# ALERT

TRANSL A TION OF



## BOLLETTINO TECNICO N° 

# 109EP-30

The technical content of this document is approved

under the author i t y of D O A nr. EASA.21J.005

. D A T E June 21, 2002

REV. C September 29, 2006

Compliance w i th

this bulletin is:



# ALERT Page 1 of 18 SUBJECT: INSPECTION FOR CRACKS OF TAIL ROTOR BLADES P/N 109-8132-01-111, THEI R REPLACEMENT AND TAIL ROTOR GRIP

BUSHINGS REPLACEMENT.

REASON: Prescribe checks/inspections to verify for the possible presence of cracks on

the tail rotor blades P/N 109-8132-01-111 (on both upper and lower surfaces). In addition, replacement of the bush ings P/N 109-0132-55 with new bushing

P/N 109-8131-29-101 in order to reduce blade loads and the installation of a new pair of tail rotor blades P/N 109-8132-01-111.

Furthermore cancellation of the Vne limitations.

HELICOPTERS AFFECTED:

PART I^: All Agusta A109E helicopters t hat install hub and blades assy

P/N 109-8131-02-151.

PART II^ and PART III^: All Agusta A109E helicopters that install tail rotor blades P/N

109-8132-01-111.

PART IV^ and PART V^: All Agusta A109E helicopters t hat install hub and blades assy

P/N 109-8131-02-151.

PART VI^: All Agusta A109E helicopters affect ed by PART V^ of this Bollettino. C CB.T. 109EP-30

Page 2 of 18 COMPLIANCE:

PART I^: Upon receipt of this Bollettino until complian ce with PART IV^ of this Bollettino.

PART II^:

• For helicopters that adopt the “Standard Inspection Program ”:

Each airworthiness check and at each pilot’s preflight check.

• For helicopters that adopt the “E xtended Inspection Program” and the “Progressive Inspection Program ”: Each pilot’s daily preflight check and at each pilot’s preflight check.

PART III^: Each 25 (twenty-five) operatin g hours from receipt of th is Bollettino or however if any abnormal increase of vibratory level should arise.

PART IV^: Upon accomplishment of 200 (two hundred) operating hours of each tail rotor

blade P/N 109-8132-01-111.

WARNING For helicopters equipped with tail rotor blades P/N 109-8132-01-111, which upon receipt of this Bollettino have reached 200 (two hundred) or more operating hours. Comply with

this PART of the Bo llettino within 10 (ten) operating hours from receipt of

this Bollettino. During this time interval, the check prescribed in PART III^ shall be accomplished. At eac h daily preflight check and however each 5 (five) operating hours or if any abnormal increase of vibratory level should

arise.

CAUTION Any spare tail rotor blades that have

accumulated service hours on the A109E and/or A119 helicopter models, may be used only up to 200 (two hundred) operating hours maximum. Upon reaching this limit,

the blades shall be removed from

service.B.T. 109EP-30

Page 3 of 18 PART V^: Within and not later than May 31, 2003.

CAUTION

The new blades installed on hub and grips P/N 109-8131-02-159 (that

install bushing P/N 109-8131-30-109) maintain the s a me retirement life of 1000 hour s as reported in Chapter 04 of the A109E

Maintenance Manual.

PART VI^: C Each 200 (two hundred) flight hours from compliance with PART V^.

DES CRIPT ION: On an in-service A109E helicopter, a case of a crac k on a tail rotor blade

P/N 109-8132-01-111 has oc curred, without any consequence to the

continuation of t he flight mission. The crack was detected during a post f light inspection following an abnormal increase in ground vibr atory level. Whilst awaiting compliance with PART V^ of this Bollettino, a Vne limitation is

introduced in order to decrease t he loads on the tail rotor blades. Agusta subsequently designed a new bu shing P/N 109-8131-30-109, that

when installed on tail r o tor grip as sy P/N 109-8131-29-101, reduces the loads acting upon the tail rotor blades. In addition, as a precautionary measure an d whilst awaiting modification of the configuration as prescribed in PART V^, the tail rotor blade P/N

109-8132-01-111 retirement life is reduc ed to 200 (two hundred) operating

hours. This Bollettino therefore prescribes:

• a reduction of all Vne by 28 KIAS including o p tional equipment (PART I^);

• a visual check by the pilot and/ or qualified personnel (PART II^);

• a visual inspection with the aid of a magnifying glass by qualified personnel and, if necessary, a liquid penetrant inspection (PART III^);

• for tail rotor blades P/N 109-8132-01- 111 installed on the grip assy P/N 109-8131-02-127, reduction of retire ment life to 200 (two hundred) operating hours (PART IV^);B.T. 109EP-30

