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TRANSLATION OF
BOLLETTINO TECNICO N° 109K-57
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, 2013 xx, 2011
Compliance with This bollettino is:
An appropriate 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 6
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 A109K2 that install the main transmission P/N 109-0400-03-103 and have not applied the Bollettino Tecnico n° 109K-56.
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 109-0400-03-103, 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.
A AgustaWestland S.p.A Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) Italy Tel.: +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. 109K-57
Page 2 of 6 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 originated from the bottom of one of 40 threaded holes and that the Gleason crown installed on the 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 current scheduled 3200 FH and 4800 FH inspections and the introduction of one repetitive inspection every 1600 flight hours, after the achievement of the each overhaul limit, scheduled at 4800 FH. In case of crack is found on Gleason crown P/N 109-0403-07-103, it is required to 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 threaded holes) by mean application of BT 109K-56.
REQUIRED MANPOWER:
An estimated 24 manpower hours are required for compliance 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 A
B.T. 109K-57
Page 3 of 6
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 109K2 Maintenance Manual;
A119/A109 Series Overhaul Manual.
PUBLICATIONS AFFECTED:
A 109K2 Maintenance Planning Manual;
A 109K2 Maintenance Manual.
A119/A109 Series Overhaul Manual.
COMPLIANCE INSTRUCTIONS:
1. Prepare the helicopter on ground for a safe main tenance and disconnect any power supply in accordance with the instructions given in the A 109K2 Maintenance Manual.
2. Gain access to Main transmission area removing t he Transmission Front Fairing and the Transmission Rea r fairing in accordance with the procedure given in the A 109K2 Maintenance Manual.
3. In accordance with the instructions given in the A 109K2 Maintenance Manual, remove the main rotor blades and the main rotor head.
4. In accordance with the instructions given in the A 109K2 Maintenance Manual remove the main transmis sion from the helicopter.
5. Remove and perform the magnetic particle inspect ion of the Gleason crown as shown in A 109K2 Maintenance Manua l and Annex 1.
B.T. 109K-57
Page 4 of 6
NOTE During the execution of Gleason crown magnetic particle inspection, look at the presence of cracks at the bottom of threaded holes and in the areas adjacent to them.
6. If after inspection cracks are found, apply BT n° 109K-56.
7. If after the inspection no cracks are found, perform all the operations necessary to return the transmission in service as shown in the A 109K2 Maintenance Manual.
8. In accordance with the instructions given in the A 109K2 Maintenance Manual, reinstall the Main rotor Head and n° 4 Main Rotor Blades.
9. In accordance with the instructions given in the A 109K2 Maintenance Manual reinstall the Transmission Front Fairing and the Transmission Rear fairing.
10. Return the helicopter to a ready-to-flight condition.
11. Record compliance with this Bollettino in the helicopter log book.
B.T. 109K-57
Page 5 of 6
ANNEX 1
MAGNETIC PARTICLE INSPECTION (ASTM-E-1444)
A. General.
(1) Consumable materials:
WARNING: THE CONSUMABLE MATERIALS THE NOMENCLATURE OF WHICH IN THE LIST IS PREFIXED BY «D» ARE DANGEROUS MATERIALS.
BEFORE USE, MAKE SURE TO KNOW THE SAFETY PRECAUTIONS AND FIRST AID INSTRUCTIONS PRINTED ON:
— THE LABEL ON THE CONTAINER THE MATERIAL WAS SUPPLIED IN — THE MATERIAL SAFETY DATA SHEET — THE LOCAL SAFETY REGULATIONS.
ALSO MAKE SURE THAT THE APPLICABLE FIRST AID MATERIALS ARE AVAILABLE.
— (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. Remove any remaining finish or aged 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, coatings, or conditions which could mask 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 the 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 be 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 small compared to the 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. Longitudinal 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 determined by the formula:
B.T. 109K-57
Page 6 of 6
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 part several times to ensure complete coverage of the part.
A maximum of 15000 ampere
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 long axis of the coil unless otherwise specified.
F. Application of magnetic particles in suspension
(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 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
NOMENCL. INSP. AREA
AMP.
Gleason crown Minor I.D.
Major O.D.
2000
3400
NOTE [1] Rotate part by 60° and repeat the inspection at 6 points.
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.
fines the amperage that passes through the coil multiplied by the number 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.
ication 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 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.
The part on which a film of liquid remains must be rinsed, magnetized and sprayed with
(5) After inspection, acceptable parts shall be cleaned and demagnetized. Check parts with a magnetization.
(6) Apply a film of lubricating oil on the parts to prevent corrosion.
Surface or subsurface defects will be revealed by magnetic particle accumulation around ecommended magnetization currents for magnetic particle inspection
CIRCULAR MAGNETISM
AMP.
CENTR COND DIA (mm) INSP.
AXIS NOTE 2000 3400 50
Thread-ing bar (INSU- LATED) Longit. [1] ] Rotate part by 60° and repeat the inspection at 6 points.
turns and magnetize the turns shall be used on any part with a l/d ratio less than 3.
fines the amperage that passes through the coil multiplied by the number center of the coil with the long axis of the part parallel to the
(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
(3) Close the magnetization circuit 1/5 to 1/2 second while the part is covered with a film of The part on which a film of liquid remains must be rinsed, magnetized and sprayed with
(5) After inspection, acceptable parts shall be cleaned and demagnetized. Check parts with a Surface or subsurface defects will be revealed by magnetic particle accumulation around currents for magnetic particle inspection.
LONGITUDINAL
MAGNETISM INSP.
AREA AMP.
x TURNS NOTE Entire item 15000 [4]
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.