{"id":"F2005L02370","name":"AD/R22/52 - Door and Window Assembly","slug":"ad-r22-52-door-and-window-assembly","collection":"legislative_instrument","jurisdiction":"commonwealth","status":"in_force","isInForce":true,"actNumber":null,"makingDate":null,"administeringDepartment":null,"currentVersion":{"id":36767,"registerId":"commonwealth-F2005L02370-current","compilationNumber":null,"startDate":"2026-04-01","status":"InForce","reasons":null,"registeredAt":null},"sections":[{"sectionNumber":"Robinson R22 Series Helicopters","sectionType":"division","heading":"Robinson R22 Series Helicopters","content":"### Robinson R22 Series Helicopters\n\n| AD/R22/52 | Door and Window Assembly | 11/2005 DM |\n| --------- | ------------------------ | ---------- |\n\n| Applicability: | Model R22 series helicopters, modified with a door assembly manufactured by Tech-Tool Plastics, Inc., in accordance with STC No. SR09189RC. |\n| -------------- | ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| Requirement: | 1. Inspect the left-hand and right-hand door assemblies as follows:Visually inspect each pilot and co-pilot door assembly integral frame for a crack in the locations depicted in Figure 1 of this Directive. 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/NR-22-101-54 (right-hand door assembly), with a serviceable door assembly. If the above part number door assemblies are used as the replacement, then accomplish the replacement in accordance with Tech-Tool Plastics, Inc., Installation Instructions TTP-1R, Revision A, dated 21 November 1997, and with the sections titled “Door Weather Seal Installation” and “Cotter Pin Installation” in Tech-Tool Plastics, Inc., Service Bulletin (SB) No. TTP2005-01 Revision A, dated 1 February 2005. |\n| | 2. If no crack is found in any door assembly integral frame, accomplish the following:a. Visually inspect the weather seal set in each door assembly to determine if it is serviceable and correctly installed. If the seal is unserviceable, 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 SB No. TTP2005-01 Revision A, or replace it with any other serviceable door weather seal set in accordance with the applicable FAA-approved installation instructions. If a serviceable weather seal set, P/N 74418X14L and P/N 74814X12BL, is not installed correctly, before further flight, re-install it in accordance with SB No. TTP2005-01 Revision A. If the incorrectly installed weather seal set is not the weather seal set supplied by Tech-Tool Plastics Inc., before further flight, re-install it in accordance with the applicable FAA-approved installation instructions.b. 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 SB No. TTP2005-01 Revision A. If a cotter pin is not installed in accordance with the “Cotter Pin Installation” section of the service bulletin, before further flight, install the cotter pins in accordance with the “Cotter Pin Installation” section of the service bulletin.Note 1: The installation of nylon adjustment screws and the trimming of door assembly edges are important maintenance actions that may reduce the strength of the door assembly if not done correctly.Note 2: FAA AD 2005-16-05 Amdt 39-14210 refers. |\n| Compliance: | Within 30 days after 26 August 2005. Thereafter, inspect in accordance with Requirement 1, at intervals not to exceed 100 hours time in service. |\n| | This Airworthiness Directive becomes effective on 26 August 2005. |\n| Background: | Reports of a fatal accident and an incident prompted the FAA to require the actions specified in this Directive. The actions specified in this Directive 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 the helicopter. |\n\n![](image.002.png) \nDavid Punshon \nDelegate of the Civil Aviation Safety Authority\n\n24 August 2005","sortOrder":0},{"sectionNumber":"AD/R22/52","sectionType":"part","heading":"AD/R22/52","content":"## AD/R22/52","sortOrder":1},{"sectionNumber":"Door and Window Assembly","sectionType":"part","heading":"Door and Window Assembly","content":"## Door and Window Assembly","sortOrder":2},{"sectionNumber":"11/2005 DM","sectionType":"part","heading":"11/2005 DM","content":"## 11/2005 DM","sortOrder":3}],"analysis":{"flash_summary":{"complexity_score":4,"scope_assessment":{"changed":false,"description":"Scope is confined to R22 series helicopters modified with the specified Tech‑Tool Plastics door assemblies per STC SR09189RC. The directive prescribes inspections, corrective replacements or reinstallations, and recurring intervals; it does not expand applicability beyond that defined set."