Robinson Helicopter AD 2024-23-01: What You Need To Know

Posted by Clinton McJenkin on Dec 6th 2024

Robinson Helicopter Safety Alert: What You Need to Know About AD 2024-23-01: Owners and operators of Robinson R44 and R44 II helicopters need to be aware of a critical safety alert issued by the Federal Aviation Administration (FAA). A new Airworthiness Directive (AD), number 2024-23-01, addresses a concerning issue involving the potential failure of clutch actuators and their mounting brackets. The information is based on the Airworthiness Directive (AD) 2024-23-01, issued by the Federal Aviation Administration (FAA).

Clinton McJenkin

December 6, 2024

Fighting the aviation scams on social media and what BAS Part Sales is doing about it

The Problem

Several reports have surfaced detailing failures of clutch actuators and the rivets securing the actuator brackets to the fan scroll housing. This failure can lead to a dangerous situation, potentially causing:

Detachment of the bracket:

The bracket separating from the fan scroll housing.

Clutch Actuator Failure:

A complete failure of the clutch actuator assembly.

Loss of Rotor Drive:

Loss of main and tail rotor drive.

Loss of Control:

Ultimately, this can result in a loss of control of the helicopter.

This isn't a hypothetical risk; these failures have already occurred in the field. The FAA is taking proactive steps to prevent further incidents.

The Robinson Helicopter Company's R44 and R44 II helicopters experienced failed clutch actuators and rivets attaching the clutch actuator bracket to the fan scroll housing. This led to the bracket separating from the housing, causing belt tension actuator failure in several reported incidents.

The Solution:
Mandatory Inspections and Repairs

AD 2024-23-01 mandates inspections and potential repairs to affected helicopters. The solution, as outlined in the FAA's Airworthiness Directive (AD 2024-23-01), is to inspect the brackets for looseness and fretting. Depending on the inspection results, further actions are required, potentially including:

Visual Inspection

Inspect the fiberglass and rivet holes for delamination.

Rivet Inspection

Check the quantity and size of rivets (they should be 5/32-inch rivets).

Part Replacement

Replace loose or damaged brackets, inner plates, and fan scroll housings.

Repair

Repair any delamination in the fiberglass or rivet holes.

Further Actions (Dependent on Inspection Results):

Within 300 hours time-in-service or 12 months of the AD's effective date (January 7, 2025), whichever comes first, inspect each bracket for looseness and fretting with the fanwheel removed.

No Looseness or Fretting:

Visually inspect the fiberglass adjacent to the rivets for delamination. If delamination is found, replace the fan scroll housing with an airworthy one using the specified rivets.

Looseness or Fretting:

Remove all brackets and inner plates. Inspect for cracks, deformation, and delamination in the brackets, inner plates, and fan scroll housing. Replace any damaged parts with airworthy components and ensure proper rivet installation (5/32-inch rivets) and application of a torque stripe to each rivet.

Key Details and Compliance

Affected Helicopters

This AD applies to Robinson R44 and R44 II helicopters with specific serial number ranges and those equipped with riveted belt tension clutch actuator brackets (part numbers A185-1, A185-2, or A185-5). Helicopters with screw-mounted brackets are not affected.

Reference Material

The AD references Robinson Helicopter Company R44 Service Letter SL-61B, which provides detailed diagrams and procedures for inspection and repair. This document should be consulted for a complete understanding of the required actions.

Compliance Time

Compliance is required within the specified timeframes, unless already accomplished.

What Should You Do?

If you own or operate an affected Robinson R44 or R44 II helicopter, immediately review AD 2024-23-01 and SL-61B. Contact your maintenance personnel to schedule the necessary inspections and repairs as soon as possible. Addressing this issue promptly is crucial for the safety of pilots, passengers, and the helicopter itself. Failure to comply with the AD can lead to serious consequences.

Airworthiness Directive (AD) - 2024-23-01

https://drs.faa.gov/browse/excelExternalWindow/FR-ADFRAWD-2024-28178-0000000000.0001

You Might Also Like...

Robinson Helicopter: A Legacy of Affordable Flight

Robinson Helicopter Company, founded in 1973 by Frank Robinson, revolutionized the helicopter industry by focusing on simplicity, affordability, and ease of maintenance. Unlike the complex and expensive helicopters of the time, Robinson's designs prioritized practicality, making flight training and personal helicopter ownership accessible [...]

Robinson R44 SAIB 2024-05: Understanding and Addressing the Gearmotor Issue

Robinson R44 Gearmotor Assembly Looseness: A Comprehensive Overview - This document provides a detailed analysis of the gearmotor assembly looseness issue affecting certain Robinson R44 helicopters, outlining the problem, the implemented solutions, and the specific aircraft models impacted. The information is based on [...]

BAS Kansas City Takes Flight: A Behind-the-Scenes Look with Kate Broug

It's been about a year and a half since BAS acquired the former White Industries and rebranded it as BAS Kansas City. It has been a wild ride, to say the least. One of the key goals for our leadership and marketing teams [...]