Page 4 of 18 • the replacement of the bushings P/N 109-0132-55 and spacer

P/N 109-0132-13 with bushi ng P/N 109-8131-30-109 on tail rotor grip

P/N 109-8131-29-101 t ogether with the installation of a new pair of tail rotor blades P/N 109-8132-01-111 (PART V^). This replacement permits:

3⁄4 cancellation of the Vne limitations prescribed in PART I^, thus returning to the values reported in the pertinent A109E Rotorcraft Flight Manual;

3⁄4 cancellation of the limitations pre scribed in PART IV^, thus returning to the retirement life (1000 hours) reported in Chapter 04 of the A109E Maintenance Manual;

• a periodical check of the maximum a llowable internal diameter of the bushing P/N 109-8131-30-109 (PART VI^).

REQUIRED MANPOWER: The following estimated manpo wer hours are required for compliance with this

Bollettino:

PART I^: Negligible.

PART II^: Negligible.

PART III^: 30 (thirty) minutes fo r each blade (magnifying glass inspection).

PART IV^: 2 (two) hours for each pair of tail rotor blades

P/N 109-8132-01-111.

PART V^: 16 (sixteen) hours for the inst allation of the new bushings P/N 109-8131-30-109 inside the gr ips and a new pair of tail rotor blades P/N 109-8132-01-111;

or 6 (six) hours for the installati on of the new gr ip and bushing assy P/N 109-8131-02-161 (refer to figure 2) and a new pair of

tail rotor blades P/N 109-8132-01-111.

PART VI^: 7 (seven) hours to execute the inspection.

WARRANTY: The issue will be treated with a separat e dedicated warranty policy letter.

REQUIRED MATERIALS:

PART I^ and PART II^:

N.A.B.T. 109EP-30

Page 5 of 18 PART III^: For the compliance with this PART of the Bollettino the following materials may be required:

• Solvent (hexane or petro leum ether or aliphatic naphtha according to TT-N-95 type 2).

• Visible dye penetrant P6 R available from BR ENT International;

• nonaqueous wet developer 9D1B sp ray available from BRENT International;

• one or more white light sources able to provide an illuminance of at least 2000 lux on inspection area.

CAUTION It is prohibited to use alternative products of solvents, penetrant and developers to those specified in this

Bollettino.

PART IV^:

For the compliance of this PART of t he Bollettino the following materials are required:

P/N DENOMINATION Q.TY’

109-8132-01-111 Tail rotor blade A.R. LN94-20025 Cotter pin C.R.

PART V^:

For the compliance of this PART of t he Bollettino the following materials are required:

P/N DENOMINATION Q.TY’ 109-8131-30-109 Bushing 2 RR187S Retainer ring 2

or M27426-3147D Retainer ring 2 LN94-20025 Cotter pin 4

109-8132-01-111 Tail rotor blade 2 109-0131-27-101 Gasket assy 4 each assy consists of:

109-0131-27-103 Gasket

. 1 109-0131-27-105 Ring

. 1B.T. 109EP-30

Page 6 of 18 Or alternatively at the operator’s discretion:

P/N DENOMINATION Q.TY’ LN94-20025 Cotter pin 4

109-8132-01-111 Tail rotor blade 2 109-8131-02-161 Grip and bushing assy 2 (P/N assigned only for spare parts purposes) Each grip and bushing assy consists of (refer to figure 2): 109-8131-29-101 Grip assy Ref. 109-8131-30-109 Bushing Ref.

109-8131-16-101 Washer Ref. RR187S Retainer ring Ref.

or M27426-3147D Retainer ring Ref. 109-0131-27-101 Gasket assy Ref.

In addition, the following consumable materials are required (normally commercially available but also available at Service Stations):

SPECIFICATION DENOMINATION Q.TY’

MIL-P-23377 Primer A.R. (cod. 900004523)

MIL-T-81772 Thinner A.R. (cod. 900002527) MIL-C-16173 Corrosion preventive compound A.R. Grade 2 (cod. 501221820)

PART VI^:

The following materials may be necessary for compliance with this PART of

the Bollettino:

P/N DENOMINATION Q.TY’ 109-8131-30-109 Bushing 1 RR187S Retainer ring 1

or M27426-3147D Retainer ring 1 109-0131-27-101 Gasket assy 2 each gasket assy consists of:

109-0131-27-103 Gasket

. 1 109-0131-27-105 Ring

. 1

SPECIAL TOOLS:

• P/N 109-3130-56-111 (tool for the installation of the new bushings P/N 109-8131-30-109) ) consists of:

3⁄4 n°1 Base P/N 109-3130-56-113

3⁄4 n°1 Centering pin P/N 109-3130-56-115

3⁄4 n°1 Pusher P/N 109-3130-56-119.B.T. 109EP-30

Page 7 of 18 • P/N 109-3130-72-101 (tool for the removal of the bushings P/N 109-0132-55).

