99-18-02 BELL HELICOPTER, TEXTRON, INC.: Amendment 39-11268; Docket No. 98- SW-72-AD. Issued August 18, 1999.
Applicability: Model 205A-1 helicopters with vertical fin spar cap, part number (P/N) 212-030-447-001 or -101, installed, and Model 205B helicopters with vertical fin spar cap, P/N 212-030-447-101, installed, certificated in any category.
NOTE 1: This AD applies to each helicopter identified in the preceding applicability provision, regardless of whether it has been otherwise modified, altered, or repaired in the area subject to the requirements of this AD. For helicopters that have been modified, altered, or repaired so that the performance of the requirements of this AD is affected, the owner/operator must request approval for an alternative method of compliance in accordance with paragraph (d) of this AD. The request should include an assessment of the effect of the modification, alteration, or repair on the unsafe condition addressed by this AD; and, if the unsafe condition has not been eliminated, the request should include specific proposed actions to address it.
Compliance: Required as indicated, unless accomplished previously.
To prevent failure of the vertical fin (fin) spar, loss of the tail rotor, and subsequent loss of control of the helicopter, accomplish the following:
(a) For Model 205A-1 helicopters with a fin spar cap (spar cap), P/N 212-030-447- 001, installed, accomplish the following:
(1) Within 8 hours time-in-service (TIS), modify the vertical fin and visually inspect the fin spar for cracks in accordance with Part I (A1), paragraphs 1 through 4 of Bell Helicopter Textron, Inc. Alert Service Bulletin No. 205-98-70, Revision A, dated September 21, 1998 (ASB).
(i) If a crack is discovered on the fin spar, replace the fin spar assembly with an airworthy fin spar assembly before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(ii) After inspecting, apply MIL-PRF-81352 clear lacquer or an equivalent coating to the area where the paint and primer were removed. Spray, brush, or wipe on a protective coat of MIL-C-16173, Grade 2, or equivalent compound, over the clear lacquer or equivalent coating.
(iii) Install the inspection door, intermediate gearbox cover, and tail rotor driveshaft cover.
(2) After initially modifying and inspecting the fin, inspect the fin spar for cracks at intervals not to exceed 8 hours TIS as follows:
(i) Accomplish Part I (A2), paragraphs 1 through 3, of the ASB.
(ii) If a crack is discovered on the fin spar, replace the fin spar cap or spar assembly with airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(iii) After inspecting, accomplish Part I (A2), paragraphs 5 and 6, of the ASB.
(3) Within 25 hours TIS, inspect and modify the fin assembly as follows:
(i) Accomplish Part II (C1), paragraph 1, of the ASB.
(ii) Remove the clip, part number (P/N) 212-030-099-091, and radius block, P/N 212-030-099-095, if existing. Remove the retainer, P/N 212-030-121-037, and sufficient rivets from the bottom row of the forward left-hand fin skin to allow trimming of the forward left-hand skin along the skin "cutline", approximately fin station 66.31 (see Figure 2 of the ASB).
(iii) Before drilling or reaming, inspect all holes in the spar cap where rivets were removed for short edge distance. If an existing edge distance will be less than 1.5 times the diameter of the drill or reamed hole, repairs must be performed and must be FAA approved before proceeding.
(iv) Accomplish Part II (C1), paragraphs 3, 4, and 6, in the ASB.
(v) If a crack is discovered on the fin spar, replace the fin spar cap or spar assembly with airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection beforefurther flight.
(vi) Accomplish Part II (C1), paragraphs 10 through 14, of the ASB.
(4) After initially modifying and dye-penetrant inspecting the fin spar, inspect the fin spar at intervals not to exceed 300 hours TIS as follows:
(i) Accomplish Part II (C2), paragraphs 1, 2, 3, 4, 5, and 7, of the ASB.
(ii) If a crack is discovered on the fin spar, replace the fin spar cap or spar assembly with airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(iii) Accomplish Part II (C2), paragraphs 11 through 14, of the ASB.
(5) Within 12 calendar months, remove the left-hand fin spar cap, P/N 212- 030-447-001. Replace it with an airworthy fin spar cap or spar assembly configuration that has been demonstrated to the FAA to satisfy the structural fatigue requirements of repeated high- torque events and is approved by the Manager, Rotorcraft Standards Staff.
(6) Installationof a fin spar cap or assembly that has been approved by the Manager, Rotorcraft Standards Staff, constitutes terminating action for the requirements of this AD.
(b) For Model 205A-1 helicopters with a fin spar cap, P/N 212-030-447-101, installed, accomplish the following:
(1) Within 8 hours TIS, modify the vertical fin and visually inspect the fin spar for cracks in accordance with Part II (A1), paragraphs 1 through 5, of the ASB.