},"complexity_factors":["Narrow applicability tied to a specific STC (SR09189RC) and manufacturer (Tech‑Tool Plastics) — requires checking registry/configuration for applicability.","Multiple exact part numbers referenced (door assembly and weather seal P/Ns, cotter pin P/N MS24665-136) increasing procedural precision.","Cross-references to external documents (Tech‑Tool Installation Instructions TTP-1R Rev A and SB TTP2005-01 Rev A) for correct repairs and installations.","Conditional, branching requirements: different actions depending on whether cracks or installation defects are found (replace vs re-install vs inspect).","Mandatory ‘before further flight’ corrective action imposes immediate grounding/repair when defects are found.","Recurring compliance interval (every 100 flight hours) creates ongoing maintenance and tracking burden for operators.","Technical inspection and repair work requires personnel able to detect cracks and follow manufacturer FAA‑approved procedures.","Reference to related FAA AD introduces potential reliance on foreign regulator materials and standards."],"plain_english_summary":"Requires operators of Robinson R22 helicopters fitted with Tech‑Tool Plastics door assemblies (per STC SR09189RC) to inspect door frames, weather seals and cotter pins, and to replace or reinstall parts found cracked, unserviceable or incorrectly fitted. Compliance is mandatory within 30 days of 26 August 2005 and then every 100 flight hours; unsafe findings must be rectified before further flight. The directive aims to prevent door/window separation that could damage the tail rotor. Operators bear inspection and replacement costs; CASA's delegate enforces the directive."},"flash_summary_failed":{"failed":true,"reason":"A positive credit balance is required for all requests, including BYOK, so fallback providers remain available. Add credits at https://vercel.com/d?to=%2F%5Bteam%5D%2F%7E%2Fai%3Fmodal%3Dtop-up to continue.","source":"analysis-cron"},"kimi_summary":{"content_quality":"ok","complexity_score":4,"scope_assessment":{"changed":false,"description":"This is a standard Airworthiness Directive with a focused, narrow scope: addressing a specific safety defect in a specific aftermarket modification to a specific helicopter model. The scope remains tightly constrained to door/window assembly integrity and has not expanded beyond the original safety purpose."},"complexity_factors":["Multiple nested conditional requirements (if crack found → replace; if no crack → check seals; if seals unserviceable → replace; if seals incorrectly installed → reinstall; etc.)","Specific part number references (P/N R-22-101-51, P/N 74418X14L, etc.) that require cross-referencing with manufacturer documentation","References to external documents: Tech-Tool Plastics Installation Instructions TTP-1R Revision A, Service Bulletin TTP2005-01 Revision A, and FAA AD 2005-16-05","Dual-path compliance depending on inspection findings (crack vs. no crack)","Specific applicability criteria requiring verification of STC number and manufacturer"],"plain_english_summary":"This CASA Airworthiness Directive mandates owners/operators of Robinson R22 helicopters fitted with the Tech‑Tool Plastics door kit (STC No. SR09189RC) to inspect both pilot doors for cracks within 30 days of 26 Aug 2005 and every 100 flight hours thereafter, replacing any cracked door before flight and checking seals and cotter pins.\n\nIt responds to a fatal accident and an incident where in‑flight door/window separation risked tail‑rotor impact and loss of control."}},"importantCases":[],"_links":{"self":"/api/acts/ad-r22-52-door-and-window-assembly","history":"/api/acts/ad-r22-52-door-and-window-assembly/history","analysis":"/api/acts/ad-r22-52-door-and-window-assembly/analysis","conflicts":"/api/acts/ad-r22-52-door-and-window-assembly/conflicts","importantCases":"/api/acts/ad-r22-52-door-and-window-assembly/important-cases","documents":"/api/acts/ad-r22-52-door-and-window-assembly/documents"}}