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TRANSLATION OF B OLLETTINO TECNICO N° 109EP-128
The technical content of this document is approved under the authority of DOA nr EASA.21J.005.
DATE January 21, 2013
REV. A May 28, 2013xx, 2011
Compliance with T his bollettino is:
A n a ppropriate entry should be made in the aircraft log book upon accomplishment.
If ownership of aircraft has changed, please forward to new owner.
XX Page 1 of 7
SUBJECT:INSPECTION OF GLEASON CROWN P/N 109-0403-07-103.
REASON: Introduction of additional inspections of Gleason crown P/N 109-0403-07-103.
HELICOPTERS AFFECTED:
All the Agusta helicopters A109 E that install the main transmission P/N 109-0400-03-109 up to S/N L48 included and have not applied the Bollettino Tecnico n° 109EP-126.
NOTE 1 Serial Numbers follow alphabetic order for the letter and increasing numbering.
NOTE 2 For main transmissions S/N L49 and subsequent, which carried out maintenance activity, check on the pertinent documentation that Gleason Crown Assy P/N 109-0401-27-107 has not been replaced with a Gleason crown assy P/N 109-0401-27-101/-109 (these installing the Gleason Crown P/N 109-0403-07-103 subject to this BT).
AgustaWestland S.p.A Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) Italy T el.: +39 0331 229111 - Fax: +39 0331 229605/222595
MANDATORY An appropriate entry should be made in the aircraft log book upon accomplishment.
If ownership of aircraft has changed, please, forward to new owner.
B.T. 109EP-128
Page 2 of 7
NOTE 3 All the helicopter which have already performed the magnetic particle inspection required by the first edition of this BT are not required to repeat it up to the overhaul.
COMPLIANCE:
Flight Hours (FH) accumulated by the tra nsmission:
P/N 109-0400-03- 109, on the effective date of this Bollettino Compliance time Less or equal to 2400 FH Before exceeding 200 FH after the 2400 FH accumulated by the transmission.
More than 2400 and less than 3000 FH Before exceeding the next 200 FH accumulated by the transmission.
More or equal to 3000 FH and less than 3200 FH Perform the scheduled special inspection per the Maintenance Manual at 3200 FH accumulated by the transmission.
More than 3200 and less than 4000 FH Before exceeding 200 FH after the 4000 FH accumulated by the transmission.
More than 4000 FH and less than 4600 FH Before exceeding the next 200 FH accumulated by the transmission.
More or equal to 4600 FH Before exceeding the overhaul limit (4800 FH) and then each 1600 FH after each TBO.
DESCRIPTION:
On Agusta A119 helicopter, during the execution of the main transmission P/N 109-0400-05-103 overhaul, a crack on Gleason crown P/N 109-0403-07-103 was found.
The investigations show that the crack was originat ed from the bottom of one of 40 threaded holes and that the Gleason crown installed on the A
B.T. 109EP-128
Page 3 of 7
main transmission object of this Bollettino, could be subject to similar problem.
This Bollettino therefore requires the introduction of two unscheduled inspection of the Gleason crown P/N 109-0403-07-103 ; One before the current scheduled 3200 FH, and one between the curr ent scheduled 3200 FH and 4800 FH inspections and the introductio n of one repetitive inspection every 1600 flight hours, after the achie vement of the each overhaul limit, scheduled at 4800 FH. In case of cr ack is found on Gleason crown P/N 109-0403-07-103, it is required t o replace it with a new support assy Gleason crown P/N 109-0401-27-107 (welded to the mast support, therefore it does not have the 40 thr eaded holes) by mean application of BT 109EP-126.
REQUIRED MANPOWER:
An estimated 24 manpower hours are required for com pliance with this Bollettino.
WARRANTY:
Within the calendar terms mentioned at point “Compliance”, the parts required to apply the present Bollettino shall be supplied on a free of charge basis by AgustaWestland S.p.A. upon Customer’s request, with the exception for Consumable materials and Tools; all the parts required after the “Compliance date” will be dispatched on charge basis for the Customer.
