# Leonardo Alert Service Bulletin 119-121: No revision named - Rights: © Leonardo S.p.A. Filed by the FAA in regulations.gov docket FAA-2023-1207, the docket of AD 2023-17-07. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Leonardo Alert Service Bulletin 119-121](https://openairdocs.org/service-documents/leonardo/sb-119-121.md) - Title as filed: Leonardo Helicopters ASB No. 119-121 - Pages: 22 - PDF: https://openairdocs.org/files/sha256/67/73/6773ec8a8a06c451e97ce770a08f37bfb86b3144cd8bade838efad042479f921 - Page: https://openairdocs.org/service-documents/leonardo/sb-119-121/file/6773ec8a8a06 ## Text Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 P age 1 of 21 N ° 119-121 D ATE: June 21, 2022 REV. : / - February 25, 2022 TITLE ATA 24 – STARTER-GENERATOR DRIVE SHAFT INSPECTION REVISION LOG First 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°119-121 ALERT DATE: June 21, 2022 Page 2 of 21 REVISION: / 1. PLANNING INFORMATION A. EFFECTIVITY Part I: NOTE A spare starter-generator is considered as serviceable if: - Never installed since new or since overhaul, or - Inspected in accordance with this Service Bulletin and no discrepancy found, or - Always installed in accordance with the instructions of this Service Bulletin since new, since overhaul, or since the replacement of the drive shaft. All A119/AW119 MKII helicopters with a starter-gener ator P/N 200SGL129Q1 or 200SGL129Q-2 that has been removed at least once after aircraft delivery. All the starter-generators P/N 200SGL129Q1 or 200SGL129Q-2 kept at stock that cannot be considered as serviceable in accordance with this SB. Part II: all A119/AW119 MKII helicopters. B. COMPLIANCE Part I: Within and not later than 50 flight hours or 3 months whichever occurs first after the issue of this Service Bulletin. Part II: At each starter-generator removal / installation. C. CONCURRENT REQUIREMENTS N.A. D. REASON This Service Bulletin is issued to provide the necessary instructions on how to perform a detailed inspection of the drive shaft of the starter-generator P/N 200SGL129Q1 or P/N 200SGL129Q-2, in order to prevent its rupture in flight and, consequently, the loss of electrical generation. This SB also provides updated instructions on how to correctly install and remove the starter-generator in order to prevent any future damage. ### Page 3 S.B. N°119-121 ALERT DATE: June 21, 2022 REVISION: / Page 3 of 21 E. DESCRIPTION A case of electrical failure, caused by the rupture of the drive shaft of the starter- generator P/N 200SGL129Q1, occurred on an AW119 MKII helicopter. Although the investigation on the root cause is still in progress, it seems to be related to a misalignment/mishandling of the starter-generator drive shaft during installation or removal procedures. For this reason, Leonardo Helicopters decided to issue this SB. Part I requires to perform a borescope inspection to verify the correct alignment between the drive shaft and the starter-generator body. In case misalignment is detected a liquid penetrant inspection on the critical section of the drive shaft to detect potential cracks is required. If damages are detected, the starter-generator must be sent to an authorized service station for repair. In addition, to assure the integrity of the drive shaft, Part II provides the updated instructions to be performed at each starter- generator removal/installation in compliance with Skurka’s SB 150SG114 . 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 LH 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: 4 (four) MMH; Part II: 2 (two) MMH. MMH are based on hands-on time and can change with personnel and facilities available. MMH are not comprehensive of the overall hours necessary to get access to work areas and to remove all the equipment that interferes with the application of the prescribed instructions. For removal and installation of the starter-generator two mechanics are required. ### Page 4 S.B. N°119-121 ALERT DATE: June 21, 2022 Page 4 of 21 REVISION: / H. WEIGHT AND BALANCE N.A. I. REFERENCES 1) PUBLICATIONS Following Data Modules refer to MM: DATA MODULE DESCRIPTION PART DM01 MM Paragraph 00-20-1 Helicopter safety I, II DM02 MM Paragraph 06-40-1 Access panels and doors I DM03 MM Paragraph 24-31-34 Starter generator - Removal/Installation I, II 2) ACRONYMS & ABBREVIATIONS MM Maintenance Manual DOA Design Organization Approval EASA European Aviation Safety Agency LH Leonardo Helicopters MMH Maintenance Man Hours P/N Part Number AR As required FH Flight Hours SB Service Bulletin S/N Serial Number 3) ANNEX ANNEX A – AW119 Starter-Generator Shaft Localized Penetrant Inspection Type 1, Method C, Level 2, Form “d” J. PUBLICATIONS AFFECTED A119/AW119MKII MM - Maintenance Manual K. SOFTWARE ACCOMPLISHMENT SUMMARY N.A. ### Page 5 S.B. N°119-121 ALERT DATE: June 21, 2022 REVISION: / Page 5 of 21 2. MATERIAL INFORMATION A. REQUIRED MATERIALS 1) PARTS PART I: # P/N ALTERNATIVE P/N DESCRIPTION Q.TY LVL NOTE LOG P/N 1 200SGL129Q-2 200SGL129Q1 Starter generator assy AR (1) - 2 M83248/1-113 AS3209-113 O-ring AR (2) - PART II: N.A. Refer also to IPC for the spare parts required to comply with the MM Paragraphs referenced in the accomplishment instructions. 