months after the effective date of this AD, do not install a TRB identified in paragraph (c) of this AD on any helicopter. (h) Alternative Methods of Compliance (AMOCs) (1) The Manager, West Certification Branch, FAA, has the authority to approve AMOCs for this AD, if requested using the procedures found in 14 CFR 39.19. In accordance with 14 CFR 39.19, send your request to your principal inspector or local Flight Standards District Office, as appropriate. If sending information directly to the manager of the West Certification Branch, send it to the attention of the person identified in paragraph (i)(1) of this AD. Information may be emailed to: 9-ANM-LAACO- AMOC-REQUESTS@faa.gov. (2) Before using any approved AMOC, notify your appropriate principal inspector, or lacking a principal inspector, the manager of the local flight standards district office/certificate holding district office. (i) Additional Information (1) For more information about this AD, contact James Guo, Aviation Safety Engineer, FAA, 3960 Paramount Boulevard, Lakewood, CA 90712; phone: (562) 627–5357; email: james.guo@faa.gov. (2) For service information identified in this AD that is not incorporated by reference, contact Robinson Helicopter Company, Technical Support Department, 2901 Airport Drive, Torrance, CA 90505; phone (310) 539–0508; fax (310) 539–5198; email ts1@robinsonheli.com; or website robinsonheli.com. You may view this service information at the FAA, Office of the Regional Counsel, Southwest Region, 10101 Hillwood Parkway, Room 6N–321, Fort Worth, TX 76177. For information on the availability of this material at the FAA, call (817) 222–5110. (j) Material Incorporated by Reference None. Issued on February 13, 2024. Victor Wicklund, Deputy Director, Compliance & Airworthiness Division, Aircraft Certification Service. [FR Doc. 2024–03920 Filed 2–26–24; 8:45 am] 2/27/24, 8:52 AM about:blank about:blank 8/8 BILLING CODE 4910–13–P Date: See digital signature In Reply Refer To: 772-25-00024 Mr. Stephen Turnour Robinson Helicopter Company 2901 Airport Drive Torrance, California 90505 References: (1) Robinson Helicopter Company (RHC) Request Letter 66-25-01-02 dated January 13, 2025, COS - AMOC Request -Robinson AD 2024-04-02, with Enclosures (2) RHC Report RTR 635, Revision J, dated March 08, 2024 Dear Mr. Turnour: Subject: Approval of Global Alternative Method of Compliance (AMOC) to AD 2024- 04-02 for Robinson Helicopter Company R22, R22 Alpha, R22 Beta, R22 Mariner, R44, R44 II, R66 Helicopters The Federal Aviation Administration (FAA) has received your reference (1) letter proposing an AMOC to paragraph (g)(4) of AD 2024-04-02. AD 2024-04-02 addresses corrosion of tail rotor blade (TRB) tip caps that could cause debonding and liberation of the TRB tip cap. Affected aircraft and TRB are identified in paragraph (c) of AD 2024-04-02. Paragraph (g)(4) requires all TRB identified in paragraph (c) to be removed from service 10 months after the effective date of AD 2024-04-02. RHC has identified that recent production rates would not allow the current fleet of affected aircraft to comply in time with the AD. You are proposing as an AMOC to paragraph (g)(4) of AD 2024-04-02, to extend the compliance time 5 additional months (15 months after the effective date of the AD) to remove all TRBs identified in paragraph (c) of AD 2024-04-02 from service. This is under the condition that until removal from service, a repeat 10x visual maintenance inspection for corrosion along the TRB tip cap bond line at the leading edge, trailing edge, inboard and outboard surfaces is performed every 15 calendar days, and any evidence of corrosion must be removed before further flight. The FAA has reviewed your request and finds that your proposal provides an acceptable level of safety with regards to the requirements of paragraph (g)(4) of AD 2024-04-02. This determination was based on your reference (2) substantiation detailing the development of corrosion of the tip cap material along with FAA evaluation of the safety determination and risk evaluations used in the development of AD 2024-04-02. This 5-month extension however is the limit that the FAA can extend the compliance to paragraph (g)(4) of AD 2024-04-02 and no further extensions using any type of visual inspection will be granted as a global AMOC. Aviation Safety Aircraft Certification Service Compliance & Airworthiness Division West Certification Branch 3960 Paramount Boulevard, Suite 100 Lakewood, CA 90712-4102 772-25-00024 2 The FAA approves your AMOC proposal to paragraph (g)(4) of AD 2024-04-02, to extend the compliance time by 5 additional months (15 months after the effective date of the AD) under the condition that a repeat 10x visual maintenance inspection for corrosion along the tip cap bond line is performed at all the following locations: At the leading edge of the TRB tip cap bond line On the inboard surface of the TRB tip cap bond line On the outboard surface of the TRB tip cap bond line At the trailing edge of the TRB tip cap bond line Corrosion may be indicated by an exposed tip cap bond line or bubbled paint as identified in Figure 1 of paragraph (g)(1) of AD 2024-04-02. This inspection is to be repeated every 15 calendar days until the affected TRB is removed from service. If there is evidence of corrosion, an exposed tip cap bond line, or bubbled paint, before further flight, remove all the corrosion. The following limitations apply to this AMOC: All provisions of AD 2024-04-02 that are not specifically referenced above remain fully applicable and must be complied with accordingly. This approval is applicable to Robinson Helicopter Company R22, R22 Alpha, R22 Beta, R22 Mariner, R44, R44 II, R66 helicopters identified within the applicability of AD 2024-04-02 Affected tail rotor blades identified in paragraph (c) of AD 2024-04-02 must be removed from service within 15 months after the effective date of AD 2024-04-02. This FAA AMOC is transferable with the aircraft to another owner/operator. Before using this AMOC, notify your appropriate principal inspector, or lacking a principal inspector, the manager of the local Flight Standards District Office/Certificate Holding District Office. The preceding paragraph also applies to any applicable foreign-registered aircraft upon transfer of the aircraft to the U.S. registry if compliance with the AMOC has not been accomplished. This AMOC only applies to the FAA AD listed above. The FAA does not have the authority to approve this as an AMOC to any AD issued by another civil aviation authority (CAA). Approval of an AMOC to another CAA’s AD must come from that CAA. A copy of this response will be forwarded to the CAA where these aircraft are registered for their consideration. 772-25-00024 3 If you have any questions, or need additional information, please contact James Guo at (562) 627-5357 or email at james.guo@faa.gov. Sincerely, for Gregory S. DiLibero Manager, West Certification Branch Compliance & Airworthiness Division Aircraft Certification Service

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