WEIGHT AND BALANCE CHANGES: PART I^, PART II^, PART III^ and PART IV^:

N.A.

PART V^: Negligible.

PART VI^:

N.A.

REFERENCES:

• A109E Maintenance Manual and applicable Temporary Revisions (refer to COMPLIANCE INSTRUCTIONS FOR PART V^ and PART VI^).

• Pertinent A109E Rotorcraft Flight Manual and applicable Temporary Revisions (refer to COMPLIANCE INSTRUCTIONS FOR PART I^ and PART II^).

PUBLICATIONS AFFECTED:

A109E Maintenance Manual. Pertinent A109E Rotorcraft Flight Manual.

Pertinent A109E Illust rated Parts Catalog.

A109E Overhaul Manual.

COMPLIANCE INSTRUCTIONS:

PART I^:

1. Apply, on the central beam of the cockpit above the placard

“Vne AIRSPEED LIMITATIONS – KI AS”, an adhesive label with the wording given below:



### Reduce all Vne by 28 KIAS optional equipment included

2. On the glass of the airspeed indica tors apply a red mark over the value

of 140 Kts.B.T. 109EP-30

Page 8 of 18 3. Insert in the Rotorcraft Fli ght Manual the pertinent Temporary

Revisions.

Helicopter Manual Temporary

Revisions n° A109E equipped with Pratt&Whitney PW206C engines. Rotorcraft Flight Manual Agusta A109E (A109E RFM ) 1-1 and 1-2.

A 109E equipped with

Turbomeca Arrius TM2K1 engines. Rotorcraft Flight Manual Agusta A109E

Turbomeca Arrius TM2K1 Engine (A109E-RFM TM2K1) 1-1 and 1-2.

4. Record compliance with this PART of the Bollettino in the helicopter log

book.

PART II^:

NOTE The procedure repor ted below must be performed on each one of the two

tail rotor blades.

CAUTION If during the inspections cracks are found, remove from service the

affected blade and consider it rejected.

In this case inform: Agusta Service Engineering A109

Tel. +39-0331711281

Fax: +39-0331711397

Fax: +39-0331711254

1. Perform a visual check for cra cks, on both upper and lower sides of blade in the area shown in figure 1.

NOTE Paint irregularities may be due to

cracks.B.T. 109EP-30

Page 9 of 18 2. Insert in the Rotorcraft Fli ght Manual the pertinent Temporary

Revisions.

Helicopter Manual Temporary

Revisions n° A109E equipped with Pratt&Whitney PW206C engines. Rotorcraft Flight Manual Agusta A109E (A109E RFM) 2-3.

A 109E equipped with

Turbomeca Arrius TM2K1 engines. Rotorcraft Flight Manual Agusta A109E

Turbomeca Arrius TM2K1 Engine (A109E-RFM TM2K1) 2-5 and 2-6.

3. Record compliance with this PART of the Bollettino in the helicopter log

book.

PART III^:

NOTE The procedure repor ted below must be performed on each one of the two

tail rotor blades.

CAUTION If during the inspections cracks are found, remove from service the

affected blade and consider it rejected.

In this case inform: Agusta Service Engineering A109

Tel. +39-0331711281

Fax: +39-0331711397

Fax: +39-0331711254

1. Prepare the helicopter on ground for a safe maintenance, disconnect

any power source.

2. Identify inspection area, on both upper and lower sides of the blade, in accordance with figure 1.

3. Using a 5 power magnification lens , visually inspect area for cracks. Pay particular attention, on both upper and lower si des, to leading edge, along the blade in a chordwise se nse corresponding to STA 540.00.

4. Thoroughly degrease inspection area using a cloth soaked in solvent.B.T. 109EP-30

Page 10 of 18 5. Repeat inspection prescribed in above step 3.

NOTE Repeating this inspection with first the blade dirty and then the blade clean, is helpful in revealing the possible presence of cracks.

CAUTION If in doubt on the presence of cracks, accomplish the inspection with the liquid penetrant met hod as instructed

below.

6. Inspection with the liquid penetrant method:

NOTE This inspection must be performed without removing the paint, permitting the blades not to be removed from helicopter.

6.1. It is possible to outline the area us ing only tape in which the adhesive does not absorb the solvent (ref. step 2).

NOTE During all inspection phases, the inspection area shall be lighted to

2000 lux minimum.

