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ROBINSON
HELICOPTER COMPANY 2901 Airport Drive, Torrance, California 90505 Phone (310) 539-0508 Fax (310) 539-5198 Page 1 of 3 R22 SERVICE BULLETIN SB-103 DATE: 30 April 2010 IO: R22 owners, operators, and maintenance personnel SUBJECT: Main Rotor Blade Bond Inspection ROTORCRAFT AFFECTED: R22-series helicopters with A016-4 main rotor blades.
TIME OF COMPLIANCE: At next 100-nour inspection, annual inspection, or by 31 July 2010, whichever occurs first, and at each 100-hour and annual inspection thereafter.
BACKGROUND: Debonding of rotor blade skins can occur when the bond line is exposed due to erosion of the blade finish, or when corrosion occurs on the internal aluminum tip cap. Proper inspection and protection (refinishing) of bonded areas is required. Debonding resulting from improper inspection and maintenance could cause a catastrophic accident.
COMPLIANCE PROCEDURE:
NOTE To facilitate inspection, blade may be teetered down, collective fully raised, and cyclic stick positioned to apply maximum up pitch.
1. Refer to Figures 1 and 2. Remove both main rotor blade tip covers and clean the blades.
2. Using 10x magnification, visually inspect uncovered skin-to-tip cap bond joints. Using a 1965-or-later United States quarter-dollar coin, tap test skin-to-tip cap bond joints on both upper and lower surfaces. If corrosion, separation, or voids are detected, blade is unairworthy. Tap test tutorial video is available at: www.robinsonheli.com/support.htm.
3. Using 10x magnification, visually inspect any exposed skin-to-spar bond line for gaps (empty space between skin and spar). Blade is unairworthy if any gap, including "pin hole(s)", is detected in the bond line.
4. Refer to Figure 2. Mark outboard 120 inches of blade lower surface as shown to identify skin-to-spar bond joint area.
5. Verify no visible dents within the bond joint area. Blade is unairworthy if bond joint area is dented.
(OVER)
R22 SB-103 Page 2 of 3
6. Tap test the lower skin-to-spar bond joint and verify no voids exist. Blade is unairworthy if a void is detected.
7. Refinish all exposed bare metal per R22 SL-56B.
8. Install blade tip covers.
9. Make appropriate maintenance record entries.
Approximate Cost:
Parts: $5 for KI-199 Kit if ordered by 31 July 2010.
KI-199 Kit includes:
1 ea MT332-22 tool 1 ea SAN30001 Sharpie® marker Labor: Less than 1 man-hour.
GAP in bond line requires blade replacement (example).
PIN HOLE in bond line requires blade replacement (example).
SKIN-TO-SPAR BOND LINE, located Bond Line (adhesive)
0.96 inch from leading edge of blade (requires inspection and evaluation if exposed, see text)
EXPOSED SPAR METAL (example)
REMOVABLE
TIP COVER
EXPOSED PAINT PRIMER (example)
SKIN-TO-TIP CAP
CRITICAL BOND JOINT
• YELLOW PAINT
0.75 inch
1.0 inch FIGURE 1 TIP AREAAND LOWER SURFACE (Example, Blade with Excessive Paint Erosion)
R22 SB-103 Page 3 of 3 Hold MT332-22 (R22-series) tool against main rotor blade surface and leading edge while moving it spanwise.
- 0.078-inch diameter Holes Marked Lines Insert felt tip of Sharpie® (brand) 30000-series "FINE POINT PERMANENT MARKER" thru holes in tool and mark two spanwise lines along lower surface from tip inboard 120 inches.