Leonardo ASB 109K-074: Revision A

N° 1 09K-074 DAT E: April 26, 2021 REV. : A - May 18, 2021 P ag e 1 of 36 TITLE ATA 64 - INSPECTION OF TAIL ROTOR SHAFT ASSY P/N 109-0445-08-(ALL DASHES) AN D TAIL ROTOR SLEEVE ASSY P/N 109-0130-90-117/-121

REVISION LOG Helicopters already compliant with Part I and Part III of this Service Bulletin Rev./ do not need an y additional action.

Helicopters which are already complying with previous issue of this Service Bulletin must not change their current scheduling for recurring inspection.

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

- EFFECTIVITY paragraph update;

- COMPLIANCE paragraph update;

- Figures 1 and 2 update;

- Minor amendments.

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°109K-074 ALERT DATE: April 26, 2021 Page 2 of 36 REVISION: A - May 18, 2021

1. PLANNING INFORMATION A. EFFECTIVITY NOTE If the helicopter installs a TR Sleeve with an unreadable S/N, it must be considered as affected by this Service Bulletin.

NOTE If the helicopter has installed an affected TR sleeve assy after last overhaul, and currently install a non-affected TR sleeve, it is affected only by Part I and Part IV.

If it is not possible to determine if the helicopter has installed an affected sleeve since the last overhaul, and currently install a non-affected TR sleeve, it is affected only by Part I and Part IV.

NOTE It is allowed to install an affected TR sleeve assy kept at stock on a non-affected helicopter, provided that the component has passed (no defect found) the relevant inspections required by Part I. Following the installation of an affected part, that helicopter must comply with Part II of this Service Bulletin.

NOTE It is allowed to install an affected TR sleeve assy kept at stock on an already affected helicopter, provided that the component has passed (no defect found) the relevant inspections required by Part I. Following the installation of an affected part, that helicopter must comply with this Service Bulletin.

All the Leonardo S.p.a. A109K2 helicopters installin g a TR sleeve assy P/N 109-0130- 90-117 all S/Ns, or P/N 109-0130-90-121 with S/Ns MO.001 to S/N MO.677 and with S/N MOR678 to MOR1140.

S.B. N°109K-074 ALERT DATE: April 26, 2021 REVISION: A - May 18, 2021 Page 3 of 36 B. COMPLIANCE NOTE TR sleeve assy P/N 109-0130-90-117/-121 marked with letter “R” after S/N are not affected by Part II and Part III.

Part I:

Within and not later than 25 flight hours or 3 months whichever occurs first after the issue of this Service Bulletin.

Part II:

Every 25 flight hours after accomplishment of part I and until application of Part III of this Service Bulletin or until installation of a non affected sleeve.

Part III:

At any bushing replacement.

Part IV:

In conjunction with every 400 FH scheduled inspection after application of Part I of this Service Bulletin until next TGB overhaul.

C. CONCURRENT REQUIREMENTS N.A.

D. REASON This Service Bulletin is issued in order to provide the necessary instruction on how to perform a detailed inspection of tail rotor shaft assy P/N 109-0445-08-(all dashes) and tail rotor sleeve assy P/N 109-0130-90-117/-121.

E. DESCRIPTION During tail rotor system inspections required after an abnormal vibration event, an extensive crack has been found on the tail rotor mast of an A109E helicopter at the interface with the tail rotor sleeve. In order to assure the airworthiness of the fleet and to collect data for the investigation, LH decided to issue this SB to perform (Part I) a tail rotor and mast visual inspection together with a dye penetrant fluorescent liquid inspection in the area potentially affected by the issue and (Part II) a recurrent check for condition of the TR sleeve bushing. In case of sleeve bushing debonding is found, instructions are given to replace it (Part III). Part IV provides instruction to restore, if necessary, solid lubricant protection on the area inspected with dye penetrant fluorescent liquid.

S.B. N°109K-074 ALERT DATE: April 26, 2021 Page 4 of 36 REVISION: A - May 18, 2021 Revision A of this Service Bulletin is issued to update the Effectivity paragraph in order to require the TR mast inspection of all the helicopters that installed an affected TR sleeve assy after the last overhaul.

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: 5 (five) MMH;

Part II: 0,5 (half an hour) MMH;

Part III: 4 (four) MMH (without considering the adhesive curing time);

Part IV: 0,25 (a quarter of hour) MMH.