(i) If a crack is discovered on the fin spar, replace the fin spar cap or assembly with an airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(ii) After inspecting, apply MIL-PRF-81352 clear lacquer or an equivalent coating to the two lower rivet holes and on the surface where paint and primer were removed. Spray, brush, or wipe on a protective coat of MIL-C-16173, Grade 2 or equivalent compound, over the clear lacquer or equivalent coating. To facilitate subsequent inspections, do not replace the two lower rivets (see Figure 2 of the ASB).
(iii) Before drilling or reaming, inspect all holes in the spar cap where rivets were removed for short edge distance. If an existing edge distance will be less than 1.5 times the diameter of the drill or reamed hole, repairs must be performed and must be FAA approved before proceeding.
(iv) Fasten the forward left-hand fin skin and the retainer, P/N 212- 030-121-037, to the spar assembly using Hi-Loks and blind rivets as specified in Figure 2 of the ASB. Reinstall the clip and radius block, if existing, that were removed in accordance with paragraph 2 of Part II (A1) of the ASB.
(v) Refinish the reworked area.
(vi) Install the inspection door, intermediate gearbox cover, and tail rotor driveshaft cover.
(2) After initially modifying and inspecting the fin, inspect the fin spar for cracks at intervals not to exceed 8 hours TIS as follows:
(i) Accomplish Part II (A2), paragraphs 1 through 3, of the ASB.
(ii) If a crack is discovered on the fin spar, replace the fin spar cap or assembly with airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(iii) After inspecting, accomplish Part II (A2), paragraphs 5 and 6, of the ASB.
(3) Within 25 hours TIS, modify and inspect the vertical fin as follows:
(i) Accomplish Part II (C1), paragraph 1, of the ASB.
(ii) Remove the clip, P/N 212-030-099-091, and radius block, P/N 212-030-099-095, if existing. Remove the retainer, P/N 212-030-121-037, and sufficient rivets from the bottom row of the forward left-hand fin skin to allow trimming of the forward left-hand fin skin along the skin "cutline", approximately fin station 66.31 (see Figure 2 of the ASB).
(iii) Before drilling or reaming, inspect all holes in the spar cap where rivets were removed for short edge distance. If an existing edge distance will be less than 1.5 times the diameter of the drill or reamed hole, repairs must be performed and must be FAA approved before proceeding.
(iv) Accomplish Part II (C1), paragraphs 3, 4, and 6, of the ASB.
(v) If a crack is discovered on the fin spar, replace the fin spar cap or assembly with airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(vi) Accomplish Part II (C1), paragraphs 10 through 14, of the ASB.
(4) After initially modifying and dye-penetrant inspecting the fin spar, inspect the fin spar at intervals not to exceed 300 hours TIS as follows:
(i) Accomplish Part II (C2), paragraphs 1 through 7, of the ASB.
(ii) If a crack is discovered on the fin spar, replace the fin spar cap or assembly with airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(iii) Accomplish Part II (C2), paragraphs 11 through 14, of the ASB.
(5) Within 25 hours TIS, and thereafter at intervals not to exceed 300 hours TIS, inspect the fin spar as follows:
(i) Accomplish Part II (B), paragraphs 1 through 13, of the ASB.
(ii) Repair any disbonding discovered during the inspection before further flight.
(6) Within 12 calendar months, remove the left-hand fin spar cap, P/N 212- 030-447-101. Replace it with an airworthy fin spar cap or spar assembly configuration that has been demonstrated to the FAA to satisfy the structural fatigue requirements of repeated high- torque events and is approved by the Manager, Rotorcraft Standards Staff.
(7) Installation of a fin spar that has been approved by the Manager, Rotorcraft Standards Staff, that satisfies the requirements of paragraph (b)(6) of this AD constitutes terminating action for the requirements of this AD.
(c) For Model 205B helicopters with a fin spar cap, P/N 212-030-447-101, installed, accomplish the following:
(1) Within 8 hours TIS, modify the fin and visually inspect the fin spar for cracks in accordance with Part I (A1), paragraphs 1 through 5, of Bell Helicopter Textron, Inc. Alert Service Bulletin No. 205B-98-26, Revision A, dated September 21, 1998 (205B ASB).
(i) If a crack is discovered on the fin spar, replace the fin spar cap or assembly with airworthy parts before further flight. Repair any corrosion or disbonding discovered during the inspection before further flight.
(ii) After inspecting, apply MIL-PRF-81352 clear lacquer or an equivalent coating to the two lower rivet holes and on the surface where paint and primer were removed. Spray, brush, or wipe on a protective coat of MIL-C-16173, Grade 2, or equivalent compound, over the clear lacquer. To facilitate subsequent inspections, do not replace the two lower rivets (see Figure 2 of the 205B ASB).
