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Via Giovanni Agusta, 520 AGUSTA 21017 Cascina Costa di Samarate (VA) Italy Tel.: +39 0331-229111 - Fax: +39 0331-229605/222595
AN AGUSTAWESTLAND COMPANY TRANSLATION OF N° 109EP-73
BOLLETTINO TECNICO The technical content of this document is approved DATE December 4, 2006 under the authority of DOA nr EASA.21J.005.
REV.
Compliance with MANDATORY this bollettino is:
SUBJECT:INSPECTION AND REPLACEMENT OF THE HYDRAULIC PIPES P/N 109-0761-64-103, 109-0761-65-103 BY MEANS OF THE KIT P/N 109-0824-03-101 APPLICATION.
REASON: Avoid the possible interference between the hydraulic pipes P/N 109-0761-64-103 and 109-0761-65-103, of the n° 1 hydraulic system, and the tail rotor control rod assy P/N 109-0032-01-41.
HELICOPTERS AFFECTED:
All Agusta A109E helicopters up to S/N 11158 included, and from S/N 11501 to S/N 11510 included.
COMPLIANCE:
PARTI Within the next 50 flight hours and successively periodically repeat the inspection each 100 flight hours up to the compliance of PART I^ PART I^ Within and not later than November 30, 2007 DESCRIPTION:
Cases of interference between the hydraulic pipe P/N 109-0761-65-103 and the tail rotor control rod assy have been reported.
The interference can produce, during the normal flight operations, the wear of the hydraulic pipe with the subsequent loss of hydraulic fluid.
To avoid the above, two new pipes P/N 109-0763-96-101 and P/N 109-0763-97-101 have been produced, that coupled with a new An appropriate entry should be made in the aircraft log book upon accomplishment.
If ownership of aircraft has changed, please, forward to new owner.
Pag. 1 di 19.
B.T. 109EP-73 fixing method, permit to increase the clearance between the pipes and the tail rotor control rod assy.
This Bollettino is issued in order to provide:
- Inspection requirements (PART I^), for interference, until the compliance of the PART II^ of this Bollettino;
- the necessary instructions for the Kit P/N 109-0824-03-101 installation (PART I).
REQUIRED MANPOWER:
The following estimated manpower hours are required for compliance with this Bollettino:
PART 11: 2 (two).
PART I: 16 (sixteen).
WARRANTY:
The parts required to apply the present Bollettino shall be supplied on a free of charge basis by Agusta upon request, except for the consumable Upon application of this Bollettino, Customers are requested to submit to Agusta Warranty Administration the Technical Bulletin Compliance form attached to this Bollettino duly completed in all its parts.
REQUIRED MATERIALS:
The following materials are required for compliance with this Bollettino:
PART I^:
N.A.
PART I^:
PART NUMBER DENOMINATION Q.TY 109-0824-03-101 Hydraulic line tail rotor servo actuator retrofit kit 109-0763-96-101 Pipe assy . 1 109-0763-97-101 Pipe assy AN3-22A Bolt MS21042L3 Self-locking nut . 1 MS21919WDG4 Clamp . 1 MS21919WDG5 Clamp _. 1 NAS1149D0332K Washer .. 1 NAS43DD3-36N Spacer .2 NAS43DD3-35N Spacer AN743Z13 Bracket .2 NAS1738B4-2 Rivet AN832-4D Fitting 999-8001-64-1 Sleeve .300 mm Pag. 2 di 19
B.T. 109EP-73 In addition the following consumable materials are necessary SPECIFICATION DENOMINATION Q.TY TT-N-95 Aliphatic naphtha A.R.
or:
PD-680 Type I| Cleaning solvent A.R.
MIL-P-23377 Epoxy polyamide primer A.R.
(cod. 900004523) MS20995C32E Lockwire A.R.
SPECIAL TOOLS:
N.A.
WEIGHT AND BALANCE CHANGES:
Negligible.
REFERENCES:
A109E Maintenance Manual.
A109E Rotorcraft Flight Manual.
PUBLICATIONS AFFECTED:
A109E Illustrated Parts Catalog up to S/N 11600.