2) CONSUMABLES # SPEC./LHD CODE NUMBER DESCRIPTION Q.TY NOTE PART 3 Commercial Lock wire AR (3) - 4 ASTM D740, Type I Methyl Ethyl Ketone (MEK) solvent (C511) AR (3) - 5 Commercial Plastic bristled brush AR (3) - 6 Commercial Aluminium adhesive tape AR (3) - 7 SAE-AMS-2644, Type 1, Method C, Sensitivity Level 2 Dye Penetrant AR (3)(4) - 8 SAE-AMS-2644 Class 2 Penetrant remover / Solvent (C290) AR (3)(4) - 9 SAE-AMS-2644 Form “d” Developer AR (3)(4) - 10 Commercial Small soft clean brush AR (3) - 11 Commercial Clean, dry, lint-free cloth or absorbent toweling AR (3) - Refer also to AMDI for the consumable materials required to comply with the MM Paragraphs referenced in the accomplishment instructions. Refer also to Annex A for the consumable materials required for the liquid penetrant inspection of the starter-generator drive shaft. 3) LOGISTIC MATRIX N.A. NOTE (1) Item necessary only if found damaged during liquid penetrant inspection. It is required one starter-generator assy for each helicopter. (2) Item necessary only if the starter-generator has to be removed from the helicopter. ### Page 6 S.B. N°119-121 ALERT DATE: June 21, 2022 Page 6 of 21 REVISION: / It is required one o-ring for each helicopter. (3) Item to be procured as local supply. (4) 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 The following special tools, or equivalent, are necessary to accomplish this Service Bulletin: # P/N DESCRIPTION Q.TY NOTE PART 12 Commercial Borescope 1 (B1) - 13 Commercial Dark curtain 1 (B1)(B3) - 14 Commercial Magnifying lens 10x 1 (B1) - 15 Commercial UV-A inspection lamp 1 (B1)(B2) - 16 Commercial UV-A/Ambient light meters 1 (B1) - Refer also 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 of the starter-generator drive shaft. SPECIAL TOOLS NOTE Tool 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. If not available, a darkened room is needed. C. INDUSTRY SUPPORT INFORMATION WARRANTY: 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: 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: The INSPECTION REPORT and PICTURE are mandatory; in case the MMIR is not accompanied by these documents, it will be rejected. ### Page 7 S.B. N°119-121 ALERT DATE: June 21, 2022 REVISION: / Page 7 of 21 NOTE: WRM will include RETURN MATERIAL AUTHORIZATION (RMA) number; the unit removed from the aircraft has to be returned to LH as per instructions defined into LH Information Letter GEN-15-047. ### Page 8 S.B. N°119-121 ALERT DATE: June 21, 2022 Page 8 of 21 REVISION: / 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) Exposed thread surface and nut must be protected using a layer of tectyl according to MIL-C-16173 grade I. 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. In accordance with MM Paragraph 06-40-1, remove all external panels required to gain access to the area affected by this Service Bulletin. NOTE Perform steps 3 thru 4 only for starter-generator installed on board the helicopter. For starter-generator at stock proceed with step 5. NOTE It is not required to rotate the drive shaft of the starter- generator to perform the borescope inspection. 3. With reference to Figures 1 thru 3 and in accorda nce to the steps below, using a borescope, perform a visual inspection to verify the correct alignment between the drive shaft and the starter-generator body. No misalignment is acceptable. 3.1 With reference to Figure 1, enter the borescope and perform the inspection through at least two of the access points on support P/N 200SGL1040-2. 3.2 With reference to Figures 2 and 3, verify that the drive shaft flange and the starter-generator flange are concentric and aligned. 3.3 If the alignment is correct, proceed with step 9. If the alignment is incorrect or the alignment is not clear, remove the starter- generator from the helicopter as per step 2 in Part II and proceed with step 4. ### Page 9 S.B. N°119-121 ALERT DATE: June 21, 2022 REVISION: / Page 9 of 21 4. Visually inspect the correct alignment between the drive shaft and the starter-generator body. If the misalignment is confirmed proceed with step 5. Otherwise, reinstall the starter-generator on board the helicopter as per step 3 in Part II and proceed with step 9. 