Upon application of this Bollettino, Customers are requested to submit to AgustaWestland S.p.A. Warranty Administration the Bollettino Tecnico Compliance form attached to this Bollettino duly completed in all its parts, and relevant W.M.M. form ( (W)arranty Claim (M)aintenance Work Order (M)alfunction Report ).
REQUIRED MATERIALS:
N.A.
SPECIAL TOOLS:
N.A.
WEIGHT AND BALANCE CHANGES:
N.A.
REFERENCES:
A 109E Maintenance Manual;
A119/A109 Series Overhaul Manual.
PUBLICATIONS AFFECTED:
A 109E Maintenance Planning Manual;
A 109E Maintenance Manual.
A119/A109 Series Overhaul Manual.
COMPLIANCE INSTRUCTIONS:
A
B.T. 109EP-128
Page 4 of 7
1. Prepare the helicopter on ground for a safe maintenance and disconnect any power supply in accordance with the instructions given in the A 109E Maintenance Manual.
2. Gain access to Main transmission area removing the Transmission Front Fairing and the Transmission Rear fairing in accordance with the procedure given in the A 109E Maintenance Manual.
3. Verify that the S/N of the main transmission P/N 109-0400-03-109 is S/N “L48” included and previous.
NOTE 1 Serial Numbers follow alphabetic order for the letter and increasing numbering.
NOTE 2 For main transmissions S/N L49 and subsequent, which carried out maintenance activity, check on the pertinent documentation that Gleason Crown Assy P/N 109-0401-27-107 has not been replaced with a Gleason crown 109-0403-07-103 subject to this BT.
4. If the main transmission P/N 109-0400-03-109 is S/N L49 and subsequent, and the Gleason Crown Assy P/N 109-0401-27-107 has not been replaced with a Gleason crown 109-0403-07-103, perform paragraph n° 10.
5. If the main transmission P/N 109-0400-03-109, is S/N L48 included and previous and if S/N is L49 and subsequent, and the Gleason Crown Assy P/N 109-0401-27-107 has been replaced with a Gleason crown 109-0403-07-103, proceed with the following steps:
5.1. In accordance with the instructions given in the A 109E Maintenance Manual, remove the main rotor blades and the main rotor head.
5.2. In accordance with the instructions given in the A 109E Maintenance Manual remove the main transmission from the helicopter.
6. Remove and perform the magnetic particle inspection of the Gleason crown as shown in A 109E Maintenance Manual and Annex 1.
NOTE During the execution of Gleason crown magnetic particle inspection, look at the
B.T. 109EP-128
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presence of cracks at the bottom of threaded holes and in the areas adjacent to them.
7. If after inspection cracks are found, apply BT n ° 109EP-126:
8. If after the inspection no cracks are found, per form all the operations necessary to return the transmission in service as shown in the A 109E Maintenance Manual.
9. In accordance with the instructions given in the A 109E Maintenance Manual, reinstall the Main rotor Head a nd n° 4 Blades.
10. In accordance with the instructions given in th e A 109E Maintenance Manual reinstall the Transmission Front Fairing and the Transmission Rear fairing.
11. Return the helicopter to a ready-to-flight cond ition.
12. Record compliance with this Bollettino in the h elicopter log book.
B.T. 109EP-128
Page 6 of 7
MAGNETIC PARTICLE IN SPECTION (ASTM
A. General.
(1) Consumable materials:
WARNING: THE CONSUMABLE MATER PREFIXED BY «D» ARE DANGEROUS MATERIALS.
BEFORE USE, MAKE SUR E TO KNOW INSTRUCTIONS PRINTED ON:
— THE LABEL ON THE CON — THE MATERIAL SAFETY — THE LOCAL SAFETY REG
ALSO MAKE SURE THAT THE APPLICABLE FIRST — (D) Paint remover.
— (D) MEK — Abrasive pad .
— (D) Aliphatic naphtha — Lubricating.
