Leonardo Emergency Alert Service Bulletin 109S-076: Revision A

N° 109S-076 DATE: May 9, 2017 REV. : A May 12, 2017 Page 1 of 14 TITLE ATA 55 – THE LEFT ELEVATOR ASSY P/N 109-0200- 02-601/-801 AND RIGHT ELEVATOR ASSY P/N 109-0200-02-602/802, INSPECTION OF.

REVISION LOG This revision is issued in order:

- to remove the requirement of complying with initial inspection of Part II within July 31, 2017, for the helicopters installing an affected elevator with more or equal than 400FH;

- to introduce the APPROVAL chapter;

- to correct the adhesive type recalled in the basic issue;

- to improve the endoscope inspection procedures;

Helicopters which have already complied with Part I and/or initial inspection of Part II of the basic issue are not required to repeat them.

Leonardo S.p.A.

Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) Italy Tel.: +39 0331 229111 - Fax: +39 0331 229605/222595 An appropriate entry should be made in the aircraft log book upon accomplishment.

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

EMERGENCY ALERT

SERVICE BULLETIN

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 Page 2 of 14 REVISION: A – May 12, 2017

1. PLANNING INFORMATION A. EFFECTIVITY Part I:

All the A109S helicopters which install a left elevator assy P/N 109- 0200-02-601/-801 and/or a right elevator assy P/N 109- 0200-02-602/-802 having more or equal than 400 (four hundred) flight hours.

Part II:

All the A109S helicopters which install a left elevator assy P/N 109-0200-02-601/-801 and/or a right elevator assy P/N 109-0200-02-602/-802.

B. COMPLIANCE Part I:

Before the next flight.

Part II:

 For those left elevator assy P/N 109- 0200-02-601/-801 and/or right elevator assy P/N 109- 0200-02-602/-802 having less than 400 (four hundred) flight hours:

 at reaching of 400 (four hundred) flight hours and subsequently each 25 (twenty five) flight hours.

 For those left elevator assy P/N 109- 0200-02-601/-801 and/or right elevator assy P/N 109-0200-02-602/-802 having more or equal than 400 (four hundred) flight hours:

 within and not later than 10 (ten) flight hours after the receipt of this SB and subsequently each 25 (twenty five) flight hours.

C. CONCURRENT REQUIREMENTS This document supersedes and cancels the BT 109S-044.

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 REVISION: A – May 12, 2017 Page 3 of 14 D. REASON This Service Bulletin is issued in order to provide all necessary instructions to perform accurate inspections on elevator assy P/N 109- 0200-02-601/-801 and P/N 109- 0200-02-602/-802 to verify the presence of cracks on the elevator skin or longerons.

E. DESCRIPTION A case of fracture of the elevator assy has been reported on an A109S helicopter. The damage didn’t jeopardize the flight and it was discovered on ground.

This damage was located in the area affected by the BT 109S-044.

Even if the investigation is ongoing, in advance to the analysis completion, as a precautionary measure Leonardo Helicopters with this Service Bulletin intends to cancel the inspection required by the BT 109S-044 and to introduce a new recurring inspection in order to verify the presence of cracks and prevent damages of the elevator assy.

Part I of this Service Bulletin contains the necessary instructions in order to perform a one-time visual inspection with a 5 ÷ 10 magnification lens on the elevator assy skin .

In case of doubt the presence or absence of cracks will be verified with a liquid penetrant inspection;

Part II of this Service Bulletin contains the necessary instruction in order to allow a recurring inspection with the endoscope; this inspection will require a structural modification on the elevator assy lower skin.

F. APPROVAL The Technical content of this Service Bulletin is approved under the authority of DOA nr. EASA.21.J.005.

E.A.S.A. 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, 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.

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 Page 4 of 14 REVISION: A – May 12, 2017 G. MANPOWER To comply with this Service Bulletin the following Maintenance-Man-Hours (MMH) are deemed necessary Part I: one (1) Maintenance-Man-Hours (MMH) for each elevator in case of liquid penetrant inspection.

Part II: one (1) Maintenance-Man-Hours (MMH) for each elevator.

Maintenance-Man-Hours are based on hands-on time and can change with personnel and facilities available.