5. With reference to Annex A, perform a liquid penetrant inspection of the drive-shaft, in order to detect the presence of eventual cracks. 6. If no evidence of existing cracks is detected at step 5, reinstall the starter-generator on board the helicopter as per step 3 in Part II and proceed with step 9. NOTE “XXXXX” in the subject line below is the helicopter S/N. 7. If evidence of existing cracks is detected at ste p 5, send the liquid penetrant inspection report with Subject line “SB 119-121 rev. / - S/N XXXXX - Notification of drive shaft damage” to the following mail box: engineering.support.lhd@leonardo.com NOTE To send the starter-generator directly to an authorized repair station for repair, contact LH spare management. 8. Send the starter-generator to an authorized repai r station for repair and replace the starter-generator with a serviceable part. Install the serviceable starter-generator on board the helicopter as per step 3 in Part II and proceed with step 9. 9. In accordance with MM Paragraph 06-40-1, reinstall all external panels previously removed at step 2. 10. Return the helicopter to flight configuration and record for compliance with Part I of this Service Bulletin on the starter-generator log card and on the helicopter logbook. 11. Send the attached compliance form to the following mail box: engineering.support.lhd@leonardo.com As an alternative, gain access to My Communications section on Leonardo WebPortal and compile the “Service Bulletin Application Communication”. ### Page 10 S.B. N°119-121 ALERT DATE: June 21, 2022 Page 10 of 21 REVISION: / PART II 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. CAUTION The MM Paragraph 24-31-34 has been updated to embody Manufacturer’s requirements regarding correct removal/installation procedures of the starting- generator so as to avoid any damage to the drive shaft. As such, you are required to download the latest instructions from LH portal before performing the following steps. 2. S tarter-generator removal procedure CAUTION For step 2.1 accomplishment, two mechanics are required to properly remove the starter-generator from the helicopter. An inadequate removal of the starter- generator can damage the drive shaft. 2.1 With reference to MM Paragraph 24-31-34, remove the starter-generator P/N 200SGL129Q1 or P/N 200SGL129Q-2 from the helicopter. 3. Starter-generator installation procedure CAUTION For step 3.1 accomplishment, two mechanics are required to properly install the starter-generator on the helicopter. An inadequate installation of the starter- generator can damage the drive shaft. 3.1 With reference to MM Paragraph 24-31-34, install a serviceable starter-generator: 4. Return the helicopter to flight configuration and record for compliance with Part II of this Service Bulletin on the helicopter logbook. 5. Send the attached compliance form to the following mail box: engineering.support.lhd@leonardo.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 11 Figure 1 S.B. N°119-121 DATE: June 21, 2022 REVISION: / Page 11 of 21 For reference only. ### Page 12 Figure 2 S.B. N°119-121 DATE: June 21, 2022 Page 12 of 21 REVISION: / For reference only. ### Page 13 Figure 3 S.B. N°119-121 DATE: June 21, 2022 REVISION: / Page 13 of 21 For reference only. Drive shaft flange concentric with starter-generator flange. Drive shaft flange not concentric with starter-generator flange. ### Page 14 ANNEX A S.B. N°119-121 DATE: June 21, 2022 Page 14 of 21 REVISION: / ANNEX A AW119 Starter-Generator Shaft Localized Penetrant Inspection Type 1, Method C, Level 2, Form “d” ### Page 15 ANNEX A S.B. N°119-121 DATE: June 21, 2022 REVISION: / Page 15 of 21 1 PURPOSE AND APPLICABILITY This procedure details the requirements for the Liquid Penetrant Inspection (PT) on the AW119 starter-generator shaft in correspondence of i ts reduced section zone highlighted in yellow in Figure A1. The specific Penetrant system to be used is Type I, Method C, Sensitivity Level 2, form “d”. Purpose of this inspection is the detection of a ny possible crack located in the affected area. 2 REFERENCES The following documents in their last revision are considered part of this procedure: ASTM E1417 Standard Practice for Liquid Penetrant Testing; 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 Materials, Penetrant; SAE AMS2644 Inspection Materials, Penetrant. 3 EQUIPMENT AND MATERIALS For the application of this work instruction the following equipments and materials are required. 