ASB 206L-09-163A Page 1 of 26 ECCN EAR99 ALERT SERVICE BULLETIN 206L-09-163 13 November 2009 Revision A, 19 April 2012

MODELS AFFECTED: 206L, 206L-1, 206L-3 and 206L-4

SUBJECT: MAIN ROTOR BLAD ES P/N 206-015-001-115 /-117, /-119 & -121 SPAR SPACER, ONE TIME INSPECTION OF.

HELICOPTERS AFFECTED: Serial num bers 45004 through 45790, 46601 through 46617, 51001 thr ough 51612 and 52001 through 52399 with the following main rotor blades installed: P/N 206-015-001-115 /-117 /-119 and -121 with serial number A-XXXX, as listed in Table 1 or Table 2 of this bulletin.

[Serial number 52400 and subsequent will have the intent of this bulletin accomplished prior to delivery.]

COMPLIANCE: PART I. Within the next 25 flight hours or 7 days, whichever comes first. Veri fy if your main rotor blade is listed in Table 1 or 2 of this bulletin.

PART II A and B. For main rotor blades listed in Table 1 or 2, at the next scheduled 100 flight hours inspection following the accomplishment of PART I of this bulletin.

PART III. Within the next 60 engi ne starts and every 60 engine starts thereafter, for the main rotor blades listed in Table 2 of this bulletin that have oversized spar spacers installed as verified per the accomplishment of PART II B of this bulletin. This check shall be accomplished on blades that have accumulated more than 12 00 flight hours and until the main rotor blade is removed from service or as instructed in PART IV of this bulletin.ASB 206L-09-163A Page 2 of 26 ECCN EAR99 PART IV. As an option to the Ow ners/Operators that have to accomplish PART III of this bulletin.

After review of the spar radiographs by Bell Helicopter, a letter will be provided to the Owners/Operators indicating that the main rotor blade can remain in serv ice with no further action required (terminating action with regards to PART III of this bulletin) or, that the blade can remain in service provided that PART III of this bulletin is accomplished until the main rotor blade reaches retirement life.

DESCRIPTION:

Bell Helicopter recently discovered that some P/N 206-015-001-115 , /-117, /-119 and -121 main rotor blades have been manufactured with a spar spacer (aft spar closure) that was approximately 0.030 inch oversized. Upon analysis of this condition, Bell Helicopter is reducing the retirement life from 3600 to 2300 flight hours for the affected main rotor blades.

The investigation has also es tablished that a fatigue crack could occur if there was a combination of both oversized spar spacer and a larger than acceptable void in the adhesive applied between the blade's internal lead inertia weight and the spar, between blade stations 100 and 145. If such a condition exists, a fatigue crack may be induced by the centrifugal force variation that occurs during t he helicopter start/stop cycles.

Main rotor blades listed in Table 2 ma y have the described co mbination of both oversized spar spacers and a larger than acceptable adhesive void between the internal lead inertia weight and the blade s par. To be considered at risk of developing a crack, both conditions have to be met. Once the presence of an oversized spacer has been confirmed, an x-ray inspection of t he spar can identify if an unacceptable void exists between the inertia weight and the spar. If, after accomplishment of PART IV of this bulletin, it is confirmed that no void exceeding the li mitation is found, the blade is no longer considered at risk and no further accomplishment of PART III will be required.

Revision A of this bu lletin indicates June 30 th 2012 as being the termi nating date for all warranty considerations. Consequently, o perators are not obliged to purchase a replacement blade or reach 2300hrs on re-id entified blades to re ceive their 37% credit reimbursement.

PART I of this bulletin has you ve rify if your main rotor blade is listed in Table 1 or Table 2 of this bulletin. For main rotor blades in spares stock, accomplish this verification upon receipt of this bulletin.ASB 206L-09-163A Page 3 of 26 ECCN EAR99 PART II A of this bulletin provides you with in structions on how to measure the main rotor blades spar spacer. Blades with oversiz ed spar spacers have to be re-identified and their retirement life reduced to 2300 flight hours. It is applicable to the main rotor blades listed in Table 1 of th is bulletin. These main roto r blades have had PART IV of this bulletin accomplished prior to delivery.

PART II B of this bulletin provides you with in structions on how to measure the main rotor blades spar spacer. Blades with oversiz ed spar spacers have to be re-identified and their retirement life reduced to 2300 flight hours. In addition, for main rotor blades with more than 1200 flight hours, a main roto r blade spar wipe check is required every 60 engine starts. It is applicable to the main rotor blades listed in Table 2 of this bulletin. These main rotor blades “DID NOT” have PART IV of this bulletin accomplished prior to delivery.

Applicability of PART II A or B of this bulle tin to any spare part shall be accomplished upon completion of PART I of this bulletin.

-NOTEPART III affects only the blades listed in Table 2 with the oversized spar spacer as c onfirmed by PART II B of this bulletin.

PART III of this bulletin introduces a recurri ng main rotor blade spar wipe check at every 60 engine starts for the main rotor blades that have oversized spar spacers installed as confirmed per the accomplishment of PART II B of this bulletin. This check is to be performed on main rotor blades that have accumulated more than 1200 flight hours.

Applicability of PART III of this bulletin is for blades in service only.

-NOTEPART IV is offered as an alternate option to the Owners/Operators with main ro tor blades that are affected by the accomplishment of PART III of this bulletin.