6.2. After the complete evaporation of the solvent (ref. step 4), perform the liquid penetrant inspection as follows:

CAUTION Personnel conducting the liquid penetrant inspection must be qualified in accordance with the ASNT practice SNT-TC-1A or other equivalent practice or standard. The blade, the penetrant and ambient temperatures shall be between

15 and 45°C.

6.2.1. Apply the penetrant P6R in the area identified in figure 1 for

30 - 40 minutes dwell time.B.T. 109EP-30

Page 11 of 18 6.2.2. Remove excess penetrant firstl y with a dry clean cloth and then a cloth dampened with solvent. Avoid soaking the cloth with solvent and most of all avoid direct contact

of solvent with blade.

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

CAUTION To avoid any damage to the paint and/or problems in determining possible presence of cracks, the application of the developer must be accomplished in such a manner as to obtain a thin, even and uniform layer of developer. Under these circumstances when the developer is completely dry, the underlying paint color is clearly visible throughout.

NOTE A further application of developer, and consequently the entire inspection may not be repeated prior to an elapsed time of 24 hours.

6.2.4. After 10 minutes of developer dwell time, carefully inspect the inspection area. Pay particular attention, on both upper and lower si des, to leading edge, along the blade in a chordwise sense corresponding to STA 540.00.

6.2.5. After inspection, if no cracks are found, wait 15 minutes and clean affected area with a clean dry cloth and subsequently a cloth soaked in solvent to remove any developer residue.

7. Return the helicopter in a ready to flight condition.

8. Record compliance with this PART of the Bollettino in the helicopter log

book.

PART IV^:

1. Prepare the helicopter on ground for a safe maintenance, disconnect

any power source.

2. Remove and discard, tail rotor blades P/N 109-8132-01 -111 affected by compliance of this PART of the Bollettino, in accordance with procedures reported in the A109E Maintenance Manual.B.T. 109EP-30

Page 12 of 18 CAUTION

The blades removed from service following compliance with PART IV^ of this Bollettino must be rejected and returned to Agusta.

3. Install tail rotor blades P/N 109-8132-01-111 on the hub in accordance with the procedures reported in the A109E Maintenance Manual.

NOTE Use metric wrenches to apply torque

as follows:

•

• wrench size #17 mm. for the bolt head;

wrench size #19 mm. for the nut.

4. Perform tail rotor dynamic balance in accordance with the procedures reported in the A109E Maintenance Manual.

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

6. Record compliance with this PART of the Bollettino in the helicopter log

book.

CAUTION

The blades that have been installed in compliance with this PART of the

Bollettino shall be removed and discarded upon reaching 200 (two hundred) operating hours.

PART V^:

NOTE Compliance with this PART of the Bollettino permits:

3⁄4 cancellation of t he Vne limitations prescribed in PART I^, thus returning to the values reported in the pertinent A109E Rotorcraft Flight Manual;

3⁄4 cancellation of the limitations prescribed in PART IV^, thus returning to the retirement life reported in Chapter 04 of the

A109E Maintenance Manual.B.T. 109EP-30

Page 13 of 18 1. Prepare the helicopter on ground for safe maintenance, disconnect any

power source.

2. Remove tail rotor hub and blades assy in accordance with the procedures reported in the A109E Maintenance Manual.

3. Remove and discard the tail ro tor blades P/N 109-8132-01-111 in accordance with the procedures repor ted in the A109E Maintenance

Manual.

CAUTION

The blades removed from service following compliance with PART V^ of this Bollettino, must be rejected (irrespective of the accumulated operating hours) and returned to Agusta.

4. Remove from hub, the grip assemblies P/N 109-8131-29-101, in accordance with the procedures repor ted in the A109E Maintenance

Manual.

5. Remove and discard the grip re tainer ring P/N RR187S and gasket assemblies P/N 109-0131-27-101 from the grip.

6. Heat the grips to a temperature of 80°C. Do not exceed this temperature.

7. From each grip P/N 109-8131-29-101, remove and discard bushings P/N 109-0132-55 and spacer P/N 109-0132-13 in accordance with procedures reported in the A109E Maintenance Manual.

NOTE To remove bushings and spacer use

tool P/N 109-3130- 72-101 and a

press.

8. In addition, remove the washer P/N 109-8131-16-101 a nd put aside for

later reuse.

9. Accomplish installation of the ne w bushing P/N 109-8131-30-109 inside grip assy P/N 109-8131-29- 101 as written below:

NOTE The procedure repor ted below must be performed on each one of the two tail rotor grips.B.T. 109EP-30

Page 14 of 18 9.1. Inspect and clean the grip in a ccordance with the procedures reported

in the A109E Main tenance Manual.

