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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,  cer-
    tificated 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 in-
    clusive (P/N F029-1 REV A through F inclusive), installed.

(d) SUBJECT

    Joint Aircraft System Component (JASC) Code 6410, Tail Rotor Blades.

(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 al-
    ready 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.

                        ILLUSTRATION (Figure 1)

(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 cor-
    rosion.

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 regard-
ing 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 in-
    spector,  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 robin
    sonheli.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.

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.
PREAMBLE 

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 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.
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-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.
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

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

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. 106(g), 40113, 44701.

Sec. 39.13 [Amended]

2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive: