# Leonardo Alert Service Bulletin 109S-101: No revision named - Rights: © Leonardo S.p.A. Filed by the FAA in regulations.gov docket FAA-2021-0686, the docket of AD 2021-17-18. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Leonardo Alert Service Bulletin 109S-101](https://openairdocs.org/service-documents/leonardo/109s-101.md) - Title as filed: Leonardo Helicopters ASB No. 109S-101 - Pages: 34 - PDF: https://openairdocs.org/files/sha256/71/bb/71bb3385684d16249861f150ccfdd9bcca6bc1227d5fe119e33871eb53222d92 - Page: https://openairdocs.org/service-documents/leonardo/109s-101/file/71bb3385684d ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 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 ### Page 2 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 ### Page 3 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 ### Page 4 S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 4 of 33 REVISION: / 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. ### Page 5 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. ### Page 6 S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 6 of 33 REVISION: / 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. ### Page 7 S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 7 of 33 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. ### Page 8 S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 8 of 33 REVISION: / 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. ### Page 9 S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 9 of 33 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 re- use. 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 ### Page 10 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 ### Page 11 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”. ### Page 12 S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 12 of 33 REVISION: / 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. ### Page 13 S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 13 of 33 4.7 On the tail rotor sleeve assy P/N 109-0130-90-121 before its removal, inspect the bushing P/N 109-0133-07-101 for correct installation and debonding 4.7.1 In case the bushing is not found in the correct pos ition or it is debonded so that can be moved off from its seat, take pictures of the bushing and sleeve, record the findings on the Detailed Inspection Form and replace the bushing in accordance with part III. If necessary, in accordance with AMP DM 0B-A-64-31-00-00A-720A-A, replace the TR sleev e with a serviceable part. 4.7.2 In case of no findings, verify the bushing displa cement measuring tool as per Part I, step 11. 4.8 In accordance with AMP DM 0B-A-64-31-00-00A-720A-A , re-install previously removed pitch change mechanism. 4.9 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. Proceed to step 7. 5. With reference to Figure 3, attach aft boot P/N 10 9-0130-96-101 on pitch change slider assy. 6. Return anti torque pedal to center. In accordance wi th AMP DM 0B-A-12-42-00-00A-510A- A, disconnect the hydraulic test bench from the helicopter. 7. Return the helicopter to a ready to flight conditi on and record for compliance with Part II 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 II”. “XXXXX” is the helicopter S/N. 8. 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”. ### Page 14 S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 14 of 33 REVISION: / PART III 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-64-00-00-00A-520A-A or 0B-B-64-00-00-00A-520A-A, remove the tail rotor hub and blade assy. 3. In accordance with AMP DM 0B-A-64-31-00-00A-520A-A, remove the pitch change mechanism. 4. In accordance with Annex B, replace the bushing P/N 1 09-0133-07-101. 5. In accordance with AMP DM 0B-A-64-31-00-00A-720A-A , re-install previously removed pitch change mechanism. 6. 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. 7. Return the helicopter to a ready to flight conditi on and record for compliance with Part III of this Service Bulletin on the helicopter logbook. 8. Send the attached compliance form 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”. ### Page 15 S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 15 of 33 PART IV 1. During application of tail rotor gearbox 400 FH s cheduled inspection, with reference to Figure 2 Detail B, verify the presence of solid film lubricant on “inspection area” (it should be present only on the “4.0mm section” and on vertical side of shoulder). If necessary, restore the layer of solid film lubricant MIL-L-23398 Type IV as follows: 1.1 Mask off surrounding areas near the inspection zone (Figure 2, Detail B) with adhesive Aluminium tape. 1.2 Clean the part with a clean cloth soaked with Class 2 solvent listed in QPL-AMS- 2644. 1.3 In accordance with CPCP 20-70-10, touch up where ne cessary with solid film lubricant with MIL-L-23398 Type IV product. 2. Record for compliance with Part IV of this Service Bu lletin on the helicopter logbook. 3. Send the attached compliance form 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”.  Non cancellare mai questo segnalibro Non cancellare mai interruzione sezione ### Page 16 Figure 1 S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 16 of 33 REVISION: / ### Page 17 (OCR) K LEONARDO HELICOPTERS INSPECTION AREA DETAIL B PARTS OMIT ER FOR TO FIGURE ANITY PURPOSE 150.0 INSPECTION AREA 150.0 DETAIL A PARTS OMITTED FOR BETTER CLARITY PURPOSE (REFER TO FIGURE 1) Figure 2 S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 17 of 33 ### Page 18 Figure 3 S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 18 of 33 REVISION: / ROTATION 109-0133-18-103 PLUG (REF) TORQUE 59÷69 Nm VIEW C TAIL ROTOR INSTALLATION STRUCTURE AND SYSTEMS ARE PARTIALLY OMITTED FOR BETTER CLARITY PURPOSE VIEW C STRUCTURE AND SYSTEMS ARE PARTIALLY OMITTED FOR BETTER CLARITY PURPOSE 109-0130-90-117/-121 TR SLEEVE ASSY (REF) 109-0130-98-101 AFT BOOT (REF) 109-0130-91-(ALL DASHES) PITCH CHANGE SLIDER ASSY (REF) REF DETAIL D ### Page 19 Figure 4 S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 19 of 33 TRIM AREA DETAIL E STRUCTURE AND SYSTEMS ARE PARTIALLY OMITTED FOR BETTER CLARITY PURPOSE 109-0130-91-(ALL DASHES) PITCH CHANGE SLIDER ASSY (REF) DETAIL D STRUCTURE AND SYSTEMS ARE PARTIALLY OMITTED FOR BETTER CLARITY PURPOSE 109-0130-90-117/-121 TR SLEEVE ASSY (REF)109-0133-07-101 BUSHING (REF) BUSHING DISPLACEMENT MEASURING TOOL POINT OF CONTACT DETAIL E BUSHING DISPLACEMENT MEASURING TOOL 40 mm (REF) 15 mm (REF) ### Page 20 ANNEX A S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 20 of 33 REVISION: / ANNEX A AW109 TR SHAFT LOCALIZED PENETRANT INSPECTION TYPE 1, METHOD C, LEVEL 2, FORM “d” ### Page 21 ANNEX A S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 21 of 33 1 PURPOSE AND APPLICABILITY This procedure details the requirements for the Liquid Penetrant Inspection (PT) on the Tail Rotor Shaft Assy. The specific Penetrant system to b e used is Type I, Method C, Sensitivity Level 2, form “d”. Purpose of this inspecti on is the detection of any possible crack located on a specific surface of the tail rotor shaft assy. 2 REFERENCES The following documents in their last revision are considered part of this procedure: ASTM E1417 Standard Practice for Liquid Penetrant Te sting; ASTM E3022 Standard Practice for Measurement of Emission Characteristics and Requirements for LED UV-A Lamps Used in Fluorescent Penetrant and Magnetic Particle Testing; EN4179/NAS410 Qualification and approval of personnel for non-destructive testing; QPL AMS2644 Qualified Product List of Inspection Mate rials, Penetrant; SAE AMS2644 Inspection Materials, Penetrant. 3 EQUIPMENT AND MATERIALS The following materials, equipment and tools are requested. 3.1 MATERIALS WARNING SOLVENT CLEANERS AND DEVELOPER CARRIER FLUIDS ARE DANGEROUS. OBSERVE ALL RELEVANT SAFETY PRECAUTIONS TO PREVENT THE RISK OF INJURY, FIRE OR EXPLOSION. a. Dye Penetrant SAE-AMS-2644 TY I, Method C, Level 2 (*); b. Developer SAE-AMS-2644 Form “d” (*); c. Solvent SAE-AMS-2644 Class 2 (*). d. Methyl Ethyl Ketone (MEK) solvent. (*) All the materials shall be certified in accordance with AMS2644, obtained from a supplier listed in QPL-AMS2644, supplied from the same manufacturer and in aerosol cans packaging. 3.2 EQUIPMENT/TOOLS a. dark curtain; b. UV-A inspection lamp emitting at least 1200 µW/cm² a nd no more than 20lux at 38cm from the front of the filter to the face of the sensor; ### Page 22 ANNEX A S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 22 of 33 REVISION: / c. UV-A/White light meters; d. plastic bristled brush; e. small soft clean brush; f. aluminum adhesive tape; g. clean, dry, lint-free cloth or absorbent toweling; h. a magnification lens (max 5X); i. an environmental thermometer. 4 PERSONNEL All Personnel performing this inspection and reporting results shall be approved to the appropriate level in accordance with EN4179/NAS410, or equivalent. The personnel shall also be familiar with the purpose of this procedure. 5 INSPECTION INSTRUCTION 5.1 PART PREPARATION Make sure that the temperature of the part to be insp ected is between 10°C and 45°C degrees (50-113 Fahrenheit). WARNING USE OF ANY ABRASIVE MATERIALS OR TOOLS IS STRICTLY FORBIDDEN. Mask off surrounding areas near the inspection zone (F igure 2, Detail B) with adhesive Aluminium tape and remove dry film lubricant using both MEK and plastic bristled brush taking care to the area of the shoulder and related fillet radius. Make sure that dry film lubricant is fully removed fro m all the inspection area and that part surface is degreased and dry. Clean white paper can be used to prove the complete removal of the dry film lubricant. 5.2 PENETRANT APPLICATION NOTE Do not spray the liquid penetrant directly on the inspection area. After the solvent (MEK) is completely evaporated, appl y Type 1, Method C, Sensitivity Level 2 liquid penetrant listed in QPL-AMS-2644 using a small soft clean dry brush. Take care to cover all the inspection area (Figure 2, Detail B). Penetrant Dwell Time shall be a minimum of 30 minutes and no more than 60 minutes. ### Page 23 ANNEX A S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 23 of 33 5.3 PENETRANT REMOVAL Excess penetrant removal shall be performed by using clean dry “lint free” cloths (or paper). Darken the part and switch on UV-A light lamp to achieve irradiance not less than 100 µW/cm² on the working surface and ambient wh ite light illuminance not exceeding 100 lx. NOTE The surface of the component shall not be flushed with solvent and the cloth or towel shall not be saturated with solvent. Removal shall be performed by first wiping the excess penetrant with a clean, lint- free, dry cloth or absorbent toweling and the remainder of the surface penetrant shall then be removed with a solvent-dampened lint-free cl oth or towel (solvent Class 2 listed in QPL-AMS-2644). The masking tape can be remo ved before using the solvent-dampened cloth in order to achieve a better pe rformance in excess penetrant removal. The surface will dry immediately at completion of this phase. 5.4 DEVELOPING CAUTION In case of any developer dripping, the part shall be carefully cleaned and the whole process repeated from “Part Preparation”. In case of exceeding 60 minutes, the part shall be carefully cleaned and the whole process repeated from “Part Preparation”. Shake Nonaqueous Developer can for at least 30 seconds a nd spray form “d” developer listed in QPL-AMS-2644 as a uniform thin coa ting over the entire inspection area. A correct application will result in a l ayer that gives an insight into the underlying metal. Development time shall be minimum 20 minutes and maximum 60 minutes. 5.5 EXAMINATION Fluorescent Penetrant examination shall be carried out in conditions of subdued background lighting (maximum illuminance 20 lux) using UV-A inspection light source able to provide not less than 1200 µW/cm² at 38cm. Inspector’s vision shall be dark adapted for a minimum of 1 min prior to examining components. ### Page 24 ANNEX A S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 24 of 33 REVISION: / Inspectors shall not wear photochromic or permanently da rkened lenses while processing or reviewing parts under UV-A light. The use of magnifying lens (5x) to support the interpr etation of liquid penetrant indications is recommended. 5.6 EVALUATION In case any crack-like indication, considered as relevant indication, is found, contact Leonardo Helicopters for instructions. 5.7 POST INSPECTION CLEANING At the end of the inspection, in case of no finding, ca refully clean the part from any residual of the products used with a clean cloth soaked with Class 2 solvent listed in QPL-AMS-2644. In accordance with CPCP 20-70-10, restore solid film lu bricant MIL-L-23398 Type IV in the area of inspection. 6 RECORDS Report the result of the inspection as necessary using pertinent documentation. ### Page 25 ANNEX B S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 25 of 33 ANNEX B AW109 TR SLEEVE ASSY BUSHING REPLACEMENT ### Page 26 ANNEX B S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 26 of 33 REVISION: / 1 PURPOSE AND APPLICABILITY This procedure details the instructions to replace the bushing P/N 109-0133-07-101 of the TR Sleeve Assy. This procedure has to be performed b y qualified maintenance personnel in authorized facilities. 2 EQUIPMENT AND MATERIALS The following materials, equipment and tools are requested. 2.1 MATERIALS WARNING SOLVENT FLUID IS DANGEROUS. OBSERVE ALL RELEVANT SAFETY PRECAUTIONS TO PREVENT THE RISK OF INJURY, FIRE OR EXPLOSION. a. Bushing P/N 109-0133-07-101; b. Aluminium oxide, 80-grit (C208); c. Adhesive 199-05-002, Type II, Class 2 (C054); d. Cloth, soft lint-free (C011); e. Cleaning solvent MIL-PRF-680, Type II (C287). 2.2 EQUIPMENT/TOOLS a. Parallel lathe; b. Caliper; c. Dry abrasive blasting equipment; 3 INSPECTION INSTRUCTION NOTE The tail rotor sleeve assy P/N 109-0130-90-121 is considered already removed from the helicopter as per applicable AMP DM. 3.1 Put the tail rotor sleeve assy P/N 109-0130-90-121 on an applicable work table. 3.2 Visually examine the sleeve assy for damage. In case of evident signs of scratches, puncture or gouges, replace it. CAUTION Be careful to not damage the seat of the bushing in the sleeve. ### Page 27 ANNEX B S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 27 of 33 NOTE To decrease the thickness of the bushing, perform the operation in different steps in order not to exceed t he internal diameter of 35.42 thru 35.52 mm. NOTE If a parallel lathe is not available, a screwdriver can be used as alternative. Be careful not to damage the sleeve. 3.3 Proceed to decrease the thickness of the bushing, in the sleeve, with a parallel lathe to remove the bushing and the adhesive. Remove and discard the bushing. NOTE Use an applicable light source, a mirror and a scriber to perform next step. 3.4 With reference to Figure B1, Detail F, examine t he mating surface between the sleeve and the tail rotor shaft assy (X Area), for wear and stepping. No wear or stepping is permitted. In case of any doubt, clean with the cleaning solvent MIL- PRF-680, Type II and perform again the inspection. If the presence of damage is confirmed, replace the sleeve. 3.5 Verify that the internal diameter of the sleeve is 35.42 thru 35.52 mm. 3.6 Prepare the sleeve and the new bushing P/N 109-01 33-07-101 for the bonding as follows: 3.6.1 Clean the areas in contact of the sleeve and the bushing with vapour degreasing procedure or with the solvent ASTM D740, Ty pe I and the cloth, soft lint-free. 3.6.2 Prepare the seat of the bushing in the sleeve wi th the dry abrasive blasting procedure. To do this, use the Aluminium oxide , 80-grit at a constant pressure of 345 thru 552 kPa. 3.6.3 Clean again the areas in contact of the sleeve and the bushing with vapour degreasing procedure or with the solvent ASTM D740, Type I and the cloth, soft lint-free. CAUTION You must apply the adhesive within 4 hours from the cleaning. 3.6.4 Apply a thin film of the adhesive 199-05-002, Type II, Class 2 on the seat of the bushing in the sleeve. 