PART IV of this bulletin provides instructi ons on how to perform a one-time x-ray inspection. A radiographic pict ure of the main rotor blade spar is taken and then sent to Bell Helicopter for review. After review, depending on the results, Bell Helicopter will issue a letter that contains one of the following statements:

a. The blade can remain in service wit h no further action required (terminating action with regards to the PART III of this bulletin). ORASB 206L-09-163A Page 4 of 26 ECCN EAR99 b. The blade can remain in service but PART III of this bulletin requires accomplishment until retired from service

. The radiograph must be taken by a Non-Dest ructive-Inspection (NDI) facility that has experience with accomplishing x-rays for the aerospace industry. The NDI facility shall also be capable of performing the work descr ibed in PART IV of the Accomplishment Instruction of this Alert Service Bulletin. Owners/Operators can contact their local Bell Helicopter Customer Service Facility (CSF), or refer to the Bell Helicopter Customer Support and Service Directory to locate the cl osest facility with x -ray capability in the CSF network, or a Bell Helicopter approv ed main rotor blade repair facility.

In addition, a list of faciliti es with x-ray capabilities can be found in Table 5 of this bulletin. This list is not inclusive and is provided as a reference. The x-ray can be taken with either the blade installed or removed from the helicopter.

Applicability of PART IV of this bulletin to any spare part is optional and shall be determined prior to its instal lation on an affected aircraft.

APPROVAL:

The engineering design aspects of this bulletin are Transport Canada Civil Aviation (TCCA) approved.

CONTACT INFO:

For any questions regarding this bulletin, please contact:

Bell Helicopter Product Support E ngineering - Light Helicopters Tel: 450-437-2862 / 1-800-363-8023 / pse light@bellhelicopter.textron.com

MANPOWER:

Approximately 0.5 man-hour is required to complete PART I of this bulletin. Approximately 2.5 man-hours are required to complete PART II A or B of this bulletin. Approximately 1.0 man-hour is required to complete PART III of this bulletin. Approximately 10 man-hours are r equired to complete PART IV of this bulletin. This estimate is based on hands-on time, and may vary with personnel and facilities available.

WARRANTY:

Owners / Operators of Bell Helicopters who comp ly with the instructions in this bulletin and find a cracked blade per PART III 5. and/or 6.b. will be eligible to receive a prorated credit for the replacement main ro tor blade P/N 206-015-00 1-115/-117/-119/-121 outlined under the Requir ed Material section.ASB 206L-09-163A Page 5 of 26 ECCN EAR99 In addition, Bell Helicopter will allow a cred it reimbursement for x-rays described in PART IV of this bulletin together with freigh t costs up to a maximum of $1,000.00 per blade. To receive this credit you will be requ ired to provide copies of the invoices for both the x-ray and freight cost s to the warranty department.

For blades that are identified to have a spar spacer that is larger than the dimensions described in PART II A & B of this bulletin, you will be able to receive a 37% credit for the unused 1,300 hours as a result of the r eduction in life of the blade. Purchasing a replacement blade from a BHT supply source is not necessary to receive the credit.

To receive either of the credits listed above:

 Only those serial numbered blades that are listed in Table 2 of this bulletin are eligible for the x -ray and freight credit.

 Comply with the instructions contai ned in the Compliance section of this bulletin.

 Submit an MMIR to the Be ll Warranty Department re ferencing this bulletin for the replacement part/x-ray & freight cost or for obtaining the 37% credit relative to the unused portion of 1,300hours.

NOTE: Warranty compensations as stated abov e are no longer applicable after June 30 th 2012. No other labor cost will be covered under this bulletin.

MATERIAL:

Required Material: The following material is required for the accomplishment of this bulletin and may be obtained through your Bell Helico pter Textron Supply Center.

Part Number Nomenclature Quantity Note

206-015-001-115 Main Rotor Blade (Standard white) A/R 1

206-015-001-117 Main Rotor Blade (High visibility, black & white) A/R 1

206-015-001-119 Main Rotor Blade (High visibility, orange & white) A/R 1

206-015-001-121 Main Rotor Blade (All black) A/R 1

NOTE:

1. Required only if a main roto r blade spar is found cracked.ASB 206L-09-163A Page 6 of 26 ECCN EAR99 Consumable Material: The following material is required to acco mplish this bulletin, but may not require ordering, depending on the operator ’s consumable material stock levels. This material may be obtained through your Bell He licopter Textron Supply Center.

For PART II A and B of this bulletin

Part Number Nomenclature Notes Quantity Reference 320 GRIT CLOTH 9X11 Abrasive Cloth, 320 grit 1 As required C-406 240 GRIT CLOTH 9X11 Abrasive Cloth, 240 grit 1 As required C-406 TT-N-95,TYII Aliphatic Napht ha 2 As required C-305 MIL-P-85582, TY1, CL2 Prim er As required C-246 MIL-PRF85285 Paint 3 As required C-245 299-947-072 Fairing Compound 4 As required C-323

* C-XXX numbers refer to the co nsumables list in BHT-ALL-SPM Standard Practices Manual

NOTES:

1. Or equivalent Aluminum Oxide cloth 2. As an alternate use Methyl Ethy l Ketone ( C-309 ) or Acetone ( C-316 ) 3. Color code per FED-STD-595 as follows: a. Semi gloss white #27925 b. Lusterless black #37038 c. Gloss orange #12197 d. Tip, orange yellow #33538 4. Hysol EA 960

For PART III of this Alert Service Bulletin

Part Number Nomenclature Notes Quantity Reference

MILC87936TYI 5GAL Detergent 1 As required C-318 31-080AD002026 Decal 2 2 per blade N/A 3950 SCOTCHCAL Decal Sealer 3 As required C-349 TT-I735 ISOPROPYL Isopropyl Al cohol As required C-385 N/A Blue Food Coloring 4 As required N/A

* C-XXX numbers refer to the co nsumables list in BHT-ALL-SPM Standard Practices Manual

NOTES:

1. Or equivalent aviation approved detergent. 2. As an alternate, 0.25 inch X 2.50 inches red stripes can be painted. Color code #11136, FED-STD-595. 3. Or equivalent sealer. 4. Locally procured.ASB 206L-09-163A Page 7 of 26 ECCN EAR99 SPECIAL TOOLS:

None required.

