Leonardo ASB 109EP-177: No revision named

Pa ge 1 of 53 N° 109EP-177 DA TE: January 11, 2022 REV. : A - M arch 3, 2022 TITLE ATA 62 – INSPECTION OF MAIN ROTOR SCISSOR CHAIN

REVISION LOG Helicopters which are already complying with previous issue of this Service Bulletin must n ot perform any additional actions.

Revision A is issued in order to introduce the following changes:

- added tolerance for Part IV and Part V compliance time;

- PSE mailbox update;

- Minor amendments.

Revision bars identify changes.

An appropriate entry should be made in the aircraft log book upon accomplishment.

If ownership of aircraft has changed, please, forward to new owner.

Leonardo S.p.A.

Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) Italy Tel.: +39 0331 229111 - Fax: +39 0331 229605/222595 ALERT

SERVICE BULLETIN

S.B. N°109EP-177 ALERT DATE: January 11, 2022 Page 2 of 53 REVISION: A - March 3, 2022

1. PLANNING INFORMATION A. EFFECTIVITY Part I: all A109E helicopters.

Part II: all A109E helicopters not fulfilling Part I or Part IV or Part V requirements.

Part III: all A109E helicopters not fulfilling Part I or Part IV or Part V requirements.

Part IV: all A109E helicopters.

Part V: all A109E helicopters.

B. COMPLIANCE Part I: Within and not later than 25 FH or 3 months, whichever occurs first, after the issue of this Service Bulletin.

Part II: Every 25 FH until replacement of affected components as per Part III.

Part III: Within and not later than 400 FH or 2 years, whichever occurs first, after the detection of affected parts.

Part IV: Every 50 FH. A tolerance of 5 FH is allowed. Tolerances are not cumulative.

Part V: Every 200 FH. A tolerance of 10 FH is allowed. Tolerances are not cumulative.

C. CONCURRENT REQUIREMENTS N.A.

D. REASON This Service Bulletin is issued in order to provide the necessary instructions on how to perform the inspection of the main rotor scissor bearing P/N NHBY6V204.

E. DESCRIPTION Some cases of excessive axial play have been detected on the ball bearing of the lower half of the M/R rotating scissor assy. In few cases, this resulted in the slippage of the ball bearing outside its seat without jeopardizing the functionality of the scissor assy. These events have been detected on-ground during the required maintenance scheduled inspections or Pilot’s Daily Pre-Flight Checks of the rotating scissor for condition and security. The investigation on the root cause is still ongoing but Leonardo Helicopters decided, as a precautionary measure, to issue this SB to perform (Part I) a one-time check to evaluate the correct coupling between the two halves of the rotating scissor assy and to check the axial play of the ball bearing P/N NHBY6V204. In case non-conformities are detected, instructions are provided to keep the axial play under control (Part II) until the replacement of the affected parts

S.B. N°109EP-177 ALERT DATE: January 11, 2022 REVISION: A - March 3, 2022 Page 3 of 53 (Part III). In addition, instructions are provided to perform qualitative (Part IV) and quantitative (Part V) evaluations of the axial play of the ball bearing as a regular inspection task.

Revision A of this Service Bulletin is issued to allow a tolerance to the compliance time of Part IV and Part V.

F. APPROVAL The technical content of this Service Bulletin is approved under the authority of DOA nr. EASA.21.J.005. For helicopters registered under other Aviation Authorities, before applying the Service Bulletin, applicable Aviation Authority approval must be checked within Leonardo Helicopters customer portal.

EASA states mandatory compliance with inspections, modifications or technical directives and related time of compliance by means of relevant Airworthiness Directives.

If an aircraft listed in the effectivity embodies a modification or repair not LHD certified and affecting the content of this Service Bulletin, it is responsibility of the Owner/Operator to obtain a formal approval by Aviation Authority having jurisdiction on the aircraft, for any adaptation necessary before incorporation of the present Service Bulletin.

G. MANPOWER To comply with this Service Bulletin, the following MMH are deemed necessary:

Part I: 2 (two) MMH Part II: 1 (one) MMH Part III: 4 (four) MMH Part IV: 0,30 (half an hour) MMH Part V: 1 (one) MMH MMH do not consider inspections and/or replacements which depend on inspections outcomes. MMH are based on hands-on time and can change with personnel and facilities available.