9.2. Install inside the grip the previously removed washer P/N 109-8131-16-101 ensuring that chamfer ed side is inserted towards the bottom side of the grip.

9.3. Install the gasket assemblies P/N 109-0131-27-101 inside the new bushing P/N 109-8131-30-109.

9.4. Heat the grip to a temperature of 80°C. Do not exceed this temperature.

9.5. Apply on bushing external surfac e a thin and uniform layer of thinned primer (MIL-P-23377 and MIL-T-81722).

9.6. Install the new bushing P/N 109- 8131-30-109 up to grip shoulder (complete with gasket assemblies P/N 109-0131-27- 101), using the new tool P/N 109-3130-56-111 and a press.

NOTE Install the new bushing

P/N 109-8131-30-109 wh ile primer is

still wet.

9.7. Apply on the entire surface of t he retainer ring P/N RR187S a thin and uniform layer of corrosion prevent ive compound spec. MIL-C-16173 Grade 2, and install inside the grip.

CAUTION Using a red felt tip pen, apply a red

mark on the outer surface of the external strap laminates, in proximity of the strap holes. During the installati on of the grip and bushing assy, check that the red sign

is visibile to ascertain that all the strap laminates have been correctly nested and none have accidentally

been bent.

10. Install on the tail rotor hub the gr ip and bushing assy in accordance with the procedures reported in the A109E Maintenance Manual.

CAUTION The promiscuous use of grips with bushings P/N 109-0132-55 and bushing P/N 109-8131-30-109 on the same hub is prohibited.B.T. 109EP-30

Page 15 of 18 NOTE As an alternative to the operations given in steps 5. thru 9. it is possible to install a new grip and bushing assembly P/N 109-8131-02-161 for spare parts only (refer to figure 2). The grips and bushings removed from service following the installation of the new grips and bushings

P/N 109-8131-02-161 shall be returned to Agusta.

11. Install on the hub a pair of new tail rotor blades P/N 109-8132-01-111, in accordance with the procedures given in the A109E Maintenance

Manual.

CAUTION It is prohibited to install tail rotor

blades P/N 109-8132- 01-111 that

have accumulated more than 200 (two hundred) operating hours on the hub and grips assemblies

P/N 109-8131-02-127 (that installs the bushings P/N 109-0132-55).

NOTE Use metric wrenches to apply torque

as follows:

•

• wrench size #17 mm. for the bolt head;

wrench size #19 mm. for the nut.

12. Using an etch pen, modify the P/N on the identificatio n plate of the hub and grips assy with P/N 109- 8131-02-159 in lieu of P / N

109-8131-02-127.

13. Using an etch pen, modify the P/N on the identification pl ate installed on the hub and blade assy with P/ N 109-8131-02-157 in lieu of

P/N 109-8131-02-151.

14. Perform tail rotor dynamic bal ance in accordance with the A109E Maintenance Manual procedures.

15. Remove the adhesive label, the red mark on the glass of the airspeed indicators and also remove and discard the associated Temporary Revisions prescribed in PART I^ of this Bollettino.B.T. 109EP-30

Page 16 of 18 16. Return the helicopter in a ready to flight condition.

17. Insert in the A109E Maintenanc e Manual the foll owing Temporary

Revisions:

Helicopter Manual Temporary

Revisions n° A109E equipped with Pratt&Whitney PW206C engines and/or with

Turbomeca Arrius TM2K1 engines Maintenance Manual Agusta A109E (A109E-MM PW206C/TM2K1) 00-1, 64-1, 64-2,

and 64-4.

18. Record compliance with this PART of the Bollettino in the helicopter log

book.

PART VI^:

1. Inspect lining of bushing P/N 109-8131-30-109 for wear and condition

and measure internal diameter. Ensure that the value does not exceed 41,35 mm. (refer to figure 2).

CAUTION

If the resultant value is above 41,35 mm, the bushing shall be removed from service and replaced with a new bushing of the same P/N.

2. Insert in the A109E Maintenanc e Manual the foll owing Temporary

Revisions:

Helicopter Manual Temporary

Revisions n° A109E equipped with Pratt&Whitney PW206C engines and/or with

Turbomeca Arrius TM2K1 engines Maintenance Manual Agusta A109E (A109E-MM PW206C/TM2K1) 05-6, 05-7 and

64-3.

3. Record compliance with this PART of the Bollettino in the helicopter log

book.B.T. 109EP-30

Page 17 of 18B.T. 109EP-30

Page 18 of 18 Drawing not in scale



# FIGURE 2

(P/N 109-8131-02-161)