WEIGHT AND BALANCE:

Not affected

ELECTRICAL LOAD DATA:

Not affected.

REFERENCES:

BHT-206L-MM-1 Chapter 65-00-00 BHT-206L1-MM-1 Chapter 65-00-00 BHT-206L3-MM-6 Chapter 62-00-00 BHT-206L4-MM-6 Chapter 62-00-00 Customer Support and Service Directory

PUBLICATIONS AFFECTED:

BHT-206L-MM-1 Chapter 05- 00-00 and Chapter 65-00-00 BHT-206L1-MM-1 Chapter 05 -00-00 and Chapter 65-00-00 BHT-206L3-MM-1 Chapter 05-00-00 BHT-206L3-MM-6 Chapter 62-00-00 BHT-206L4-MM-1 Chapter 05-00-00 BHT-206L4-MM-6 Chapter 62-00-00

ACCOMPLISHMENT INSTRUCTIONS:

PART I. Verify if Your Main Rotor Blade is Affected

1. Verify if your main rotor blade did or did not have PART IV of this bulletin accomplished prior to delivery as follows:

a. Check if your main rotor blade S/N is listed in Table 1 and 2 of this bulletin.ASB 206L-09-163A Page 8 of 26 ECCN EAR99 Table 1. List of Main Roto r Blades Serial Number (S/N) That Had PART IV of This Bulletin Accomplished Prior to Delivery

A-6710 A-6781 to A-6795 A-6877 A-6713 A-6797 to A-6802 A-6883 to A-6885 A-6717 & A-6718 A-6804 A-6887 A-6722 to A-6725 A-6806 A-6889 to A-6895 A-6736 & A-6737 A-6808 to A-6818 A-6897 to A-6902 A-6740 to A-6744 A-6821 to A-6826 A-6906 to A-6910 A-6747 & A-6748 A-6828 to A-6833 A-6912 & A-6913 A-6750 to A-6758 A-6836 A-6916 A-6760 to A-6769 A-6840 to A-6843 A-6919 to A-6921 A-6771 to A-6775 A-6845 & A-6846 A-6923 & A-6924 A-6777 A-6848 to A- 6856 A-6927 & A-6928 A-6779 A-6860 to A-6874 A-6958

Table 2. List of Main Rotor Blades S/ N That “DID NOT” Have PART IV of This Bulletin Accomplished Prior to Delivery

A-6027 A-6598 to A-6609 A-6693 to A-6698 A-6208 A-6613 & A-6614 A-6704 to A-6706 A-6547 A-6616 to A- 6626 A-6708 & A-6709 A-6549 & A-6550 A-6628 to A-6660 A-6711 & A-6712 A-6555 A-6663 to A-6665 A-6715 A-6560 to A-6563 A-6667 to A-6682 A-6726 to A-6728 A-6565 A-6684 to A- 6687 A-6734 & A-6735 A-6567 to A-6596 A- 6689 & A-6690 A-6738

b. If your main rotor blade S/ N is listed in Table 1, proc eed with PART II A of this bulletin within the next scheduled 100 flight hour inspection.

c. If your main rotor blade S/N is list ed in the Table 2, a ccomplish PART II B of this bulletin within the next sched uled 100 flight hour inspection.

2. If your main rotor blade S/N is not listed in either Table 1 or Table 2, no further action is required. Make required record en try indicating the finding to show that PART I of this bulletin is accomplished.

PART II A. Main Rotor Blade Spar Spacer Measurement

For main rotor blades that had PART IV of this bulletin accomplished prior to main rotor blade delivery as listed in Table 1.ASB 206L-09-163A Page 9 of 26 ECCN EAR99-NOTEAt the next scheduled 100 flight hour inspec tion following the accomplishment of PART I of this bulletin.

1. Remove the tip weight support assembly (2) from the main ro tor blade as follows: (Refer to Figure 1).

a. Remove the four screws (1) holding t he tip weight support assembly (2).

b. Use a soft scraper and remove the filler around the tip weight support assembly (2).

CAUTION

When removing the tip weight support assembly (2) from the main rotor blade (5), be careful as washer (3) may have been installed between the main rotor blade spar (4) and the tip weight support assembly (2). Make sure you record the location of these washers (3) if installed. They are used to maintain the tip weight support assembly (2) contour alignment with the main rotor blade spar (4).

c. Remove the tip weight support assembly (2) and record the location of the washer (3) if installed.

2. Proceed with the measuring of the spar spacer (6) as follows:

a. Use abrasive cloth grit 320 grit ( C-406 ) or finer and sand just enough paint or primer to permit identification of the bond line between t he main rotor blade spar (4) and spar spacer (6).

b. Use a caliper and measure the main roto r blade spar spacer (6) tang width as shown on Figure 1.

c. Record your dimension.

3. Proceed with the installati on of the tip weight support assembly on the main rotor blade as follows:

a. Use a soft scraper and abrasive clot h 240 grit ( C-406 ) and remove the remaining filler.ASB 206L-09-163A Page 10 of 26 ECCN EAR99 b. Clean the sanded area around the main ro tor blade spar (4) and spar spacer (6) with Aliphatic Naphtha ( C-305 ) and touc h-up the primer ( C-246 ) and paint ( C245 ) to make sure there is no bare metal exposed.
c. Clean the mating faces on the main rotor blade (5) a nd the tip weight support assembly (2) with Aliphatic Naphtha ( C-305 ) . To maintain the tip weight support assembly (2) to main rotor blade contour, pos ition the washers (3) if installed, in the location previously reco rded and slip the tip weig ht support assembly (2) in the main rotor blade (5) recess.

d. Install and torque the four screw s (1) to 40 inch-pounds. (4.5 Nm)

CAUTION

Make sure you do not block t he main rotor blade drain hole during the fill and fair process.

e. Clean the main rotor blade (5) and ti p weight support assembly (2) surrounding area mating line with Aliphatic Naphtha ( C -305 ) and fill and fair the area using fairing compound ( C-323 ). Use just enough fairing compound ( C-323 ) to maintain the main ro tor blade (5) contour.

f. Touch-up the area with Pr imer ( C-246 ) and paint ( C -245 ) as required making sure there is no bare metal exposed.