(2) Other recommendations:
NOTE: Refer to deals with the items in question for magnetic inspection data.
B. Strip paint finish from the part with paint remover. Remov sealant from the surfaces with a plastic scraper and MEK, or abrasive pad .
C. Vapor degrease the part with aliphatic naphtha. Surfaces to be inspected must be free from oil, dirt, paint, corrosion, or other surface films, co defects or give false indications.
NOTE: All magnetic particle inspections must be conducted by the continuous process using the longitudinal and circular methods. The inspection process must be in accordance with th manufacturer's equipment instructions.
D. Circular magnetization method.
(1) Put the part to be inspected between the contact plates of the magnetizing unit so that electrical current passes through the part or through an electrical conductor that passes through the part.
The electrical current used to produce the magnetic flux shall be 240 to 310 Ampere per cm of external diameter of the part. Proceed as follows:
a. All contact areas must be clean and wet to prevent arcing or overheating of the part to tested.
b. The central electrical conductor must be as near the size of the openings as practicable.
c. A central electrical conductor must be used when the length of a part is very small as compared to the diameter or when the wall thickness is very diameter.
d. Sharper defect indications are desired on the inner diameter of the part.
e. Very small parts which are difficult to place between the heads or on a central conductor shall be inspected with the longitudinal method.
E. Lo ngitudinal magnetization method.
(1) The part must be magnetized by placing the part in a coil and passing an electrical current through the coil. The number of ampere determined by the formula:
ANNEX 1 SPECTION (ASTM -E-1444)
THE CONSUMABLE MATER IALS THE NOMENCLATUR E OF WHICH IN THE LI DANGEROUS MATERIALS.
E TO KNOW THE SAFETY PRECAUTIO NS AND FIRST AID ON:
THE LABEL ON THE CON TAINER THE MATERIAL WAS SUPPLIED IN
THE MATERIAL SAFETY DATA SHEET THE LOCAL SAFETY REG ULATIONS.
THE APPLICABLE FIRST AID MATERIALS ARE AV Refer to deals with the items in question for magnetic inspection data.
. Strip paint finish from the part with paint remover. Remov e any remaining finish or aged sealant from the surfaces with a plastic scraper and MEK, or abrasive pad .
. Vapor degrease the part with aliphatic naphtha. Surfaces to be inspected must be free from oil, dirt, paint, corrosion, or other surface films, co atings, or conditions which could mask defects or give false indications.
All magnetic particle inspections must be conducted by the continuous process using the longitudinal and circular methods. The inspection process must be in accordance with th manufacturer's equipment instructions.
. Circular magnetization method.
(1) Put the part to be inspected between the contact plates of the magnetizing unit so that electrical current passes through the part or through an electrical conductor that passes The electrical current used to produce the magnetic flux shall be 240 to 310 Ampere per cm of external diameter of the part. Proceed as follows:
a. All contact areas must be clean and wet to prevent arcing or overheating of the part to
b. The central electrical conductor must be as near the size of the openings as practicable.
c. A central electrical conductor must be used when the length of a part is very small as compared to the diameter or when the wall thickness is very small compared to the
d. Sharper defect indications are desired on the inner diameter of the part.
e. Very small parts which are difficult to place between the heads or on a central conductor shall be inspected with the longitudinal method.
ngitudinal magnetization method.
(1) The part must be magnetized by placing the part in a coil and passing an electrical current through the coil. The number of ampere -turns used to magnetize the part must be
E OF WHICH IN THE LI ST IS
NS AND FIRST AID
WAS SUPPLIED IN AID MATERIALS ARE AV AILABLE.
e any remaining finish or aged sealant from the surfaces with a plastic scraper and MEK, or abrasive pad .
