Leonardo ASB 109S-101: No revision named

N° 109S-101 DATE: April 26, 2021 REV. : / - March 15, 2017 Page 1 of 33 TITLE ATA 64 - INSPECTION OF TAIL ROTOR SHAFT ASSY P/N 109-0445-08-(ALL DASHES) AND TAIL ROTOR SLEEVE ASSY P/N 109-0130-90-121

REVISION LOG New Issue 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°109S-101 ALERT DATE: April 26, 2021 Page 2 of 33 REVISION: /

1. PLANNING INFORMATION A. EFFECTIVITY All the Leonardo S.p.a. A109S helicopters installing a TR sleeve assy P/N 109-0130- 90-121 with S/Ns MO.001 to S/N MO.677 and with S/N MOR678 to MOR1140.

B. COMPLIANCE NOTE TR sleeve assy P/N 109-0130-90-121 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 mont hs 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 or TGB special inspection (1600 FH).

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 109-0130-90-121.

E. DESCRIPTION During tail rotor system inspections required after an a bnormal 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 assu re 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 p enetrant fluorescent liquid inspection in the area potentially affected by the issue and (Part II) a recurrent check for

S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 3 of 33 condition of the TR sleeve bushing. In case of sleeve bush ing 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 inspec ted with dye penetrant fluorescent liquid.

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 Aut hority approval must be checked within Leonardo Helicopters customer portal.

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

If an aircraft listed in the effectivity embodies a m odification 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 incor poration 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 per sonnel and facilities available.

H. WEIGHT AND BALANCE N.A.

I. REFERENCES

1) PUBLICATIONS

DATA MODULE DESCRIPTION PART DM01 0B-A-00-20-00-00A-120A-A Helicopter Safety – Pr e-operation I, II, III DM02 0B-A-64-00-00-00A-520A-A Tail rotor - Remove procedure I, II, III DM03 0B-B-64-00-00-00A-520A-A Tail rotor - Remove p rocedure I, II, III

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DATA MODULE DESCRIPTION PART DM04 0B-A-64-00-00-00A-720A-A Tail rotor - Install p rocedure I, II, III DM05 0B-B-64-00-00-00A-720A-A Tail rotor - Install p rocedure I, II, III DM06 0B-A-64-31-00-00A-520A-A Rotating control insta llation - Components - Remove procedure

I, II, III DM07 0B-A-64-31-00-00A-720A-A Rotating control insta llation - Components - Install procedure

I, II, III DM08 0B-A-64-31-00-00A-281B-B Rotating control insta llation - Components - Scheduled inspection I, II DM09 0B-A-65-21-01-00A-520A-A 90-degree gearbox - Remove procedure I DM10 0B-A-65-21-01-00A-720A-A 90-degree gearbox - Install procedure I DM11 0B-A-12-42-00-00A-730A-A External hydraulic po wer - Connect procedure I, II DM12 0B-A-12-42-00-00A-510A-A External hydraulic pow er - Disconnect procedure I, II DM13 0B-A-67-21-00-00A-271A-A Tail rotor control syst em - Adjust II DM14 0B-A-67-21-00-00A-271K-A Tail rotor control syst em - Adjust II DM15 CPCP 20-70-10 Application of solid lubricant film IV

2) ACRONYMS AMDI Aircraft Material Data Information AMP Aircraft Maintenance Publication AR As Required CPCP Corrosion Protection and Control Publication DOA Design Organization Approval IPD Illustrated Parts Data ITEP Illustrated Tool and Equipment Publication LHD Leonardo Helicopters MMH Maintenance Man Hours P/N Part Number 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°109S-101 Inspection form.

S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 5 of 33 J. PUBLICATIONS AFFECTED N.A.

K. SOFTWARE ACCOMPLISHMENT SUMMARY N.A.

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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 IPD for the spares materials required to comply with the AMP DMs 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 IV Solid film, lubricant 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) I II 14 MIL-PRF-680, Type II Cleaning solvent (C287) AR (1) III Refer also to AMDI for the consumable materials require d to comply with the AMP DMs referenced in the accomplishment instructions.

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3) LOGISTIC MATRIX N.A.

NOTE Local supply.

This material shall be certified in accordance with A MS2644, obtained from a supplier listed in QPL-AMS2644, supplied from the same manufacturer and in aerosol cans packaging.