-NOTEOversized spar spacer (6) is approximately 0.030 inch (0.762 mm) larger than the ma ximum dimension limit of 1.018 inch (25.86 mm)

4. For main rotor blade with spar spacers (6) that are “WITHIN” spar spacer width. This maximum dimension shall not exce ed 1.018 inch (25.86 mm), proceed as follows:

a. Make required helicopter record entry i ndicating the finding and that PART II A of this bulletin is accomplished. No further action is required.

5. For blades with main rotor bl ade spar spacers (6) that are “ LARGER ” than the maximum dimension of 1.018 inch (25.86 mm), proceed as follows:

a. Use a vibrating tool and strike through t he last three digits of the main rotor blade part number on the data plate. Re-identify main rotor blade data plate in accordance with the information provided in Table 3. The depth of the vibroetch must not exceed 0.005 inch (0.127 mm).ASB 206L-09-163A Page 11 of 26 ECCN EAR99 Table 3. Main Rotor Blade Re -Identification Information

EXISTING PART NUMBER NEW PART NUMBER 206-015-001-115 206-015-001-125 206-015-001-117 206-015-001-127 206-015-001-119 206-015-001-129 206-015-001-121 206-015-001-131

b. Make required record entry indicating that this specific main rotor blade retirement life is reduced from 3600 to 2300 flight hours.

c. Make required helicopter record entry indicating that the PART II A of this bulletin is accomplished. No further action required.

PART II B. Main Rotor Blade Spar Spacer Measurement

For main rotor blades that did not have PART IV of this bulletin accomplished prior to main rotor blade delivery as listed in Table 2.

-NOTEAt the next scheduled 100 flight hour inspec tion following the accomplishment of PART I of this bulletin.

1. Remove the tip weight support assembly (2) from the main rotor blade (5) as follows: (Refer to Figure 1).

a. Remove the four screws (1) holding t he tip weight support assembly (2).

b. Use a soft scraper and remove the filler around the tip weight support assembly (2).

CAUTION

When removing the tip weight support assembly (2) from the main rotor blade (5), be careful as washer (3) may have been installed between the main rotor blade spar (4) and the tip weight support assembly (2). Make sure you record the location of these washers (3) if installed. They are used to maintain the tip weight support assembly (2) contour alignment with the main rotor blade spar (4).

c. Remove the tip weight support assembly (2) and record the location of the washer (3) if installed.ASB 206L-09-163A Page 12 of 26 ECCN EAR99 2. Proceed with the measuring of the spar spacer (6) as follows:

a. Use abrasive cloth grit 320 grit ( C-406 ) or finer and sand just enough paint or primer to permit identification of the bond line between t he main rotor blade spar (4) and spar spacer (6).

b. Use a caliper and measure the main rotor blade spar spacer (6) width as shown on Figure 1.

c. Record your dimension.

3. Proceed with the installati on of the tip weight support assembly (2) on the main rotor blade (5) as follows:

a. Use a soft scraper and abrasive cloth 240 gr it ( C-406 ) to remove the remaining filler.

b. Clean the sanded area around the main ro tor blade spar (4) and spar spacer (6) with Aliphatic Naphtha ( C-305 ) and touc h-up the primer ( C-246 ) and paint ( C245 ) to make sure there is no bare metal exposed.
c. Clean the mating faces on the main rotor bl ade (5) and the tip weight support assembly (2) with Aliphatic Naphtha ( C-305 ) . To maintain the tip weight support assembly (2) to main rotor blade spar (4) contour, position the washers (3) if installed, in the location previously recorded and slip the tip weight support assembly(2) in the main rotor blade (5) recess.

d. Install and torque the four screw s (1) to 40 inch-pounds. (4.5 Nm)

CAUTION

Make sure you do not block t he main rotor blade drain hole during the fill and fair process.

e. Clean the main rotor blade (5) and ti p weight support assembly (2) surrounding area mating line with Aliphatic Naphtha ( C -305 ) and fill and fair the area using fairing compound ( C-323 ). Use just enough fairing comp ound ( C-323 ) to maintain the main ro tor blade (5) contour.

f. Touch-up the area with Pr imer ( C-246 ) and paint ( C -245 ) as required making sure there is no bare metal exposed.ASB 206L-09-163A Page 13 of 26 ECCN EAR99-NOTEOversized spar spacer (6) is approximately 0.030 inch (0.762 mm) larger than the ma ximum dimension limit of 1.018 inch (25.86 mm)

4. For main rotor blade (5) with spar spacers (6) that are “ WITHIN ” spar spacer width. This maximum dimension shall not exce ed 1.018 inch (25.86 mm), proceed as follows:

a. Make required helicopter record entry i ndicating the finding and that PART II B of this bulletin is accomplished. No further action is required.

5. For blades with main rotor bl ade spar spacers (6) that are “ LARGER ” than the maximum dimension of 1.018 inch (25.86 mm), proceed as follows:

a. Use a vibrating tool and strike through t he last three digits of the main rotor blade part number on the data plate. Re-id entify main rotor blade data plate in accordance with the information provided in Table 4. The depth of the vibroetch must not exceed 0.005 inch (0.127 mm).