H. WEIGHT AND BALANCE N.A.

I. REFERENCES

1) PUBLICATIONS Following Data Modules refer to MM:

S.B. N°109EP-177 ALERT DATE: January 11, 2022 Page 4 of 53 REVISION: A - March 3, 2022

DATA MODULE DESCRIPTION PART DM01 00-20-1 Helicopter safety – Pre-operation All DM02 06-40-1 Access panels and doors All DM03 62-31-15 Rotating scissors, Maintenance Practices All DM04 62-31-16 Rotating scissors, Inspection I, II, IV, V DM05 62-31-25A Swashplate and Support, Disassembly/Assembly III DM06 62-21-50 Floating ring, Removal/Installation III

Following Data Modules refer to CR&OP:

DATA MODULE DESCRIPTION PART DM07 3C-A-62-31-03-01C-921A-C Lower lever - Bushings - Replacement (remove and install a new item) III DM08 3C-A-62-31-03-01B-921A-C Lower lever - Bushings - Replacement (remove and install a new item) III DM09 3C-A-62-31-02-01C-921A-C Upper lever - Bushings - Replacement (remove and install a new item) III DM10 3C-A-62-31-02-01B-921A-C Upper lever - Bushings - Replacement (remove and install a new item) III DM11 3C-A-62-21-08-01A-921A-C Scissors support flange - Bushings - Replacement (remove and install a new item) III

2) ACRONYMS & ABBREVIATIONS AMDI Aircraft Material Data Information MM Maintenance Manual CR&OP Component Repair and Overhaul Publication DM Data Module DOA Design Organization Approval EASA European Aviation Safety Agency LH Leonardo Helicopters MMH Maintenance Man Hours P/N Part Number

3) ANNEX ANNEX A – M/R rotating scissor force check ANNEX B – M/R rotating scissor dimensional check

S.B. N°109EP-177 ALERT DATE: January 11, 2022 REVISION: A - March 3, 2022 Page 5 of 53 ANNEX C – M/R rotating scissor axial play check on board the helicopter ANNEX D – M/R rotating scissor axial play check on ground ANNEX E – Detailed compliance form J. PUBLICATIONS AFFECTED A109E-MM Maintenance Manual A109E Helicopter Model.

K. SOFTWARE ACCOMPLISHMENT SUMMARY N.A.

S.B. N°109EP-177 ALERT DATE: January 11, 2022 Page 6 of 53 REVISION: A - March 3, 2022

2. MATERIAL INFORMATION A. REQUIRED MATERIALS

1) PARTS PART I # P/N ALTERNATIVE P/N DESCRIPTION Q.TY LVL NOTE LOG P/N 1 MS24665-283 MS24665-285 Pin, cotter 1 . (1) - 2 MS24665-302 Pin, cotter 1 . (1) -

PART II N.A.

PART III N.A.

PART IV N.A.

PART V N.A.

Refer also to IPC for the spare parts required to comply with the MM Paragraphs/CR&OP DM referenced in the accomplishment instructions.

2) CONSUMABLES

Refer to AMDI for the consumable materials required to comply with the MM/CR&OP DM referenced in the accomplishment instructions.

3) LOGISTIC MATRIX N.A.

NOTE

(1) Item to be procured as local supply.

B. SPECIAL TOOLS The following special tools, or equivalent, are necessary to accomplish this Service Bulletin:

# P/N DESCRIPTION Q.TY NOTE PART 3 Commercial Dynamometer 1 (B1) I

S.B. N°109EP-177 ALERT DATE: January 11, 2022 REVISION: A - March 3, 2022 Page 7 of 53 # P/N DESCRIPTION Q.TY NOTE PART 4 Commercial Non-elastic cable 1 (B1) I 5 Commercial Caliper 1 (B1) I 6 Commercial or P/N 3G6005G04751 Support arm, dial gauge 1 (B2) I,II,IV,V 7 Commercial or P/N 1502251 Dial gauge 1 (B2) I,II,IV,V 8 Commercial or P/N 1500019 Extension dial gauge 1 (B2) I,II,IV,V 9 Commercial or P/N 3G6005G01531 Support dial gauge (M/R damper hub side) 1 (B2) I,II,IV,V Refer also to PTUM for the special tools required to comply with the MM Paragraphs/CR&OP DM referenced in the accomplishment instructions.

Refer also to Annex A for the equipment/tools required for the force check of the main rotor rotating scissor.

Refer also to Annex B for the equipment/tools required for the dimensional check of the main rotor rotating scissor.

Refer also to Annex C for the equipment/tools required for the axial play measurement on board the helicopter.

SPECIAL TOOLS NOTE Tool to be procured as local supply.

Equivalent P/N may be locally supplied or manufactured i.a.w. Annex C – Axial play measurement on board the helicopter.

C. INDUSTRY SUPPORT INFORMATION Owners/Operators who comply with the instructions of this Service Bulletin no later than the applicable date in the “Compliance” section will be eligible to receive REQUIRED MATERIALS on free of charge basis, except for Consumable Materials and Special Tools.

