ALERT Via GiovanniAgusta, 520 

21017 Cascina Costa di Samarate (VA) Italy 

Tel. : +39 0331-22911 1 - Fax: +39 0331 -229605/222595 

---- AGlS" -------------------AN AGUSTAW

~ 

ESTLAND COMPANY 

TRANSLATION OF 

w 109EP-85 BOLLETTINO TECNICO 

The technical content of this document is approved 

under the authority of DOA nr EASA.21J .005. 

DATE December 13, 2007 

Compliance with 

this bollettino is: MANDATORY 

REV. 

SUBJECT: INSPECTION OF THE TIP CAP P/N 709-0103-29-109 OF THE MAIN 

ROTOR BLADES P/N 709-0103-01 (ALL DASH NUMBERS). 

REASON: To inspect the subject tip cap for presence of cracks on the leading edge. 

HELICOPTERS AFFECTED: 

All the main rotor blades P/N 709-0103-01 installed on the Agusta A 1 09E 

helicopters (and/or stored as spare parts) equipped with tip cap 

P/N 709-0103-29-1 09. 

COMPLIANCE: 

NOTE 

Main Rotor blades P/N 709-0103-01 

that are not affected by the 

BT 109EP-1 Rev.B, must comply 

with this Bollettino. 

~ Tip Caps PIN 709-0103-29-109 that have accumulated more than 

600 ( six hundred ) flight hours: 

• Within 5 (five) flight hours from the receipt of this Bollettino and 

however within and not later than January 31 ,2008. 

Subsequently every 50 ( fifty ) flight hours ( plus 5 flight hours 

tolerance not cumulative). 

~ Tip Caps P/N 709-0103-29-1 09 that have accumulated less than 600 

( six hundred ) flight hours: 

• Within and not later than 600 ( six hundred ) flight hours. 

Subsequently every 50 ( fifty ) flight hours ( plus 5 flight hours 

tolerance not cumulative). 

An op propriote entry should be mode in the aircraft log book upon accomplishment. 

If ownership of aircraft has changed, please, forward to new owner. 

ALERT Page 1 of 5 
B.T. 109EP-85 

DESCRIPTION: 

A case of loss of a part of the tip P/N 709-0103-29-109 of the main rotor 

blade P/N 709-0103-01 has been reported on an A 1 09E helicopter 

model, with subsequent increase of helicopter vibratory level. 

The cause of this loss is the fracture of the welded bead ( joint line of 

shells ) of the tip leading edge. 

Further investigation by AGUSTA are still ongoing. 

This Bollettino is issued with the purpose of providing, as a precautionary 

measure, a visual inspection, with the aid of a magnifying glass, for 

cracks of the tip cap leading edge ( welded joint line of shells ) 

REQUIRED MANPOWER: 

0,5 estimated manpower hours are required for each blade (only visual 

inspection) for compliance with this Bollettino. 

WARRANTY: 

If upon implementation of this Bolletino Tecnico the tip cap is found 

cracked on the leading edge, please contact immediately our Customer 

Support Engineering 

REQUIRED MATERIALS: 

The following consumable materials will be required to accomplish this 

Bollettino: 

• abrasive paper grit No 320 or more fine 

• solvent (exane, or petroleum ether, or aliphatic naphtha according to 

TT-N-95 type 2) or solvent 9PR5 available from BRENT International; 

• visible dye penetrant P6R available from BRENT International; 

• nonaqueous wet developer 901 B spray available from BRENT 

International; 

• one or more white light sources able to provide an illuminance of at 

least 1 000 lux on inspection area. 

Alternative products to the solvents, penetrant and developer specified 

above are permitted provided that: 

• they comply to the requirements of AMS2644 (class 2 for the solvent, 

type 2 and method "c" for the penetrant and form "e" for the 

·developer); 

• they are listed in the pertinent QPL-AMS-2644-1; 

• the penetrant and developer are produced by the same company. 

SPECIAL TOOLS: 

N.A. 

WEIGHT AND BALANCE CHANGES: 

N.A. 

REFERENCES: 

N.A. 

Page 2 of 5 
PUBLICATIONS AFFECTED: 

A 1 09E Maintenance planning Manual 

A 1 09E Maintenance Manual. 

COMPLIANCE INSTRUCTIONS: 

(See figure 1) 

NOTE 

The procedures reported below are 

applicable to each one of the four main 

rotor blades, if affected by this 

Bollettino, and does not require to 

remove it from the helicopter. 