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

SECTION/PARAGRAPH DESCRIPTION PART PAR01 00-20-1 Helicopter Safety I, II, III PAR02 64-00-15 or 64-00-17 (from S/N 10001 thru 10015 and 10027) Tail Rotor Hub and Blade Assembly, Removal/Installation

I, II, III

S.B. N°109K-074 ALERT DATE: April 26, 2021 REVISION: A - May 18, 2021 Page 5 of 36

SECTION/PARAGRAPH DESCRIPTION PART PAR03 64A-00-16 or 64A-00-18 (from S/N 10001 thru 10015 and 10027) Tail Rotor Hub and Blade Assembly, Removal/Installation

I, II, III PAR04 64-30-5 or 64-31-6 (from S/N 10001 thru 10015 and 10027) Pitch Change Mechanism, Removal/Installation

I, II, III PAR05 64-30-7 or 64-31-8 (from S/N 10001 thru 10015 and 10027) Pitch Change Mechanism, Inspection I, II PAR06 65-20-5 or 65-21-6 (from S/N 10001 thru 10015 and 10027) 90-Degree Gearbox, Removal/Installation I PAR07 00-10-7 or 00-10-9 (from S/N 10001 thru 10015 and 10027) Connection Of External Hydraulic Power I, II PAR08 00-10-8 or 00-10- 10 (from S/N 10001 thru 10015 and 10027) Disconnection Of External Hydraulic Power I, II PAR09 67-00-30 or 67-00-31 (from S/N 10001 thru 10015 and 10027) Tail rotor control system adjustment II PAR10 CPCP 20-70-10 Application of solid lubricant film IV

2) ACRONYMS AMDI Aircraft Material Data Information AR As Required CPCP Corrosion Protection and Control Publication DOA Design Organization Approval IPC Illustrated Parts Catalogue LHD Leonardo Helicopters MM Maintenance Manual MMH Maintenance Man Hours P/N Part Number PTUM Pictorial Tools Usage Manual SB Service Bulletin

3) ANNEX Annex A AW109 TR shaft localized penetrant inspection Type 1, Method C, Level 2, Form “d”.

Annex B AW109 TR sleeve assy bushing replacement.

Annex C S.B. N°109K-074 Rev.A Inspection form.

J. PUBLICATIONS AFFECTED N.A.

S.B. N°109K-074 ALERT DATE: April 26, 2021 Page 6 of 36 REVISION: A - May 18, 2021 K. SOFTWARE ACCOMPLISHMENT SUMMARY N.A.

S.B. N°109K-074 ALERT DATE: April 26, 2021 REVISION: A - May 18, 2021 Page 7 of 36

2. MATERIAL INFORMATION A. REQUIRED MATERIALS

1) PARTS PART I N.A.

PART II N.A.

PART III # P/N ALTERNATIVE P/N DESCRIPTION Q.TY LVL NOTE LOG P/N 1 109-0133-07-101 Bushing 1 . -

PART IV N.A.

Refer also to IPC for the spares materials required to comply with the MM Paragraphs referenced in the accomplishment instructions.

2) CONSUMABLES The following consumable materials, or equivalent, are necessary to accomplish this Service Bulletin:

# Spec./LHD code number DESCRIPTION Q.TY NOTE PART 2 SAE-AMS-2644, Type I, Method C, Level 2 Dye Penetrant AR (1)(2) I 3 SAE-AMS-2644, Type I, Form “d” Developer AR (1)(2) I 4 SAE-AMS-2644 Cl II Solvent (C290) AR (1)(2) I 5 ASTM D740, Type I Methyl-ethyl-ketone (C511) AR (1) I, III 6 Commercial Plastic bristled brush AR (1) I 7 Commercial Aluminum adhesive tape AR (1) I 8 Commercial Small soft clean brush AR (1) I 9 Commercial Clean, dry, lint-free cloth or absorbent toweling AR (1) I 10 MIL-L-23398 Type II Solid film, lubricant Type IV AR (1) I, IV 11 Commercial Aluminium oxide, 80-grit (C208) AR (1) III 12 199-05-002, Type II, Class 2 Adhesive, (C054) AR (1) III 13 Commercial Cloth, soft lint-free (C011) AR (1) III 14 MIL-PRF-680, Type II Cleaning solvent (C287) AR (1) III Refer also to AMDI for the consumable materials required to comply with the MM Paragraphs referenced in the accomplishment instructions.

S.B. N°109K-074 ALERT DATE: April 26, 2021 Page 8 of 36 REVISION: A - May 18, 2021

3) LOGISTIC MATRIX N.A.