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. Methyl Ethyl Ketone (MEK) solvent; b . Plastic bristled brush; c. Aluminium adhesive tape; d. Dye Penetrant SAE-AMS-2644 Type 1, Method C, Sensitivity Level 2 (*); e. Solvent SAE-AMS-2644 Class 2 (*); f. Developer SAE-AMS-2644 Form “d” (*); g. Small soft clean brush; h. Clean, dry, lint-free cloth or absorbent towelling; i. Dark curtain or darkened room; j. Magnifying lens 10x. ### Page 16 ANNEX A S.B. N°119-121 DATE: June 21, 2022 Page 16 of 21 REVISION: / (*) All the materials shall be certified in accordance with AMS2644, obtained from a supplier listed in QPL-AMS2644, supplied from the same manufacturer. 3.2 EQUIPMENT/TOOLS a. UV-A inspection lamp emitting at least 1200 µW/cm² and no more than 20lux at 38cm from the front of the filter to the face of the sensor; b. UV-A/Ambient light meters. 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 Component, penetrant products and ambient temperatures shall all be in the range 10°C and 45°C degrees (50-113 Fahrenheit). Clean the area of inspection with MEK and cloth / absorbent toweling and with the help of plastic bristled brush until the part surface does not show any dirt/residue. CAUTION USE OF ANY ABRASIVE MATERIALS OR OPERATION IS STRICTLY FORBIDDEN. Mask off surrounding areas near the inspection zone with adhesive Aluminum tape (Figure A2). 5.2 PENETRANT APPLICATION NOTE Liquid penetrant product supplied in can requires to be sprayed in a clean and dry beaker to allow the mandatory application by brush on the inspection area. After MEK is completely evaporated, apply Type 1, Me thod C, Sensitivity Level 2 liquid penetrant using a small soft clean dry brush. Take care to cover all the inspection area (Figure A3). Penetrant dwell time shall be a minimum of 30 minutes and no more than 60 minutes. Verify the liquid penetrant coverage on the inspection area after both application of liquid penetrant and dwell time to make sure no separation on the surface occurs; in case it happens, clean the surface and repeat the process from “Part Preparation”. ### Page 17 ANNEX A S.B. N°119-121 DATE: June 21, 2022 REVISION: / Page 17 of 21 5.3 PENETRANT REMOVAL NOTE The surface of the component shall not be flushed with solvent and the cloth or towel shall not be saturated with solvent. Solvent-removable penetrants are removed by first wi ping the excess penetrant with a clean, lint-free, dry cloth or absorbent toweling. The remainder of the surface penetrant is then removed with a solvent-dampened (solvent Class 2 listed in QPL- AMS-2644) lint-free cloth or towel. The masking tape is recommended to be removed before the solvent-dampened cloth action in order to achieve a better performance in excess penetrant removal, particularly from the borders of the masked area. The surface will dry immediately at completion of this phase All this phase shall be performed in a darken condition switching on UV-A light lamp to achieve irradiance on the working surface not less than 100 µW/cm² and ambient light illuminance not exceeding 100 lx. 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 10 secon ds and spray form “d” developer as a uniform thin coating over the entire inspection area. The suitable application will result in a layer that provides an insight into the underlying metal: if the developer coating thickness is too heavy such that the metallic surface is completely masked, the component shall be cleaned and reprocessed starting back to “Part Preparation”. Development time shall be minimum 20 minutes and maximum 60 minutes. ### Page 18 ANNEX A S.B. N°119-121 DATE: June 21, 2022 Page 18 of 21 REVISION: / 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 at least 1200 µW/cm² at 38cm. Inspector’s vision shall be dark adapted for a minimum of 1 min prior to examining components. Inspectors shall not wear photochromic or permanently darkened lenses while processing or reviewing parts under UV-A light. The use of magnifying lens (10x) to support the interpretation of liquid penetrant indications is recommended. 5.6 EVALUATION Any crack-like linear indication is considered as relevant indication and so not acceptable. 5.7 POST INSPECTION CLEANING At the end of the inspection, if no relevant indications have been detected, carefully clean the part from any residual of the products used with a clean cloth soaked with Class 2 solvent listed in QPL-AMS-2644 6 RECORDS Report the result of the inspection as necessary using pertinent documentation. ### Page 19 ANNEX A Figure A1 S.B. N°119-121 DATE: June 21, 2022 REVISION: / Page 19 of 21 For reference only. ### Page 20 ANNEX A Figure A2 S.B. N°119-121 DATE: June 21, 2022 Page 20 of 21 REVISION: / For reference only. ### Page 21 ANNEX A Figure A1 S.B. N°119-121 DATE: June 21, 2022 REVISION: / Page 21 of 21 For reference only. A3 ### Page 22 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/). 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