. Vapor degrease the part with aliphatic naphtha. Surfaces to be inspected must be free from atings, or conditions which could mask All magnetic particle inspections must be conducted by the continuous process using the longitudinal and circular methods. The inspection process must be in accordance with th e
(1) Put the part to be inspected between the contact plates of the magnetizing unit so that electrical current passes through the part or through an electrical conductor that passes The electrical current used to produce the magnetic flux shall be 240 to 310 Ampere per
a. All contact areas must be clean and wet to prevent arcing or overheating of the part to be
b. The central electrical conductor must be as near the size of the openings as practicable.
c. A central electrical conductor must be used when the length of a part is very small as small compared to the
e. Very small parts which are difficult to place between the heads or on a central conductor
(1) The part must be magnetized by placing the part in a coil and passing an electrical current turns used to magnetize the part must be
B.T. 109EP-128
Page 7 of 7
where:
l = length of parts;
d = diameter of the part;
and the l/d ratio is between 9 and 3.
When the part has a l/d ratio greater than 9 use 5000 ampere-turns and magnetize the part several times to ensure complete coverage of the part.
A maximum of 15000 ampere-turns shall be used on any part with a l/d ratio less than 3.
NOTE 1: Ampere-turn defines the amperage that passes through the coil multiplied by the number of turns in the coil.
NOTE 2: The part should be placed off-center of the coil with the long axis of the part parallel to the long axis of the coil unless otherwise specified.
F. Application of magnetic particles in suspension - Continuous method.
(1) Prepare the solution; to do this, mix the magnetic particle powder to the suspension.
(2) Apply the magnetic particles in suspension; to do this, spray the liquid through a tube so as to obtain complete coverage of the surface under examination.
(3) Close the magnetization circuit 1/5 to 1/2 second while the part is covered with a film of liquid as necessary to give adequate indication.
(4) Discontinue spraying and leave parts to drip for several seconds.
NOTE: The part on which a film of liquid remains must be rinsed, magnetized and sprayed with the liquid per step (1).
(5) After inspection, acceptable parts shall be cleaned and demagnetized. Check parts with a field indicator to ensure demagnetization.
(6) Apply a film of lubricating oil on the parts to prevent corrosion.
G. Inspect parts with black light.
NOTE: Surface or subsurface defects will be revealed by magnetic particle accumulation around the defect.
Recommended magnetization currents for magnetic particle inspection .
NOMENCL. INSP. AREA
CIRCULAR MAGNETISM
LONGITUDINAL
MAGNETISM
AMP.
CENTR COND DIA (mm) INSP.
AXIS NOTE INSP. AREA AMP. x TURNS NOTE Gleason crown Minor I.D.
Major O.D.
2000
3400 50
Thread-ing bar (INSU- LATED) Longit. [1] Entire item 15000 [4]
NOTE [1] Rotate part by 60° and repeat the inspection at 6 points.
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Note:
Remarks:
Informazioni:
Information:
Al fine di gestire le varianti alla configurazione base, in relazione all’emissione de l Bollettino Tecnico, preghiamo di voler compilare il presente modulo in tutte le sue parti e spedirlo all’indirizzo sopra indicato. Si ringrazia per la gentile collaborazione data.
We request your cooperation in filling this form, in order to keep out statistical data relevant to aircraft configuration up- to-date. The form should be filled in all its parts and sent to the above address. We thank you beforehand for the information given.
MODULO APPLICAZIONE BOLLETTINO TECNICO
TECHNICAL BULLETIN COMPLIANCE FORM Data:
Date:
Numero:
Number:
Revisione:
Revision:
Prego spedire a questo indirizzo:
Please send to the following address:
AGUSTAWESTLAND S.p.A.
CUSTOMER SUPPORT & SERVICES - ITALY PRODUCT SUPPORT ENGINEERING DPT.
Via del Gregge, 100 21015 Lonate Pozzolo (VA) - ITALY Tel.: +39 0331 664905 Fax: +39 0331 664684 Telefono:
Telephone:
Fax:
Data Applicazione B.T.:
B.T. Compliance Date:
Denominazione Cliente ed Indirizzo:
Customer Name and Address:
Modello Elicottero Helicopter Model S/N Matricola Tail Number Ore Totali Total Hours Ore D.U.R. T.S.O.