NOTE Local supply.

This material shall be certified in accordance with AMS2644, obtained from a supplier listed in QPL-AMS2644, supplied from the same manufacturer.

B. SPECIAL TOOLS # P/N DESCRIPTION Q.TY NOTE PART 15 109-3130-32-1 Tail rotor retaining nut wrench 1 (B1) I 16 895-3130-02-101 Tool, T/R slider bushing installation 1 (B1) I 17 109-3130-53-111 Tool, T/R pitch change slider ring nut removal/installation 1 (B1) I 18 109-3130-54-101 or 109-3130-54-111 Tool, T/R pitch change housing ring nut removal/installation 1 (B1) I 19 109-3130-70-101 Tool, T/R pitch change housing duplex bearing removal 1 (B1) I 20 109-3130-69-101 Tool, T/R pitch change housing duplex bearing installation 1 (B1) I 21 109-3130-71-101 Tool, T/R pitch change slider installation 1 (B1) I 22 109-3130-55-117 Tool, T/R pitch change slider removal 1 (B1) I 23 Commercial Endoscope 1 (B2)(B2) I 24 Commercial Dark curtain 1 (B2) I 25 Commercial Magnifying lens 5x 1 (B2) I 26 Commercial UV-A inspection lamp 1 (B2)(B3) I 27 Commercial UV-A/White light meters 1 (B2) I 28 Commercial Hydraulic system test bench 1 (B2) I, II 29 Metal sheet 55x5 mm, thickness 1 mm. Bushing displacement measuring tool 1 (B4)(B5) I, II 30 Commercial Environmental thermometer 1 (B2) I 31 Commercial Parallel lathe 1 (B2) III 32 Commercial Caliper 1 (B2) III 33 Commercial Dry abrasive blasting equipment 1 (B2) III Refer to PTUM for the special tools required to comply with the MM Paragraphs referenced in the accomplishment instructions.

Refer also to Annex A for the equipment/tools required for the liquid penetrant inspection.

Refer also to Annex B for the equipment/tools required for the sleeve assy bushing replacement.

S.B. N°109K-074 ALERT DATE: April 26, 2021 REVISION: A - May 18, 2021 Page 9 of 36

SPECIAL TOOLS NOTE Please contact Leonardo Helicopters Division order administration to request the tools supply on loan. As soon as the present Service Bulletin is implemented the tools supplied on loan shall be promptly returned to Leonardo Helicopters Division.

Item to be procured as local supply.

This lamp should emit at least 1200 µW/cm² and no more than 20lux at 38cm from the front of the filter to the face of the sensor.

Local manufacturing in accordance instructions given in Part I.

The metal sheet specifications may be different. For reference, some examples are given: 2024 T3 AMS-QQ-A-250/4; 2024 T3 AMS-QQ-A-250/5; CRES 301 ¼ H, AMS5517.

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°109K-074 ALERT DATE: April 26, 2021 Page 10 of 36 REVISION: A - May 18, 2021

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 reuse.

b) All lengths are in mm.

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. Gain access to the plug P/N 109-0133-18-103 (or P/N 109-0130-85-1) installed on the tail rotor hub removing balance flange and all the necessary components. Mark the installation position of the balance masses in order to reinstall them in the same location and reduce time for the TR balancing required at the end of the reassembly. Retain all the components.

3. In accordance with Figure 3, verify that plug P/N 109-0133-18-103 (or P/N 109-0130-85-

1) is torqued at 59÷69 Nm.

3.1 Record the torque value on the annexed Detailed Inspection Form and proceed with next step.

4. In accordance with MM Paragraph 64-00-15 or 64-00-17 (from S/N 10001 thru 10015 and 10027) or 64A-00-16 or 64A-00-18 (from S/N 10001 thru 10015 and 10027), remove the tail rotor hub and blade assy.

NOTE Before the removal of the TR sleeve as per MM Paragraph 64-30-5 or 64-31-6 (from S/N 10001 thru 10015 and 10027), check the bushing P/N 109-0133- 07-101 for condition and bonding. In case it is found partially or completely displaced from its seat, before and after its removal, take pictures of bushing and sleeve, record the finding on the Detailed Inspection Form and proceed with the following step.

5. In accordance with MM Paragraph 64-30-5 or 64-31- 6 (from S/N 10001 thru 10015 and 10027), remove the pitch change mechanism.