NOTE 1: Customers who fail to comply with the instructions in this Service Bulletin before the compliance date are not eligible for the aforementioned special policy.

Please Issue relevant MMIR form to your Warranty Administration Dpt accompanied by INSPECTION REPORT and PICTURE of the affected area.

NOTE 2: The INSPECTION REPORT and PICTURE are mandatory; in case the MMIR is not accompanied by these documents, it will be rejected.

S.B. N°109EP-177 ALERT DATE: January 11, 2022 Page 8 of 53 REVISION: A - March 3, 2022

3. ACCOMPLISHMENT INSTRUCTIONS

GENERAL NOTES

a) Place an identification tag on all components that are re-usable, including the attaching hardware that has been removed to gain access to the modification area and adequately protect them until their later re-use.

b) Exposed thread surface and nut must be protected using a layer of tectyl according to MIL-C-16173 grade I.

c) All lengths are in mm.

d) The items indicated in this Service Bulletin can be installed on the helicopter with different P/N. Refer to IPD Chapter 62 for the applicable P/N.

e) The logics of operations and instructions required into this SB are explained at high level in the flow chart reported in Figure 1.

PART I

1. In accordance with MM Paragraph 00-20-1, prepare the helicopter on ground for a safe maintenance. Disconnect the battery, all electrical power sources and/or the external power supply.

2. M/R rotating scissor coupling inspection NOTE It is mandatory, in any case, to record all the measures collected during the Force Check and, if required, the Dimensional Check into the Detailed compliance form (Annex E).

2.1 Perform the upper and lower M/R rotating scissor lever reference value force check as per Annex A step 3.

2.2 Perform the upper and lower M/R rotating scissor lever maximum torque force check as per Annex A step 4.

S.B. N°109EP-177 ALERT DATE: January 11, 2022 REVISION: A - March 3, 2022 Page 9 of 53 NOTE Reinstall new cotter-pins and nuts according to the applicable AMP DMs.

NOTE The completion of the installation of the M/R rotating scissor assy is not required if the axial play check at step 3 will be performed directly on ground and not on board the helicopter.

2.3 If at least one of the measures at steps 4.1.4 a nd 4.1.6 of Annex A is not within acceptable values, perform Dimensional Check as per Annex B and proceed with step 2.4, otherwise complete the installation of the M/R scissor assy i.a.w. MM Paragraph 62-31-15 and proceed with Step 3.

2.4 If at least one of the dimensional checks required by Annex B has failed, in accordance with MM Paragraph 62-31-15, reinstall the M/R rotating scissor.

Proceed with Step 3.

2.5 If all checks as per Annex B are compliant with allowable limits, in accordance with MM Paragraph 62-31-15, partially install the M/R scissor assy attaching only the upper scissor lever assy to the bracket flange assy.

2.6 Repeat M/R rotating scissor maximum torque force check as per Annex A step 4.

If this second application is failed, contact Leonardo Helicopters for instructions.

2.7 In accordance with MM Paragraph 62-31-15, reinstall the lower scissor lever assy on the swashplate retaining bolt. Proceed to Step 3.

3. M/R rotating scissor axial play check NOTE It is mandatory, in any case, to record the measures collected during the Axial Play Check into the Detailed compliance form (Annex E).

NOTE If the ball bearing is found dislodged from its seat, record the finding on the Annex E – Detailed compliance form and proceed directly with step 4.

S.B. N°109EP-177 ALERT DATE: January 11, 2022 Page 10 of 53 REVISION: A - March 3, 2022 NOTE If support arm P/N 3G6005G04751 or equivalent is not available or the M/R rotating scissor assy has been already removed from the helicopter it is possible to perform the axial play check on ground i.a.w. Annex D.

3.1 In accordance with Annex C or with Annex D, as a pplicable, perform the axial play check of the ball bearing P/N NHBY6V204.

3.2 Record the value measured in Annex E – Detailed compliance form and proceed with step 4.

4. Inspection Outcomes

4.1 With reference to Figure 1 and to the results of the inspections recorded into the detailed compliance form (Annex E), define the applicable actions as required by Table 1 and proceed with step 5:

NOTE Colours used in Table 1 recalls the outcomes of Scissor Coupling Check and Axial Play inspection as detailed in the flow chart reported in Figure 1 and in the Detailed Compliance Form:

- Green: Test passed

- Yellow: Test failed.

- Red: Axial Play Check failed (axial play greater than

0.75mm). Immediate replacement of parts identified in Table 1 is required.