COMPLIANCE INSTRUCTIONS:
GENERAL NOTES > Unless otherwise specified retain all parts that will be removed in following operations. Replace damaged hardware.
• 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.
> Exercise extreme care during drilling operations to prevent cables or hosing damage.
> All dimensions are in mm.
Pag. 3 di 19
B.T. 109EP-73
• After the completion of structural work, remove all swarf and sharp edges. If necessary re-apply protective treatment.
• Clean the areas eventually polluted with hydraulic fluid or engine oil using aliphatic naphtha.
PARTI^
1. Prepare the helicopter on ground for a safe maintenance, disconnect any power supply.
Remove the main transmission upper forward fairing.
3. Gain access inside the beam through the pipes hole way and using a mirror and a suitable light source, inspect the possible interference area between the hydraulic pipes and the tail rotor control rod assy P/N 109-0032-01-41 (ref. figure 1).
CAUTION During the visual inspection move several times the pedals completely up and down in order to single out the least clearance point or the possible presence of e interference.
NOTE In case the displacing/removal of the water seep protections is required, after the inspection restore the protections.
In case there is no interference between the hydraulic pipes and the tail rotor control rod assy, proceed as follows:
4.1. Reinstall the main transmission upper forward fairing.
4.2. Return the helicopter to a ready to flight condition.
4.3. Record compliance with this PART of the Bollettino in the helicopter log book.
Pag. 4 di 19
B.T. 109EP-73
4.4. Repeat this PART (within the next 100 hours and subsequently every 100 hours) until the compliance with PART II of this Bollettino.
5. In case interference between the hydraulic pipes and the tail rotor control rod assy is reported, perform the PART II^.
PART I^
1. Prepare the helicopter on ground for a safe maintenance, disconnect any power supply.
2. Remove the main transmission upper forward fairing and aft fairing assemblies, the oil cooler fairing assy, the left engine cowling assy.
3. Remove the pipes P/N 109-0761-64-103 and 109-0761-65-103 as follows:
3.1. Remove the fixing of the hydraulic pipes P/N 109-0761-64-103 and 109-0761-65-103 from the helicopter roof (ref. figure 1).
NOTE Some helicopters have also installed the engine power control cable, remove the tixing screw.
Retain the hardware, screw, spacers, washer of the engine power control cable for the later reuse.
3.2. If installed, displace/remove the water seep protections.
3.3. Remove the engine oil cooler from the helicopter as follows (see figure 2):
NOTE 1 Follow the WARNINGS AND CAUTIONS related to the engine lubrication system, reported in the pertinent Maintenance Manual, chapter 12.
NOTE 2 Adequately recover the drained oil from the pipes.
Pag. 5 di 19
B.T. 109EP-73 NOTE 3 Plug all the disconnected pipes to avoid oil spillage and adequately protect to avoid contaminations.
3.4. Disconnect:
a) the rubber pipe, acting on the relevant clamp;
the supply pipe from the by-pass valve and the return pipe from the cooler fitting, the valve and the fitting must remain installed on cooler;
the forward frame assy P/N 109-0641-48 and aft frame assy P/N 109-0641-49, from helicopter airframe, retain the fixing hardware for later reuse;
d) the cooler case from the fan assy.
3.5. Remove from the helicopter the assy composed by frames, oil cooler and cooler case.
3.6. Acting on the relevant hardware remove the inspection door P/N 109-0322-10-41, now accessible, located on the beam;
retain the hardware for later reuse.
3.7. Disconnect the pipes P/N 109-0761-64-103 and 109-0761-65- 103 from the relevant fitting and withdraw them from the helicopter beam.
NOTE 1 Follow the MAINTENANCE GENERAL STANDARD PRACTICE related to the hydraulic systems, reported in the A109E Maintenance Manual, chapter 29 NOTE 2 Adequately recover the drained oil from the pipes.
NOTA 3 Plug all the disconnected pipes to avoid oil spillage and adequately protect to avoid contaminations.
