AD 2022-05-10 Prompted By Hoists Failing Lower Load Limit Inspections

The FAA is adopting a new airworthiness directive (AD) for various model helicopters with certain part-numbered Goodrich externally-mounted hoist assemblies (hoists) installed.

This AD was prompted by hoists failing lower load limit inspections. This AD requires replacing unmodified hoists, installing placards, revising the existing Rotorcraft Flight Manual (RFM) for your helicopter, deactivating or removing a hoist if a partial peel out occurs, reviewing the helicopter's hoist slip load test records, repetitively inspecting the hoist cable and overload clutch (clutch), and reporting information to the manufacturer. This AD also requires establishing operating limitations on the hoist and prohibits installing an unmodified hoist. The FAA is issuing this AD to address the unsafe condition on these products. This AD is effective April 20, 2022. 

Supplementary Information: The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 CFR part 39 by adding an AD that would apply to various model helicopters with certain part-numbered externally-mounted Goodrich hoists installed. The NPRM published in the Federal Register on December 11, 2020 (85 FR 79930). In the NPRM, the FAA proposed to require replacing unmodified hoists, installing placards, revising the existing RFM for your helicopter, deactivating or removing a hoist if a partial peel out occurs, reviewing the helicopter's hoist slip load test records, repetitively inspecting the hoist cable and clutch, and reporting information to the manufacturer.

The NPRM was prompted by a series of EASA ADs, the most recent at that time being EASA AD 2015-0226R5, Revision 5, dated July 23, 2020 (EASA AD 2015-0226R5), to correct an unsafe condition for various model helicopters with a Goodrich externally-mounted hoist with one of the following part numbers (P/Ns) or base P/Ns installed: 42315, 42325, 44301-10-1, 44301-10-2, 44301-10-4, 44301-10-5, 44301-10-6, 4430110-7, 44301-10-8, 44301-10-9, 44301-10-10, 44301-10-11, 44311, 44312, 44314, 44315, 44316, or 44318. EASA advised of an initial incident of a rescue hoist containing a dummy test load of 552 lbs. that reeled-out without command of the operator and impacted the ground during a maintenance check flight because the overload clutch had failed. EASA stated that this condition, if not detected and corrected, could lead to further cases of in-flight loss of the hoist load, possibly resulting in injury to persons on the ground or in a hoisting accident.

Accordingly, EASA AD 2015-0226R5 required a records review to determine if the cable had exceeded the allowable limit in previous load testing, a repetitive load check and test of the clutch slip value, removal or deactivation of a hoist that could not be tested due to lack of approved instructions, replacement of the old clutch P/N with a new clutch developed by Goodrich to mitigate some of the factors resulting in clutch degradation, periodic replacement of the hoist, reduction of the maximum allowable load on the hoist, addition of operational limitations to the RFM, and replacement of the hoist after a partial peel out. EASA AD 2015-0226R5 also prohibited the installation of a replacement cable that has exceeded the allowable limit in previous load testing. EASA considered AD 2015-0226R5 to be interim action and advised further AD action may follow. 

The FAA issued a supplemental notice of proposed rulemaking (SNPRM) to amend 14 CFR part 39 by adding an AD that would apply to various model helicopters with certain part-numbered externally-mounted Goodrich hoists installed. The SNPRM published in the Federal Register on September 30, 2021 (86 FR 54129). The SNPRM proposed to revise the NPRM by adding a figure and revising certain requirements, including changes to the temperatures in the maximum hoist load limitations and adding the cost of a (field) load check tool. The SNPRM was prompted by changes from the public comments, which expanded the scope of the NPRM.  Although the NPRM and SNPRM discussed the unsafe condition as described by EASA in EASA AD 2015-0226R5, the FAA based most of the proposed requirements in both the NPRM and the SNPRM on service information issued by Goodrich for all helicopter models with an affected hoist.

For the replacement intervals proposed in paragraph (g)(1) of the NPRM and SNPRM, the FAA based those actions on portions of the EASA AD that are not model specific.

FMI: www.regulations.gov