Table 4. Main Rotor Blade Re -Identification Information

EXISTING PART NUMBER NEW PART NUMBER 206-015-001-115 206-015-001-125 206-015-001-117 206-015-001-127 206-015-001-119 206-015-001-129 206-015-001-121 206-015-001-131

b. Make required record entry indicating that this specific main rotor blade retirement life is reduced from 3600 to 2300 flight hours.

c. If the main rotor blade has presently accumulated more t han 1200 flight hours or when the main rotor blade reaches 1200 flight hours, a ccomplish PART III of this bulletin within the next 60 engine starts and every 60 engine starts thereafter. PART IV of this bulletin offers an alternate option to the Owners/Operators that have to accomplish this check.

d. Make required helicopter record entry indicating that the PART II B of this bulletin is accomplished.ASB 206L-09-163A Page 14 of 26 ECCN EAR99-NOTEPART III and PART IV of this bulletin can be accomplished with the blade instal led on the helicopter.

PART III. Recurring Wipe Check Procedure.

-NOTE-

"Your National Airworthiness Authority (NAA) should be contacted to determine who can accomplish this main rotor blade wipe check, as it may be acceptable to be accomplished by a trained pi lot or by trained maintenance personnel depending on the regulat ory requirements of your NAA."

1. Accomplish this recurring wipe check pr ocedure every 60 engine starts as required per PART II B of this bulletin. This c heck shall be accomplished on blades that have accumulated more than 1200 flight hours until the main rotor blade is removed from service. PART IV of this bul letin offers a possible alternate option to the Owners/Operators t hat have to accomplish this check.

2. In order to provide a quick visual refer ence, apply a “red stripe” decal (or paint if preferred) on both sides of the main rotor blade at the location indicated on Figure 2. To prolong the life of the decal, app ly Edge sealer ( C-349 ) on the decal. Replace missing or damaged decal or re-apply paint as required.

-NOTEThe marking of the spar at station 100 and 145 is required for accomplishment of PART III of this bulletin. For accomplishment of PART IV, the x-ray must be taken between stations 90 and 145 to ensure the complete section between stations 100 and 145 is captured.

3. Mark the top surface of affected main rotor blade to id entify station 100 and 145 as follows:

a. The center of the blade bolt is blade station 18.5 (b lade station zero being at the center of the mast). Us e a permanent ink marker and make marks at blade stations 100 and 145. (Refer to Figure 2.)

4. Proceed with the spar wipe check as follows:ASB 206L-09-163A Page 15 of 26 ECCN EAR99 a. Gain access to main rotor blades upper surface.

b. Using detergent ( C-318 ), thoroughly cle an the main rotor blade upper surface between blade stations 100 to 145. A llow enough time for the blade upper surface to dry.

c. Prepare blue food coloring solution that will be used to perform the check by thoroughly mixing the followin g in a clean container:

 100 ml Isopropyl alcohol 99% ( C-385 )

 100 ml clean tap water or distilled water

 20 drops of blue food coloring

d. Apply the blue food coloring soluti on in the area to be checked using cheesecloth ( C-486 ) saturated with the solution or apply with a spray bottle.

e. After 10 to 20 seconds, wipe off the solu tion with cheesecloth ( C-486 ) in a span wise direction.
f. Carefully check affected area for evidenc e of a crack. If a crack is present, the blue food coloring solution will remain in the crack as the excess of solution is wiped off and/or the cheesecloth will catch on the rough edges of the crack.

5. If a crack is found, remove the main ro tor blade from service before further flight and contact Bell Helicopter Product Support Engineering.

-NOTEThe following inspection must be accomplished by a mechanic.

6. If the blue food coloring solution wipe chec k as specified in step 4 above reveals a surface defect and the presence of a crack cannot be confirmed, perform the following inspection:

a. With a 10X power magnifying glass examine the affected area for a crack.

b. If a crack is found, remove the blade from service before further flight and contact Bell Helicopter Product Support Engineering.

c. If no crack is found, repair the defec t in accordance with the Component Repair & Overhaul manual.

7. If no crack is found, make an entry in the helicopter technical records to show that PART III of this bulletin has been accomp lished and indicate the findings. RepeatASB 206L-09-163A Page 16 of 26 ECCN EAR99 this check every 60 engine starts or as an option accomplish PART IV of this bulletin.

Part IV. Main Rotor Blade Sp ar Radiography. (optional)

Selection of an NDI facility

1. The radiograph must be taken by a Non- Destructive-Inspection (NDI) facility that has experience with acco mplishing x-rays for the aer ospace industry. The NDI facility shall also be capable of performing the work described in PART IV of the Accomplishment Instruction of this bulle tin. Owners/Operators can contact their local Bell Helicopter Customer Service Facility (CSF), or refer to the Bell Helicopter Customer Support and Service Directory to locate the closest facility with x-ray capability in the CSF network, or a Bell He licopter approved main rotor blade repair facility.

In addition, a list of facilities with x-ray c apabilities can be found in Table 5 of this bulletin. This list is not inclusive and is provided as a reference. The x-ray can be taken with either the blade installed or removed from the helicopter.

-NOTEUntil the radiographs are review ed by Bell Helicopter and the disposition letter is received, affected blades can remain in service by complying with PAR T III of this bulletin.

2. Advise the selected NDI Facility to contact Bell Helicopter Product Support Engineering (PSE) via e-mail at pselight @bellhelicopter.textron.com for shipping details of the radiographs. Bell Helicopte r will perform the analysis and provide the main rotor blade disposition to both Owner and the NDI Facility.

3. It is acceptable to have the radiographs taken with either the blade removed or installed on the helicopter. If the chosen NDI facility does not have the capability of performing PART IV with the bl ade installed on the helicopter, remove the blade using the applicable maintena nce manual instructions and ship in a suitable container.