3.6.5 Put the bushing into its seat in the sleeve. ### Page 28 ANNEX B S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 28 of 33 REVISION: / 3.6.6 Make sure that the bushing is correctly installed and centered in its seat. 3.6.7 Turn the bushing in its seat to make sure that th e adhesive is equally applied along all the internal surface. 3.6.8 Verify the presence of an homogeneous squeeze o ut on the all the visible areas. 3.6.9 Remove the unwanted adhesive. NOTE Ensure firm contact during curing time. NOTE An alternative curing cycle at a temperature of 60 °C thru 70 °C (140 °F thru 158 °F) for 2 hours is allowed. 3.6.10 Let the adhesive to become hard at a temperatu re of 22 °C thru 26 °C (72 °F thru 79 °F) for 5-7 days or 80 °C thru 88 °C (176 °F thru 190 °F) for 1 hour. 3.6.11 Ream the bushing internal diameter to 31.42 t hru 31.44 mm. 3.7 If not already present, mark a letter “R” after S/N on sleeve assy. ### Page 29 ANNEX B S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 29 of 33 ### Page 30 ANNEX C S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 30 of 33 REVISION: / ANNEX C S.B. N°109S-101 INSPECTION FORM ### Page 31 ANNEX C S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 31 of 33 Please send to the following address LEONARDO S.p.A. CUSTOMER SUPPORT & SERVICES - ITALY PRODUCT SUPPORT ENGINEERING & LICENSES DEPT. Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) - ITALY Tel.: +39 0331 225036 Fax: +39 0331 225988 DETAILED INSPECTION FORM DATE Number: S.B. N°109S-101 Revision: / Customer Name and Address: Telephone: Fax: S.B. Compliance Date: Helicopter Model S/N Aircraft FH Sleeve FH T.S.O. Sleeve Assy P/N S/N Part I Paragraph Topic Remarks 3.1 Torque Value [Nm] 5 Findings on TR Sleeve Bushing P/N 109-0133-07-101 (before sleeve removal) 6 Findings on TR Sleeve P/N 109-0130-90 6.1 Findings on TR Sleeve bushing P/N 109-0133-07-101 (after sleeve removal) 7.5 TR Mast inspection results ### Page 32 ANNEX C S.B. N°109S-101 ALERT DATE: April 26, 2021 Page 32 of 33 REVISION: / ADDITIONAL REMARKS: NOTE Provide to LHD all the pictures taken during the inspection. FILLING NOTES  3.1 Record the tightening torque.  5 Brief description of the bushing status (e.g. Bonded and in place / Debonded and displaced)  6 Brief description of the defects found on the sleeve (e.g. No defects found / Wear / Fretting / Spalling…)  6.1 Brief description of the bushing status after detailed inspection (e.g. Bonded / Debonded)  7.5 Description of the findings of the Dye liquid penetrant inspection and of any other defect found (Wear, fretting, corrosion, spalling, cracks..) ### Page 33 ANNEX C S.B. N°109S-101 ALERT DATE: April 26, 2021 REVISION: / Page 33 of 33 Please send to the following address LEONARDO S.p.A. CUSTOMER SUPPORT & SERVICES - ITALY PRODUCT SUPPORT ENGINEERING & LICENSES DEPT. Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) - ITALY Tel.: +39 0331 225036 Fax: +39 0331 225988 DETAILED INSPECTION FORM DATE Number: S.B. N°109S-101 Revision: / Customer Name and Address: Telephone: Fax: S.B. Compliance Date: Helicopter Model S/N Aircraft FH Sleeve FH T.S.O. Sleeve Assy P/N S/N Part II, III, IV Paragraph Finding/Compliance Date Remarks Part II Part III Part IV ### Page 34 Remarks: Information:฀ SERVICE฀BULLETIN฀COMPLIANCE฀ ฀ ฀FORM Date: Number: Revision: Please฀send฀to฀the฀following฀address:฀ Telephone: Fax: ฀B.T.฀Compliance฀Date: ฀Customer฀Name฀and฀Address: ฀Helicopter฀Model S/N Total฀Number Total฀Hours฀ T.S.O. LEONARDO S.p.A. CUSTOMER SUPPORT & SERVICES - ITALY PRODUCT SUPPORT ENGINEERING & LICENSES DEPT. Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) - ITALY Tel.: +39 0331 225036 Fax: +39 0331 225988 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 or you can communicate the application also via Technical Bulletin Application Communication Section placed in Leonardo AW Customer Portal - MyCommunications Area. We thank you beforehand for the information given. --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.