3.8. Remove the clamps that fix together the removed pipes and retain the relevant hardware for later reuse.
Pag. 6 di 19
B.T. 109EP-73
4. In case during the inspection (PART I^) interference between the hydraulic pipes and the tail rotor control rod assy has been reported, perform the following procedure (from step 4.1. to step 4.16.).
4.1. Remove the left access door P/N 109-0322-10-13 and open the left upper servicing platform D9 (ref. Maintenance Manual chapter 6).
4.2. For helicopters equipped with Pratt & Whitney PW206C engines proceed to remove the engine power control cable as follows:
4.2.1. Remove the lockwire and disconnect the engine power control cable from the fuel management module as shown in figure 3.
4.2.2. Remove the two fixing clamps and the engine power control cable panel as shown in figures 3 and 4; stow the cable.
4.3. For helicopters equipped with Turbomeca Arrius 2K1 engines proceed to remove the engine power control cable as follows:
4.3.1. Disconnect the engine power control cable from the left engine power control lever up to the panel installed on the firewall in accordance with the instructions provided in the A109E Maintenance Manual.
4.3.2. Remove the panel from the firewall and stow the cable.
NOTE The complete removal of the left engine power control cable is not required.
4.4. In order to facilitate the tail rotor control rod removal, from the forward side of the upper air intake assy remove the n° 1 screw and the n° 9 bolts shown in figure 5.
4.5. Disconnect the rod assy P/N 109-0032-08 or P/N 109-0040-55 (whichever installed) from the bellcrank P/N 109-0040-35 in accordance with the instructions provided in the A109E Maintenance Manual (ref. figure 6).
4.6. Disconnect the tail rotor control rod assy P/N 109-0032-01-41 in accordance with the instructions provided in the A109E Maintenance Manual.
CAUTION Do not change the tail rotor control rod assy length for the successive reinstallation.
Pag. 7 di 19
B.T. 109EP-73
4.7. In order to avoid the tail rotor control rod assy damage, adequately protect the firewall panel hole.
4.8. Withdraw the tail rotor control rod assy P/N 109-0032-01-41 through the door P/N 109-0322-10-41 hole and the engine power control cable panel hole.
It is allowed to reuse the removed control rod when, after the inspection and the repair as per the A109E Maintenance Manual, the rod will result within the limits provided in the manual.
Be sure not to change the tail rotor control rod assy length during the repair procedure.
4.9. In case the damaged tail rotor control rod assy cannot be repaired, annotate the total length and repeat it on the new rod assy by acting on the terminal.
4.10. Place the tail rotor control rod assy P/N 109-0032-01-41 in its position through the engine power control cable panel hole the door P/N 109-0322-10-41 hole.
4.11. Install the tail rotor control rod assy P/N 109-0032-01-41 in accordance with the instructions provided in the A109E Maintenance Manual.
CAUTION If the correct length of the tail rotor control rod assy is sure, it is allowed not to perform the flight controls adjustment.
4.12. Install the rod assy P/N 109-0032-08 or P/N 109-0040-55 (whichever removed) to the bellcrank P/N 109-0040-35 in accordance with the instructions provided in the A109E Maintenance Manual (ref. figure 6).
4.13. For helicopters equipped with Pratt & Whitney PW206C engines proceed to install the engine power control cable as follows:
4.13.1. Install the engine power control cable on the fuel management module and restore the lockwire.
4.13.2. Install the two fixing clamps and the engine power control cable panel removed at step 4.2.2.
Pag. 8 di 19
B.T. 109EP-73 For helicopters equipped with Turbomeca Arrius 2K1 engines proceed to install the engine power control cable in accordance with the instructions provided in the A109E Maintenance
4.15. Install the upper and lower air intake fixing hardware, removed at step 4.4.
4.16. Install the previously removed left access door P/N 109-0322- 10-13 and close the left upper servicing platform D9 (ref.
Maintenance Manual chapter 6).
