Airworthiness Directive · Amendment 39-14210 · Robinson Helicopter Company Model R-22 Series Helicopters
Robinson Helicopter Company Model R-22 Series Helicopters
Model R-22 series helicopters, modified with a door assembly manufactured by Tech-Tool Plastics, Inc., in accordance with STC No. SR09189RC, certificated in any category.
This amendment adopts a new airworthiness directive (AD) for the specified Robinson Helicopter Company (Robinson) Model R-22 series helicopters that have been modified in accordance with Supplemental Type Certificate (STC) No. SR09189RC. This action requires inspecting the left-hand door and right-hand door for a crack in the door assembly integral frame, and replacing the door assembly if a crack is found. This AD also requires inspecting each door assembly to determine if the weather seal set is airworthy and installed properly, inspecting each door hinge for the proper installation of a cotter pin, and thereafter, at intervals not to exceed 100 hours time-in-service (TIS), inspecting each door assembly integral frame for a crack. This amendment is prompted by one accident and one incident involving Robinson Model R-22 series helicopters. The actions specified in this AD are intended to prevent separation of a door window or door assembly from the helicopter, which could damage the tail rotor during flight and result in loss of control of the helicopter.
To prevent separation of a door window or door assembly from the helicopter, which could damage the tail rotor during flight and result in loss of control of the helicopter, accomplish the following:
(a) Within 30 days, inspect the left-hand and right-hand door assemblies as follows:
(1) Visually inspect each pilot and copilot door assembly integral frame for a crack in the locations depicted in Figure 1 of this AD. If a crack is found, before further flight, replace the cracked door assembly, part number (P/N) R-22-101-51 or P/N R-22-101-53 (left-hand door assembly), or P/N R-22-101-52 or P/N R-22-101-54 (right-hand door assembly), with an airworthy door assembly. If you use door assembly, P/N R-22-101-51 or P/N R-22-101-53 (left-hand door assembly), or P/N R-22-101-52 or P/N R-22-101-54 (right-hand door assembly) as the replacement, then install it in accordance with Tech-Tool Plastics, Inc. Installation Instructions TTP-1R, Revision A, dated November 21, 1997, and with the sections titled “Door Weather Seal Installation” and “Cotter Pin Installation” in Tech-Tool Plastics, Inc. Service Bulletin No. TTP2005-01, Revision A, dated February 1, 2005 (SB).
(2) If no crack is found in any door assembly integral frame, do the following:
(i) Visually inspect the weather seal set in each door assembly to determine if it is airworthy and installed properly. If it is not airworthy, before further flight, replace it with either the weather seal set, P/N 74418X14L and P/N 74814X12BL, supplied by Tech-Tool Plastics, Inc., in accordance with the “Door Weather Seal Installation” section of the SB, or replace it with any other airworthy door weather seal set in accordance with the applicable FAA-approved installation instructions. If an airworthy weather seal set, P/N 74418X14L and P/N 74814X12BL, is not installed properly, before further flight, reinstall it in accordance with the “Door Weather Seal Installation” section of the SB. If the improperly installed weather seal set is not the weather seal set supplied by Tech-Tool Plastics, Inc., before further flight, reinstall it in accordance with the applicable FAA-approved installation instructions.
(ii) Visually inspect each door hinge on each door assembly to determine if the cotter pins, P/N MS24665-136, are installed in accordance with the “Cotter Pin Installation” section of the SB. If a cotter pin is not installed in accordance with the “Cotter Pin Installation” section of the SB, before further flight, install the cotter pins in accordance with the “Cotter Pin Installation” section of the SB.
Note: The installation of nylon adjustment screws and the trimming of door assembly edges are important maintenance actions that may reduce the strength of a door assembly if not done properly.
(b) After accomplishing the inspections in paragraphs (a) through (a)(2)(ii) of this AD, at intervals not to exceed 100 hours time-in-service, visually inspect each pilot and copilot door assembly integral frame for a crack in the locations depicted in Figure 1 of this AD.
(c) If a crack is found, before further flight, replace the cracked door assembly, P/N R-22-101-51 or P/N R-22-101-53 (left-hand door assembly), or P/N R-22-101-52 or P/N R-22-101-54 (right-hand door assembly), with an airworthy door assembly. If the replacement door assembly is P/N R-22-101-51 or P/N R-22-101-53 (left-hand door assembly), or P/N R-22-101-52 or P/N R-22-101-54 (right-hand door assembly), then install it in accordance with Tech-Tool Plastics, Inc. Installation Instructions TTP-1R, Revision A, dated November 21, 1997, and “Door Weather Seal Installation” and “Cotter Pin Installation” sections of the SB.
(d) If any of the inspections required by this AD reveal a crack in any door assembly frame, report the following information to the FAA within 30 days after discovering the crack: a description of the crack and the specific helicopter model involved. You may submit your report via mail, Fax, or telephone to the FAA, ATTN: ASW-170 (Marc Belhumeur), 2601 Meacham Blvd., Fort Worth, Texas 76137, telephone (817) 222-5177, fax (817) 222-5783. Information collection requirements contained in this AD have been approved by the Office of Management and Budget (OMB) under the provisions of the Paperwork Reduction Act of 1980 (44 U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-0056.
(e) To request a different method of compliance or a different compliance time for this AD, follow the procedures in 14 CFR 39.19. Contact the Rotorcraft Certification Office, Rotorcraft Directorate, FAA, for information about previously approved alternative methods of compliance.