4. Provide a copy of this bulletin to your NDI Facility for accomplishment of PART IV of this bulletin.ASB 206L-09-163A Page 17 of 26 ECCN EAR99 Radiography Procedure

-NOTEThe following inspection procedu re should only be used as a general guideline. The actual technique/procedure used shall be generated by the NDI Facility using technique parameters compatible with the equipment and processing chemistry utilized. Radiographs must be performed by individuals certified to a mini mum of Level II in radiography per NAS410, CGSB- 48.9712 (aerospace structures), or equivalent.

1. Thoroughly clean blade with detergent ( C-318 ).

2. The radiograph of the spar is required between stations 90 and 145. Make sure the location is marked in accordance with PART III.

3. Perform the blade spar radiograph as follows:

General Guidelines

Equipment

 Fixed or portable x-ray generating syst em capable of producing x-rays of at least 75 kV and 5 mA energy and shall have a beryllium window. A focal spot no larger than 2.5 mm diameter is preferr ed for better results. Isotopes shall not be used.

 Either an automatic proc essor or hand development tank is an acceptable means of processing r adiographs. Hand development shall be accomplished per the manufacturer’s instructions for type of film and chemicals used.

 Film must be class I or II.

Personnel

 Radiographs must be perfo rmed by individuals certified to a minimum of Level II in radiography per NAS410, CGBS-48. 9712 (aerospace structures), or equivalent.

Pre-Inspection

 Ensure cassettes and/ or rollpac films are in good condition and clear of any contaminants which may cause film artifacts.

 Prior to film processing, solution concentration and radi ographic exposure repeatability should be checked at leas t once each week using a step wedge or equivalent.ASB 206L-09-163A Page 18 of 26 ECCN EAR99  The part shall be clean and free of loose debris.

Inspection

1. Blade removed from helicopter (R efer to applicable Maintenance Manual ).

a. Secure the blade to a stable platform such as sawhorses or blade dollies.

-NOTEThe marking of the spar at station 100 and 145 is required for accomplishment of PART III of this bulletin. For accomplishment of PART IV, t he radiography must be taken between stations 90 and 145 to ensure the complete section between stations 100 and 145 is captured.

b. The blade shall be x-rayed at the bondli ne in the radius of the mid-span weight, (refer to Figures 3 and 4, from station 90 to station 145, (Refer to Figure 2).

c. Blade stations can be lo cated by placing a measuring tape at the center of the blade bolt hole. The center of the blade bo lt is blade station 18.5 (blade station zero being at the center of the mast). The blade should have marks at stations 100 and 145 previously made in PART III. (Refer to Figure 2).

d. Lead markers shall be placed on the bl ade to provide evidence of complete coverage and sufficient overlap. The film shall also contain lead numbers indicating blade P/N, S/N and station locations 90 and 145 as a minimum.

e. Align the x-ray beam perpendicular to t he blade lower surfac e and center the beam 0.8 inch from the leading e dge, (Refer to Figures 3 and 4).

f. Process the films and return them to Bell Helicopter for review.

2. Blade install ed on helicopter.

a. Rotate the blades perpendicular to the tailboom. (Refer to Figure 3).

b. Stabilize the main rotor blades to prevent movement and film distortion.

c. Due to the static droop and pitch angle of the blades, care must be taken to ensure the center of the x-ray beam stays perpendicular to the bond line, (Refer to Figure 3).

d. Inspect affected blade per above step 1.b. to 1.f.ASB 206L-09-163A Page 19 of 26 ECCN EAR99 Recommended Technique

KV** 75 Ma 4.5 Time 2.0 Min SFD Min 36” Density Range* 1.5 to 3.5 Film Agfa D4

* Density should be meas ured on the leading edge adjac ent to the bond line. * Energy settings, film, and time ar e to be used as a reference only. **. Actual exposure technique should be based on energy levels capable of exposing 0.8 inch – 0.9 inch of alum inum to a density of 2.0.

3. Prepare the radiographs for shipping an d include blade part and serial numbers with the total time in service.

4. Contact Bell Helicopter Product Suppo rt Engineering (PSE) via e-mail at pselight@bellhelicopter.text ron.com for radiograph shi pping instructions. When contacting PSE, clearly specify that the radiographs are being sent for accomplishment of ASB 206L-09-163A and ma ke sure to provide the following detailed information for both the NDI Facility and blade owner in order for Bell Helicopter to provide inspection results in a timely manner:

 Company name

 Contact name

 Phone number

 E-mail address

5. Bell Helicopter will analyze the content of the radiographs and provide a letter indicating one of the following:

a. The blade can remain in service wit h no further action required (terminating action with regards to the PART III of this bulletin). OR

b. The blade can remain in service but PART III of this bulletin requires accomplishment until retirement from service.

6. Make an entry in the helicopter technical records to show that the PART IV of this bulletin has been accomplished indicating the blade disposition based on the letter received by Bell Helicopter.ASB 206L-09-163A Page 20 of 26 ECCN EAR99 TABLE 5. List of NDI Facilities

Aviation NDT Services, PTY Ltd. Store 7, Gate 24 Operations Road Melbourne Airport Victoria, Australia 3045 Phone: 61-3-9395-0632 Australia Central Flying Service Inc. 12 th and Calhoun Little Rock, AR 72202 USA Phone: 1-800-844-6257 USA

Qantas Airways, Nondestructive Tests Section M96/1 Mascot Maintenance Base Sydney, New South Wales Australia 2020 Phone: 612-9691-7402 Australia CTC (Certified Testing & Consulting Services), LLC 3144 Venture Drive, Suite #100 Lincoln, CA 95648 USA Phone: 1-916-434-0195 USA