(iii) Before drilling or reaming, inspect all holes in the spar cap where rivets were removed for short edge distance. If an existing edge distance will be less than 1.5 times the diameter of the drill or reamed hole, repairs must be performed and must be FAA approved before proceeding.
(iv) Fasten the forward left-hand fin skin and the retainer, P/N 212- 030-121-037, to the spar assembly using Hi-Loks and blind rivets as specified in Figure 2 of the 205B ASB. Reinstall the clip and radius block, if existing, removed in paragraph 2 of Part I (A1) of the 205B ASB.
(v) Install the inspection door, intermediate gearbox cover, and tail rotor driveshaft cover.
(2) After initially modifying and inspecting the fin, inspect the fin spar for cracks at intervals not to exceed 8 hours TIS as follows:
(i) Accomplish Part I (A2), paragraphs 1 through 3, of the 205B ASB.
(ii) If a crack is discovered on the spar, replace the fin spar cap or assembly with airworthy parts before further flight. Any corrosion or disbonding discoveredduring the inspection must be repaired before further flight.
(iii) After inspecting, accomplish Part I (A2), paragraphs 5 and 6, of the 205B ASB.
(3) Within 25 hours TIS, modify and inspect the fin as follows:
(i) Accomplish Part I (C1), paragraph 1 of the 205B ASB.
(ii) Remove the clip, P/N 212-030-099-091, and radius block, P/N 212-030-099-095, if existing. Remove the retainer, P/N 212-030-121-037, and sufficient rivets from the bottom row of the forward left-hand fin skin to allow trimming of the forward left-hand fin skin along the skin "cutline", approximately fin station 66.31 (see Figure 2 of the 205B ASB).
(iii) Before drilling or reaming, inspect all holes in the spar cap where rivets were removed for short edge distance. If an existing edge distance will be less than 1.5 times the diameter of the drill or reamed hole, repairs must be performed and must be FAA approved before proceeding.
(iv) Accomplish Part I (C1), paragraphs 3, 4,and 6, in the 205B ASB.
(v) If a crack is discovered on the spar, replace the fin spar cap or assembly with airworthy parts before further flight. Any corrosion or disbonding discovered during the inspection must be repaired before further flight.
(vi) Accomplish Part I (C1), paragraphs 10 through 14, of the 205B ASB.
(4) After initially modifying and dye-penetrant inspecting the fin spar, inspect the fin spar at intervals not to exceed 300 hours TIS as follows:
(i) Accomplish Part I (C2), paragraphs 1, 2, 3, 4, 5, and 7, of the 205B ASB.
(ii) If a crack is discovered on the spar, replace the fin spar cap or assembly with airworthy parts before further flight. Any corrosion or disbonding discovered during the inspection must be repaired before further flight.
(iii) Accomplish Part I (C2), paragraphs 11 through 14, of the 205B ASB.
(5) Within 25 hours TIS, inspect the fin spar at intervals not to exceed 300 hours TIS as follows:
(i) Accomplish Part I (B), paragraphs 1 through 13, of the 205B ASB.
(ii) Any disbonding discovered during the inspection must be repaired before further flight.
(6) Within 12 calendar months, remove the left-hand fin spar cap, P/N 212- 030-447-101. Replace it with an airworthy fin spar cap configuration that has been demonstrated to the FAA to satisfy the structural fatigue requirements of repeated high-torque events and is approved by the Manager, Rotorcraft Standards Staff.
(7) Installation of a fin spar that satisfies the above requirements and has been approved by the Manager, Rotorcraft Standards Staff, constitutes a terminating action for the requirements of this AD.
(d) An alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Rotorcraft Standards Staff, Rotorcraft Directorate, FAA. Operators shall submit their requests through a FAA Principal Maintenance Inspector, who may concur or comment and then send it to the Manager, Rotorcraft Standards Staff.
NOTE 2: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Rotorcraft Standards Staff.
(e) Special flight permits may be issued in accordance with sections 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the helicopter to a location where the requirements of this AD can be accomplished.
(f) The modification of the vertical fin, the visual and dye-penetrant inspections, and any necessary repairs shall be done in accordance with Bell Helicopter Textron, Inc. Alert Service Bulletin No. 205-98-70, Revision A, or No. 205B-98-26, Revision A, both dated September 21, 1998, as applicable. This incorporation by reference was approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from Bell Helicopter Textron, Inc., P.O. Box 482, Fort Worth, Texas 76101, telephone (817) 280-3391, fax (817) 280-6466. Copies may be inspected at the FAA, Office of the Regional Counsel, Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC.
(g) This amendment becomes effective on October 5, 1999.