- Grey: Contact Leonardo Helicopters.

LEONARDO

HELICOPTERS Step 2 - SCISSOR COUPLING CHECK UNCERTAIN RESULT (2ND PASSED FAILED maximum torque force check failed) Consider the helicopter affected by Part Il until PASSED Consider the helicopter affected by Part IV and Part V. Part Ill and then consider the helicopter replacement of all affected components as per affected by Part IV and Part V.

FAILED (axial play Consider the helicopter affected by Part Il until Consider the helicopter affected by Part Il until value between 0.25 replacement of all affected components as per replacement of all affected components as per mm and 0.75 mm) Part Ill and then consider the helicopter affected by Part IV and Part V. Part Ill and then consider the helicopter affected by Part IV and Part V.

Before next flight, replace lower scissor lever assy as per Part Ill. If the lower scissor lever is the only component not fulfilling Part I FAILED (axial play Before next flight, replace lower scissor lever dimensional check, consider the helicopter value greater than assy as per Part Ill and then consider the affected by Part IV and Part V, otherwise Contact Leonardo Helicopters.

0.75 mm) helicopter affected by Part IV and Part V. consider the helicopter affected by Part Il until replacement of all affected components as per Part Ill and then consider the helicopter affected by Part IV and Part V.

Before next flight, replace lower scissor lever assy, retaining bolt and washer as per Part III.

If the lower scissor lever is the only Before next flight, replace lower scissor lever component not fulfilling Part I dimensional FAILED (ball bearing assy, retaining bolt and washer as per Part III check, consider the helicopter affected by Part dislodged) and then consider the helicopter affected by IV and Part V, otherwise consider the Part IV and Part V. helicopter affected by Part Il until replacement of all affected components as per Part III and then consider the helicopter affected by Part IV and Part V.

Table 1 - Part I inspections - Outcomes assessment

5. With reference to MM Paragraph 06-40-1, reinstall the access panels P17, P18 and P24 on the helicopter.

6. Return the helicopter to flight configuration and record for compliance with Part I of this Service Bulletin on the helicopter logbook.

NOTE "XXXXX" in the subject line below is the helicopter S/N.

7. Send the detailed compliance form (Annex E) with Subject line "109EP-177 Rev.A - S/N XXXXX - Detailed Compliance Form to the following mail box:

engineering.support. hd@leonardo.com

8. Send the attached compliance form to the following mail box:

engineering.support. hd@leonardo.com As an alternative, gain access to My Communications section on Leonardo WebPortal and compile the "Service Bulletin Application Communication".

S.B. N°109EP-177 ALERT DATE: January 11, 2022 REVISION: A - March 3, 2022 Page 11 of 53

S.B. N°109EP-177 ALERT DATE: January 11, 2022 Page 12 of 53 REVISION: A - March 3, 2022

PART II

1. In accordance with MM Paragraph 00-20-1, prepare the helicopter on ground for a safe maintenance. Disconnect the battery, all electrical power sources and/or the external power supply.

2. With reference to MM Paragraph 06-40-1, remove the access panels P17, P18 and P24 from the helicopter.

NOTE If the ball bearing is found dislodged from its seat, record the finding and proceed directly with step 4.

NOTE If support arm P/N 3G6005G04751 or equivalent is not available or the M/R rotating scissor has been already removed from the helicopter it is possible to perform axial play check on ground i.a.w. Annex D.

3. In accordance with Annex C or Annex D, as applica ble, perform the axial play check of the ball bearing P/N NHBY6V204. Record the measure acquired.

4. Accounting for the results of the inspection performed at step 3, perform the actions below:

4.1 If axial play value is between 0.25 mm and 0.75 mm, proceed with step 5.

NOTE If the lower scissor lever is the only component not fulfilling Part I requirements, after accomplishment of step 4.2 or 4.3, the helicopter has to be considered affected by Part IV and Part V.

4.2 If axial play value is greater than 0.75 mm, rep lace lower scissor lever assy P/N 109-0134-25-101 (or P/N 109-0134-10-105 or P/N 109-0134-10-101) as per Part III and proceed with step 5.

4.3 If ball bearing is found dislodged, replace lower scissor lever assy P/N 109-0134-25-101 (or P/N 109-0134-10-105 or P/N 109-0134-10-101), retaining bolt and washer as per Part III and proceed with step 5.

5. With reference to MM Paragraph 06-40-1, reinstall the access panels P17, P18 and P24 on the helicopter.

6. Return the helicopter to flight configuration and record for compliance with Part II of this Service Bulletin on the helicopter logbook.

7. Send the attached compliance form to the following mail box:

engineering.support.lhd@leonardo.com