Sabena Technics Nondestructive Inspection Dept. Brussels National Airport, Hanger #8, Door #5 Zaventem, Brussels, Belgium B1930 Phone: 3212-53-55 Belgium Certified Inspection Services, LLC 3755 Industrial Court, NW, Suite #16 Suwanee, GA 30024 USA Phone: 1-678-730-2000 USA

CAL – Compoende Aeronautica Ltda Av. Dos Ipes, 391 Flor do Vale, Tremembe-Sao Paulo 12120-000 Brazil Phone: 55-12-3672-1911 Brazil E & I Aircraft 5525 N. W. 23 rd Avenue Ft Lauderdale Executive Airport Hangar #17 Fort Lauderdale, FL 33309 USA Phone: 1-954-771-9194 USA

Cantech Aviation Inspections Ltd 120-13451 Vulcan Way Richmond, British Columbia V6V 1K4 Canada Phone: 1-604-244-9699 Canada EPPS Aviation Inc. 1 Aviation Way Atlanta, GA 30341 USA Phone: 1-770-458-9851 USA

Execaire, a Division of I.M.P. Group Limited, 2450 Derry Road East, HGR7 Mississauga, Ontario Canada L5S 1B2 Phone: 1-905-677-2484 Canada ETI Ewer Testing & Inspection Inc. 1131 South 22 nd Street Bismarck, ND 58504 USA Phone: 1-701-223-6434 USA

Execaire, a Division of I.M.P. Group Limited, 10225 Ryan Avenue, Dorval, Quebec H9P 1A2 Canada Phone : 1-514-636-7070 Canada Flight Craft 7505 N.E. Airport Way Portland Oregon 97218 USA Phone: 1-503-331-4219 USA

Perimeter Aviation 626 Ferry Road Winnipeg, Manitoba Canada R3H 0T7 Canada Flight Options LLC 26180 Curtis Wright Parkway Richmond Heights, OH 44143 USA Phone: 1-216-797-8473 USA

RTD Quality Services Inc. 2280 Pegasus Way N.E. #8 Calgary, Alberta T2E 8M5 Canada Phone: 1-403-274-8214 Canada General Dynamics Aviation Services W6365 Discovery Drive Appleton, WI 54915 USA Phone: 1-920-735-7028 USA

Hainan Airlines Co. Ltd./FIC-CAAC NDT Office 16# No. 1Street Fugian, Beijing, China 100621 Phone: 8-610-645-85945 China General Dynamics Aviation Services 5616 Haven Street Las Vegas, NV 89119 USA Phone: 1-702-947-3030 USAASB 206L-09-163A Page 21 of 26 ECCN EAR99 Aerospace NDT Ltd. Suite A, Bldg #6, Fourth Ave. Doncaster, South Yorkshire England DN9 3GE Phone: 44-1302-770771 England General Dynamics Aviation Services 6925 34 th Ave. south Minneapolis, MN 55450 USA Phone: 1-612-638-2053 USA

Morgan-Ward (NDT) ltd. Dale Road New Mills, High Peak, Derbyshire England Sk22 4NW Phone: 44 (0) 1663-74-7061 England General Electric Inspection Services 1211 Kona Drive Rancho Dominguez, CA 90220 USA Phone: 1-310-635-2700 USA

GIE – NDT Expert Sciences Parc du Perget 31770 Colomiers, France Phone : 33-53436-1200 France General Electric Inspection Services 5425 Business Parkway Theodore, AL 36582 USA Phone: 1-251-653-6060 USA

Aircraft Services Lemwerder (ASL) Flughafenstrabe 5 Lemwerder, 27809 Germany Phone: 49-421-672-2279 Germany JETS Inc. 1325 Whitlock Lane Carrollton, TX 75006 USA Phone: 1-972-323-6808 USA

RUAG Aerospace Services GmbH Flugplatz Oberpfaffenhofen Geb. 379 P.O. Box 1253 Wessling, Bayern D-82234 Germany Phone: 49-815-330-2897 Germany Metal Finishing Company 1329 South McLean Blvd Wichita, KS 67213 USA Phone: 1-316-267-7289 USA

Airworks India Engineering Pvt. Ltd Gate 8, Mumbai Old Airport Kalina, Santa Cruz (E) Mumbai, Maharashrta, India 400029 Phone : 91-22-2615-7213 India MidCoast Aviation, Inc. 6400 Curtis-Steinberg Drive Cahokia, IL 62206 USA Phone: 1-618-337-2100/Ext. 6351 USA

Air Four S.p.A. Viale Dell Aviazione 65 Milano, Italy 20138 Phone: 00-39-02-50673-404 Italy NDE Services Inc. 15552 E. Fremont Drive, Unit A106 Centennial, CO USA 80112 Phone: 1-303-741-0518 USA

CND Services (Controlli Non Distruttivi) SRL Via A. Flores, 17 Localita Monna Felicita (Zona Industriale Civitavecchia (RM) Italy 00053 Phone : 0039-766-580521 Italy NDT Inspect-Air Inc. 4557 96 th Street Franksville, WI USA 53126 Phone: 1-262-878-8700 USA

Nippi Corporation/Japan Aerospace Aircraft NDT Department 2-28 Soyagi, Yamamoto, Kanagawa, 242- 0026 Japan Phone: 046-265-2082 Japan Paragon Services, Inc. 1015 South West Street Whichita, KS 67213-1627 USA Phone: 1-316-945-5285 USA

Korean Air 1370 Gonghang-Dong Gangseo-Gu, Seoul, 157-712, Korea Phone: 82-2-660-7486 or 82-2-656- 7480 Korea Power Aviation Inc. 1255 Laquinta Drive Suite 112 Orlando, FL 32809 USA Phone : 1-407-438-1395 USAASB 206L-09-163A Page 22 of 26 ECCN EAR99 Unit Inspection Aviation S.A. Hanger Z3 Lanseria International Airport Lanseria South Africa 1748 South Africa Phone: 11-27-701-3058 South Africa Q.C. Laboratories Inc. 2870 Stirling Road Hollywood, FL 33020 USA Phone: 1-954-925-0499 USA