H. WEIGHT AND BALANCE PART I N.A

PART II Negligible I. REFERENCES

1) PUBLICATIONS 0B-A-AMP-00-X Maintenance Publication A119/A109 Series SRM

2) ACRONYMS SB Service Bulletin P/N Part Number DOA Design Organization Approval N.A. Not Applicable LHD Leonardo Helicopter Division

3) ANNEX N.A.

J. PUBLICATIONS AFFECTED N.A.

K. SOFTWARE ACCOMPLISHMENT SUMMARY N.A.

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 REVISION: A – May 12, 2017 Page 5 of 14

2. MATERIAL INFORMATION A. REQUIRED MATERIALS

1) PARTS PART I N.A.

PART II P/N DESCRIPTION Q.TY NOTE A196A750B Cap 2

2) CONSUMABLES SPEC./LH CODE NUMBER DESCRIPTION Q.TY NOTE TT-N-95 ty 2 Code No. 531055030 Aliphatic Naphtha AR Local Supply Commercial Code No.590164695 Gauze AR Local Supply AWMS05-001 Ty 1 cl B grade 2 Fillet AR Local Supply (1) Alodyne1200 AR Local Supply Commercial High speed aluminium tape AR Local Supply

NOTE

(1) The following commercial products comply with the AWMS05-001 specification:

(a) Proseal 890;

(b) Naftoseal MC780 grade 2.

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 Page 6 of 14 REVISION: A – May 12, 2017 B. SPECIAL TOOLS P/N DESCRIPTION Q.TY NOTE PART Commercial 5÷10 magnification lens

1 Local Supply I P6R Penetrant ARDROX

AR Local Supply I 9PR5 Solvent ARDROX

AR Local Supply I 9D1B Developer ARDROX

AR Local Supply I Commercial Fine-pointed brush

AR Local Supply I Commercial White light source at the least 1000 lux

1 Local Supply I, II Commercial Soft brush

1 Local Supply I Commercial Endoscope

1 Local Supply II C. INDUSTRY SUPPORT INFORMATION Owners/Operators who comply with the instructions of this 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 & Special Tools.

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

Please Issue relevant M.M.I.R. form ( (M)aintenance (M)alfunction (I)nformation (R)eport ) to your Warranty Administration Dpt.

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

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 REVISION: A – May 12, 2017 Page 7 of 14

3. ACCOMPLISHMENT INSTRUCTIONS

GENERAL NOTES

a) Exercise extreme care during drilling operations to prevent instruments, cables or hoses damage.

b) Replace the hardware found damaged during the following operation.

c) At the end of the rework operations, remove all the used tools and completely remove any working residual using a suitable air cleaner.

PART I

1. Prepare the helicopter on ground for a safe maintenance and disconnect any power supply.

2. In accordance with the instructions given in the 0B-A-AMP-00-X Maintenance Publication gain the access to the upper side of the left elevator assy P/N 109- 0200-02- 601/-801, and with reference to Figure 1 accurately clean inspection area using a gauze soaked in aliphatic naphtha.

3. Using a 5÷10 magnification lens perform a visual inspection to verify the presence of cracks in the elevator upper skin in correspondence of the fourth rib fixing rivets line in the area shown in Figure 1.

3.1 In case on the elevator upper skin there is NOT presence of cracks, no corrective action is required. Proceed as described in steps 4 and following.

3.2 In case on the elevator upper skin there is presence of cracks, replace the elevator assy with a serviceable one in accordance with the instructions given in the 0B-A-AMP-00-X Maintenance Publication. Contact Leonardo Helicopters at aw109.mbx.aw@leonardocompany.com to evaluate a possible repair.

3.3 In case of doubt about the presence of cracks on the elevator upper skin, proceed with the following liquid penetrant inspection.

CAUTION Personnel conducting the liquid penetrant inspectio n must be qualified in accordance with EN4179/NAS410A practise or standard.

3.3.1 If necessary clean again with aliphatic naphtha the area to inspect in order to remove the contaminants. Leave dry the aliphatic naphtha.

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 Page 8 of 14 REVISION: A – May 12, 2017

3.3.2 Outline the area to inspect using only tape which does not absorb the solvent.

NOTE The penetrant, the part to be inspected and the room temperatures shall be between 15÷45° C.