B. SPECIAL TOOLS # P/N DESCRIPTION Q.TY NOTE PART 15 109-3130-32-1 Tail rotor retaining nut wrench (G F-56-00) 1 (B1) I 16 895-3130-02-101 Tool, T/R slider bushing installation (GF-89-00) 1 (B1) I 17 109-3130-53-111 Tool, T/R pitch change slider ring nut removal/installation (GF-58-00) 1 (B1) I 18 109-3130-54-101 or 109-3130-54-111 Tool, T/R pitch change housing ring nut removal/installation (GF-59-00) 1 (B1) I 19 109-3130-70-101 Tool, T/R pitch change housing duplex bearing removal (GF-63-00) 1 (B1) I 20 109-3130-69-101 Tool, T/R pitch change housing duplex bearing installation (GF-62-00) 1 (B1) I 21 109-3130-71-101 Tool, T/R pitch change slider installation (GF-64-00) 1 (B1) I 22 109-3130-55-117 Tool, T/R pitch change slider removal (GF-66-00) 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 ITEP for the special tools required to comply with the AMP DMs referenced in the accomplishment instructions.

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

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

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SPECIAL TOOLS NOTE Please contact Leonardo Helicopters Division order adm inistration to request the tools supply on loan. As soon as the present Service Bull etin 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 b e 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 instruct ions 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.

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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 AMP DM 0B-A-00-20-00-00A-120A-A, 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 1 09-0133-18-103 (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 AMP DM 0B-A-64-00-00-00A-520A-A or 0B-B-64-00-00-00A-520A-A, remove the tail rotor hub and blade assy.

NOTE Before the removal of the TR sleeve as per AMP DM 0B-A-64-31-00-00A-520A-A, 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 bushin g and sleeve, record the finding on the Detailed Inspection Form and proceed with the following step.

5. In accordance with AMP DM 0B-A-64-31-00-00A-520A-A, remove the pitch change mechanism.

6. In accordance with AMP DM 0B-A-64-31-00-00A-281B-B, inspect the removed tail rotor sleeve assy P/N 109-0130-90-121 and bushing P/N 109-0133-07-101. Inspect the bushing

S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 10 of 33 REVISION: / 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, a nd contact Leonardo Helicopters to evaluate part serviceability. If necessary , in accordance with AMP DM 0B-A-64-31-00-00A-720A-A, replace it with a service able 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 Roto r Shaft Assy with the endoscope probe during the inspection.

7.1 perform internal surface endoscope inspection for a bnormal wear condition, corrosion, fretting, crack and damage;

7.2 perform external surface visual inspection for abnor mal 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, corrosio n, 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 AMP DMs 0B-A-65-21-01-00A-520A-A and 0B-A-65-21 -01-00A-720A-A, replace it with a serviceable 90-Degree Gearbox.

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

8. In accordance with AMP DM 0B-A-64-31-00-00A-720A-A , re-install previously removed pitch change mechanism.

9. In accordance with AMP DM 0B-A-64-00-00-00A-720A-A or 0B-B-64-00-00-00A-720A-A, re-install previously removed tail rotor hub and blade assy.

10. In accordance with AMP DM 0B-A-12-42-00-00A-730A-A , 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

S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 11 of 33 pedal full forward before beginning the following procedure.

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

11.1 Starting from a metal sheet of 55x5 mm (1 mm th ickness), 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 t ool 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 the 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 f or Part II inspection.

12. With reference to Figure 3, attach aft boot P/N 1 09-0130-96-101 on pitch change slider assy.

13. Return the anti torque pedal to center. In accord ance with AMP DM 0B-A-12-42-00-00A- 510A-A, 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 109S-101 - S/N XXXXX – Compliance to Part I”. “XXXXX” is the helicopter S/N.

15. Send the attached compliance form and the pictures taken during the inspections to the following mail box:

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

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PART II NOTE If tail rotor controls adjust procedure (ref. 0B-A-67-2 1- 00-00A-271A-A or 0B-A-67-21-00-00A-271K-A) has been performed after manufacturing the Bushing displacement measuring tool, discard the previous tool and manufacture a new one i.a.w. Part I, step 11.

1. In accordance with AMP DM 0B-A-00-20-00-00A-120A-A, prepare the helicopter on ground for a safe maintenance. Disconnect the battery, all electrical power sources and/or the external power supply.

2. In accordance with AMP DM 0B-A-12-42-00-00A-730A-A, 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.

3. With reference to Figure 3, detach aft boot from p itch change slider assy.

4. With reference to Figure 4, move aft boot and, usi ng bushing displacement measuring tool, verify that the distance from bushing to pitch ch ange slider assy has not changed since last inspection. If the distance decreases (long side of tool not in contact with slider assy, ref. Figure 4 Detail E), proceed as follows, otherwise proceed to step 5:

4.1 In accordance with AMP DM 0B-A-12-42-00-00A-510A- A, disconnect the hydraulic test bench from the helicopter.

4.2 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.

4.3 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.

4.4 Record the torque value on the Detailed Inspectio n Form and proceed with next step.

4.5 In accordance with AMP DM 0B-A-64-00-00-00A-520A-A or 0B-B-64-00-00-00A- 520A-A, remove the tail rotor hub and blade assy.

4.6 In accordance with AMP DM 0B-A-64-31-00-00A-520A-A , remove the pitch change mechanism.