FORCE Technology Sweden AB August Barks Gata 23B Vastra Frolunda, Goetborg, Sweden 42132 Phone: 046-031-490210 Sweden Quality Testing Services, Inc. 2305 Millpark Drive Maryland Heights, MO 63043 USA Phone: 1-314-770-0607 USA

SR Technics, TEQN Zurich Airport Zurich, ZH-8058 Switzerland Phone: 41-1-812752 Switzerla nd St. Louis Testing Laboratories Inc. 2810 Clark Avenue St. Louis, MO 63103 USA Phone: 1-314-531-8080 or 1-800- 264-1120 USA

CSE Citation Centre – UK Bournemouth IAP, Hanger #100 Christchurch, Dorset, UK BH23 6NW Phone: 44-0120-285-7759 United Kingdom Standard Aero (formerly Landmark Garrett Aviation Services) 1550 Hanger Road Augusta, GA 30906 USA Phone: 1-800-891-8889 USA

FR Aviation (formerly Flight Refueling Ltd.) Bournemouth International Airport Christchurch, Dorset BH23 6NE UK Phone: 1-44-01202-409000 United Kingdom Standard Aero (formerly Landmark Garrett Aviation Services) Springfield, Illinois 62707 USA Phone: 1-217-535-3596 USA

Marshall of Cambridge Aerospace Ltd Cambridge Airport, Cambridge UK CB5 8RX Phone: 44 (0) 1223-373216 United Kingdom Standard Aero (formerly Landmark Garrett Aviation Services) George Bush Int. Airport (IAH) 17250 Chanute Road Houston, TX USA Phone: 1-281-233-4150 USA

Material Measurements Ltd 61 Albert Road North Reigate, Surrey UK RH2 9RS Phone: +44 (0) 1737-222211 United Kingdom Standard Aero (formerly Landmark Garrett Aviation Services) 6201 West Imperial Highway Los Angeles, CA USA Phone: 1-310-568-3825 USA

Acuren Inspection Inc. 3101, 111 th St. SW, Unit “C” Everett, WA 98204 USA Phone: 1-425-355-5019 USA StarPort Cambata Aviation, Int. LLC 100 Starport Way Sanford, FL 32773 USA Phone: 1-407-321-8880 USA

Acuren – US Inspection Inc. 1485 Corporate Woods Parkway Union Town, OH 44685 USA Phone: 1-330-899-0566 USA Stork Twin City Testing Corporation 662 Cromwell Ave. St. Paul, MN 55114 USA Phone: 1-651-659-7440 USA

Aircraft NDT Service Inc. 6395 Technology Ave. Suite “C” Kalamazoo, MI 49009 USA Phone: 1-616-353-3658 USA Structural Testing Systems 97 Hering Drive L. I. MacArthur Airport Ronkonkoma, NY 11779 USA Phone: 1-516-981-0242 USAASB 206L-09-163A Page 23 of 26 ECCN EAR99 All American Inspections 106 E. Turbo San Antonio, TX 78216 USA Phone: 1-210-525-0421 USA Tailwind Inspection, Inc. 3260 N Sheridan Road Tulsa, OK 74115 USA Phone: 1-918-832-0700 USA

Apex Inspections 2530 Tarpley Suite #200 Carrollton, TX 75006 USA Phone 1-972-418-5672 USA Tailwind Inspection, Inc. 70 – C King Spring Road Windsor Locks, CT 06096 USA Phone: 1-860-623-8600 USA

Applied Technical Services Inc. 1190 Atlanta Industrial Drive Marietta, GA 30066 USA Phone: 1-770-423-1400 USA Tailwind Inspection, Inc. 7515 Lemmon Ave. Dallas, TX 75209 USA Phone: 1-214-357-9595 USA

Applied Technical Services Inc. 214 Pelham Davis Circle Greenville, SC 29615 USA Phone: 1-864-675-6060 USA The Aerospace NDT Company Inc. (formerly Rogers NDT) 3418 Cypresswood Dr. Spring, TX 77388 USA Phone: 1-281-482-0228 USA

Applied Technical Services Inc. 1325 “B” Cavalier Blvd Chesapeake, VA 23323 USA Phone: 1-757-558-0016 USA THI (The Hangar Inc.) 2930 Winchester Road, Suite 500 Memphis, TN 38118 USA Phone: 1-901-345-8885 USA

Canyon State Inspection 3625 East Ajo Way Tucson, AZ 85713 USA Phone: 1-520-745-3672 USA Aerocentro De Servicios C.A. Aeropuerto Caracas-Edifico Aerocentro. Charallavre, Mirauda VZ Post Code 1210 Phone : 1-561-317-8848 Venezuela

Canyon State Inspection 103 South Southgate Chandler, AZ 85226 USA Phone: 1-480-783-7183 USA Airtech Servicios Aereos, C.A. Aeropuerto Caracas Oscar Machado Zuloaga Edif. Airtech Charallave, Miranda 4383 Venezuela (VE) Phone: 58-14-939-1949 VenezuelaASB 206L-09-163A Page 24 of 26 ECCN EAR99 FIGURE 1. Main Rotor Blade Spar Spacer InspectionASB 206L-09-163A Page 25 of 26 ECCN EAR99 FIGURE 2. Main Rotor Blade Area to be Checked

FIGURE 3. Radiograph with Blades InstalledASB 206L-09-163A Page 26 of 26 ECCN EAR99 FIGURE 4. Cross Secti on of Main Rotor Blade