Assemble together the brackets P/N AN743Z13 (as shown in figure 7) using:
a) the clamps P/N MS21919WDG4, MS21919WDG5;
D) the bolt _P/N AN3-22A, the washers P/N NAS1149D0332K;
n° 2 spacers P/N NAS43DD3-36N, and n°1 spacer P/N NAS43DD3-35N;
a) the nut P/N MS21042L3.
6. In accordance with figure 7, using the fixing assy made at step 5, countermark the beam and drill 3,26 - 3,38 mm.
7. Remove the swarfs and restore the protective treatment using epoxy polyamide primer.
NOTE Pay particular attention to avoid that the swarfs fall in the beam.
8. From the fixing assy made at step 5 remove the brackets.
9. Install the brackets P/N AN743Z13, using n° 4 rivets P/N NAS1738B4-2 as shown in figure 7.
10. Install the new pipes in accordance with the following procedure:
10.1. Install, as shown in figure 8, between the pipes P/N 109-0763- 96-101 and P/N 109-0763-97-101 the clamps removed from pipes P/N 109-0761-64-103 and 109-0761-65-103 using the relevant hardware.
Pag. 9 di 19
B.T. 109EP-73
10.2. On the pipe P/N 109-0763-97-101, install the sleeve P/N 999- 8001-64-1, between the clamp and the fitting as shown in figure
10.3. Install and secure, using the relevant fittings, the pipes P/N 109- 0763-96-101 and P/N 109-0763-97-101 as shown in figure 8.
In case the connection between the pipe 109-0763-97-101 and the pipe P/N 109-0762-40-1 results difficult, it is possible to replace the fitting P/N AN815-4D, installed, fitting P/N AN832-4D.
10.4. Secure, to the beam, the hydraulic pipes P/N 109-0763-96-101 and P/N 109-0763-97-101 (as shown in figure 7) using:
a) the clamps P/N MS21919WDG4, MS21919WDG5;
b) the bolt P/N AN3-22A, the washers P/N NAS1149D0332K;
c) n° 2 spacers P/N NAS43DD3-36N, and n°1 spacer P/N NAS43DD3-35N;
a) the nut P/N MS21042L3.
For the helicopters that had installed the engine power control cable, reinstall it using the previously removed hardware. The installation of a washer as spacer is allowed.
11. Gain access inside the beam through the pipes hole way and, using a mirror and a suitable light source, verify that there is no interference between the hydraulic pipes P/N 109-0763-97-103, 109-0761-96-103 and the tail rotor control rod assy;
CAUTION During the visual inspection move several times the pedals completely up and down in order to be sure that there is no interference between pipes and tail rotor control rod.
12. Bleed the n° 1 hydraulic system in accordance with the instructions provided in the A109E Maintenance Manual.
13. Perform the functional check of the flight controls n° 1 hydraulic system in accordance with the instructions provided in the Pag. 10 di 19
B.T. 109EP-73 A109E Maintenance Manual and verify that there are no leakage from the installed fittings
14. Reinstall the inspection door in its position on the beam, reusing the previously removed hardware.
15. Perform the engine oil cooler installation as follows (see figure NOTE Remove the previously installed plugs from the pipes and from the oil cooler.
15.1. On the helicopter beam install the assy composed by the forward and aft frames, the oil cooler and cooler case using the previously removed hardware.
15.2. Reconnect:
the rubber pipe by acting on the relevant clamp;
b) the supply pipe to the by-pass valve and the return pipe to the cooler fitting;
c) the cooler case to the fan assy;
16. Restore the water seep protections that may have been removed at step 3.2.
17. Install the fairing and the doors previously removed. (ref. step 2)
18. Restore the engine oil level in the system in accordance with the instructions provided in the pertinent Maintenance Manual (ref. chapter 12 replenishing procedure) and verify that there are not oil leakage from the engine oil cooler piping.
NOTE Verify that the engine lubricating oil system pressure values are within the limits provided in the pertinent A109E Rotorcraft Flight
19. Return the helicopter in ready to flight condition.
20. Record compliance with this PART of the Bollettino in the helicopter log book.
Pag. 11 di 19
B.T. 109EP-73 FWD Pipe assy 109-0761-64-103 Pipe assy 109-0761-65-103