S.B. N°109K-074 ALERT DATE: April 26, 2021 REVISION: A - May 18, 2021 Page 11 of 36

6. In accordance with MM Paragraph 64-30-7 or 64-31-8 (from S/N 10001 thru 10015 and 10027), inspect the removed tail rotor sleeve assy P/N 109-0130-90-117/-121 and bushing P/N 109-0133-07-101. Inspect the bushing in the tail rotor sleeve assy for debonding.

6.1 In case anomalies are detected, take pictures of the affected bushing and sleeve, record the findings on the Detailed Inspection Form, and contact Leonardo Helicopters to evaluate part serviceability. If necessary, in accordance with MM Paragraph 64-30-5 or 64-31-6 (from S/N 10001 thru 10015 and 10027), replace it with a serviceable TR Sleeve. In the meantime, proceed with step 7.

6.2 In case of no findings, proceed to next step.

7. With reference to Figure 1 and Figure 2 detail A, gain access to tail rotor shaft assy P/N 109-0445-08-(all dashes) and:

CAUTION Pay particular attention to not damage the Tail Rotor Shaft Assy with the endoscope probe during the inspection.

7.1 perform internal surface endoscope inspection fo r abnormal wear condition, corrosion, fretting, crack and damage;

7.2 perform external surface visual inspection for abnormal wear condition, corrosion, fretting, crack and damage;

7.3 with reference to Figure 1 and Figure 2 detail B, in accordance with Annex A, perform surface Fluorescent Penetrant Inspection on the indicated area;

7.4 if no evidence of existing anomalous wear, corrosion, fretting, damage or crack is found, proceed to step 8;

7.5 if evidence of anomalous wear, corrosion, fretting, damage or crack is found, take relevant pictures, record the findings on the Detailed Inspection Form and contact Leonardo Helicopters to evaluate part serviceability. If necessary, in accordance with MM Paragraph 65-20-5 or 65-21-6 (from S/N 10001 thru 10015 and 10027), replace it with a serviceable 90-Degree Gearbox.

NOTE Do not attach aft boot to pitch change slider assy.

8. In accordance with MM Paragraph 64-30-5 or 64-31- 6 (from S/N 10001 thru 10015 and 10027), re-install previously removed pitch change mechanism.

9. In accordance with MM Paragraph 64-00-15 or 64-00-17 (from S/N 10001 thru 10015 and 10027) or 64A-00-16 or 64A-00-18 (from S/N 10001 thru 10015 and 10027), re-install previously removed tail rotor hub and blade assy.

S.B. N°109K-074 ALERT DATE: April 26, 2021 Page 12 of 36 REVISION: A - May 18, 2021 NOTE Helicopters that have installed an affected TR sleeve assy after last overhaul, and currently install a nonaffected TR sleeve should not apply steps 10, 11 and

13.

10. In accordance with MM Paragraph 00-10-7 or 00-10 -9 (from S/N 10001 thru 10015 and 10027), connect the hydraulic test bench to the helicopter and operate it at 103.5 bar (1500 psi).

CAUTION One assistant must position and hold right anti torque pedal full forward before beginning the following procedure.

11. In accordance with Figure 4, manufacture on site the bushing displacement measuring tool following the next steps:

11.1 Starting from a metal sheet of 55x5 mm (1 mm thickness), bend it to obtain an “L” shape with the size indicated in Figure 4.

11.2 In accordance with Figure 4 Detail E, insert the tool between pitch change slider assy and tail rotor shaft assy until reaching the bushing of the TR sleeve assy.

CAUTION After trimming, remove all swarf and sharp edges to avoid to scratch the tail rotor shaft assy.

11.3 If gap is present between the vertical leg of t he tool and the pitch change slider assy, start trimming the short segment until gap is removed.

11.4 Record the dimension of the tool and retain it for Part II inspection.

12. With reference to Figure 3, attach aft boot P/N 109-0130-96-101 on pitch change slider assy.

13. Return the anti torque pedal to center. In accordance with MM Paragraph 00-10-8 or 00- 10-10 (from S/N 10001 thru 10015 and 10027), disconnect the hydraulic test bench from the helicopter.

14. Return the helicopter to a ready to flight condition and record for compliance with Part I of this Service Bulletin on the helicopter logbook.

NOTA Send the Detailed Inspection Form and pictures with Subject line “ASB 109K-074 Rev.A - S/N XXXXX – Compliance to Part I”. “XXXXX” is the helicopter S/N.

15. Send the attached compliance form and the pictur es taken during the inspections to the