B.T. 109EP-85 

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

disconnect any power supply. 

2. Using a 10 power magnifying glass, visually inspect on tip cap 

leading edge welded bead Uoint line between the two metallic 

shells) for presence of cracks and/or damage (see figure 1). 

~ If the main rotor blade does not have any presence of cracks 

on the tip cap, proceed to step 5 and subsequent. 

~ If the main rotor blade does have presence of cracks on the tip 

cap, remove it from service and immediately inform AGUST A. 

~ If there are doubts on the presence of cracks, proceed with 

step 3 and subsequent. 

3. Using the visible dye penetrant method, inspect the tip cap leading 

edge along the welded joint line of the shells for presence of 

cracks as follows (refer to figure 1 ): 

3.1 . Using abrasive paper grit no320 or more fine, remove the paint 

from area B, on both upper and lower sides, inboard 5 to 10 mm 

from leading edge and starting at 30,0 mm from the trailing edge. 

Mask surrounding painted areas using adhesive tape. 

CAUTION 1 

The above operation must be 

accomplished at the first application of 

the liquid penetrant inspection. 

Page 3 of 5 
B.T. 109EP-85 

CAUTION 2 

Personnel conducting the liquid 

penetrant inspection must be qualified 

in accordance with the practice 

EN4179 I NAS410. 

The blade, the penetrant and ambient 

temperatures shall be between 4 oc and 

45°C. 

3.2. Thoroughly degrease inspection area using a cloth soaked in solvent 

(refer to paragraph REQUIRED MATERIALS). 

Leave solvent to completely evaporate. 

3.3. Using adhesive tape mask trailing edge inboard for 30,0 mm to 

avoid possible penetrant infiltration in the tip cap. 

3.4. Apply the penetrant in the inspection area extending 

approximately 5 mm inboard from trailing edge (refer to view A of 

figure 1 ), on both upper and lower sides. Penetrant dwell time 

shall be 30 to 40 minutes. 

3.5. Remove excess penetrant with a clear dry cloth followed by a cloth 

dampened in solvent until the background color has been 

completely removed . 

NOTE 

Do not directly pour the solvent on the 

inspection area. 

3.6. Apply a thin and uniform layer of developer 9D 1 B, after 10 to 15 

minutes illuminate area to 1 000 lux and examine it presence of 

cracks. 

3.7. Upon completion of inspection, clean affected area with a clean 

dry cloth followed by a cloth dampened in solvent. 

4. If the main rotor blade does not have any presence of cracks on 

the tip cap, proceed to step 5 and subsequent. 

If the main rotor blade does have presence of cracks on the tip 

cap, remove it from service and immediately inform AGUSTA 

5. Return the helicopter in ready to flight condition. 

6. Record compliance with this Bollettino in the helicopter log book. 

Page 4 of 5 
View A 

Lap plate 

Tip cap 

Inspection area on 

the leading edge 

Tip cap shell welding 

PIN 709-0103-29-109 

marking 

B.T. 109EP-85 

Inspection area on 

the leading edge 

AREA B (upper and lower sides) 

paint to remove if the liquid 

penetrant inspection is required 

Dimensions in millimeters 

FIGURE 1 

Page 5 of 5 

AA AGUSTAWESlt.ANO COMPANY 

=tJi== 

Prego spedire a questo indirizzo: Data: 

Please send to the following address: MODULO APPLICAZIONE BOLLETTINO TECNICO Date: 

TECHNICAL BULLETIN COMPLIANCE FORM 

AGUSTA S.p.A. Numero: 

CUSTOMER SUPPORT Number: 

Via per Tornavento , 15 

21019 Somma Lombardo (VA) - ITALY 

Tel.:+390331711100 Revisions: 

Fax: +39 0331 711397 Revision: 

Denominazione Cliente ed lndirizzo: Telefono: 

Customer Name and Address: Telephone: 

Fax: 

Data Appl icazione B.T.: 

B. T. Compliance Date: 

Modello Elicottero S/N Matricola Ore Totali Ore D.U.R. 

Helicopter Model Tail Number Total Hours T.S.O. 

Note: 

Remarks: 

lnformazioni: 

Information: 

AI fine di gestire le varianti alia configurazione base, in relazione all'emissione del Bollettino Tecnico, preghiamo di voler compilare il presente modulo in tutte le sue parti e spedirlo all'indirizzo sopra indicato. Si ringrazia per Ia gentile collaborazione data. 

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. We thank you beforehand for the information given.