3.3.3 Using a fine-pointed brush apply the P6R penetrant in all the area to inspect (ref. Figure 1) for 30 ÷ 40 minutes dwell time.

3.3.4 Under a white light source of at least 1000 lux, remove excess penetrant firstly with a dry clean gauze and then with a gauze dampened (NOT SOAKED) with 9PR5 solvent.

NOTE The solvent must never be poured directly over the area to inspect.

3.3.5 Repeat the removal of the excess penetrant with gauze dampened with 9PR5 solvent, until any residual background colour is completely removed.

3.3.6 After complete evaporation of solvent, apply a thin uniform layer of 9D1B developer spraying it from a distance of 30÷40 cm. Prior to use shake the developer spray can for at least 1 minute.

CAUTION Accidental developer leakages require the full clean of the part and the full re-processing of the part.

3.3.7 After 10 minutes of developer dwell time, carefully check the inspection area (ref. Figure 1) to interpret any red signs on a white background.

CAUTION The operator cannot wear sunglasses or photochromic lenses.

3.3.8 In case on the elevator upper skin there is presence of cracks, replace the elevator assy with a serviceable one in accordance with the instructions given in the 0B-A-AMP- 00-X Maintenance Publication.

Contact Leonardo Helicopters at aw109.mbx.aw@leonardocompany.com to evaluate a possible repair.

3.3.9 After inspection, accurately clean the affected area from any used products residual with a gauze soaked in 9PR5 solvent, eventually using a soft brush.

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 REVISION: A – May 12, 2017 Page 9 of 14

4. Repeat steps 2 and 3 for the right elevator assy P/N 109-0200-02-602/-802.

5. Return the helicopter to a ready to flight condition.

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

aw109.mbx.aw@leonardocompany.com As an alternative, gain access to My Communications section on Leonardo WebPortal and compile the “Service Bulletin Application Communication”.

7. Record compliance with PART I of this Service Bulletin in the helicopter log book.

PART II

1. Prepare the helicopter on ground for a safe maintenance and disconnect any power supply.

NOTE The following step 2 must be performed only at the first accomplishment of the Part II of this Service Bulletin.

NOTE After drilling operation, apply Alodine and then a light film of MIL-P-23377 epoxy polyamide primer on the hole surface.

2. Gain access to the lower face of the left elevator assy, counter mark hole position in accordance with Figure 2 and drill a hole ø 19.05 mm.

3. Through the new hole, as suitable access to internal area of the elevator assy, by means of endoscope, perform an accurate inspection of the Trailing Edge (T.E.) and Leading Edge (L.E.) longerons and upper web (ref. Figures 3, 4, 5) to verify presence of cracks.

4. In case there is presence of cracks, replace the elevator assy with a serviceable one in accordance with the instructions given in the 0B-A-AMP- 00-X Maintenance Publication.

Contact Leonardo Helicopters to evaluate a possible repair.

NOTE Waiting for the availability of the button, it is allowed to cover the hole with high-speed aluminium tape.

5. After inspection completion, install the button P/N A196A750B in accordance with Figure

2.

6. Repeat the steps from 2 to 5 for the right elevator assy.

S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 Page 10 of 14 REVISION: A – May 12, 2017

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

aw109.mbx.aw@leonardocompany.com As an alternative, gain access to My Communications section on Leonardo WebPortal and compile the “Service Bulletin Application Communication”.

8. Return the helicopter to flight configuration and record for compliance wit h Part II of this Service Bulletin on the helicopter logbook.

Figure 1 S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 REVISION: A – May 12, 2017 Page 11 of 14

• LEONARDO

HELICOPTERS 109-0200-31-101 WINGLET; RH SEN ALTEYNE 2000 APPD PRIMER BY TOUCH UP PLUG BUTTON A196A750B AWMS05-001 TYPE | CLAS B GRADE 2 + + VIEW LOOKING UP 19170717 +'+ CHORD LINE 625.0 (REF) Figure 2 S.B. N°109S-076 EMERGENCY ALERT DATE: May 9, 2017 Page 12 of 14 REVISION: A - May 12, 2017