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Leonardo S.p.A.
Vta Giovanni Agusta, 520
~LEDNRRDD
~ HELICOPTERS
21017 Caseína Costa di Samarate (VA) ltaly
Tel.: +39 0331 229111 - Fax: +39 0331 229605/222595

AgustaWestland Products

SERVICE BULLETIN Nº 109S-078

DATE: March 6, 2018
REV.: /

TITLE
ATA 53 - LEFT AND RIGHT COUNTERTORQUE CROSSBEAM FITTING PLATE
ASSEMBLIES P/N 109-0330-17 INSPECTION OF.
/
REVISION LOG
New lssue

An opprapriote entry should be mode in the oircroft lag baok upan occomplishmenl.
lf ownership of aircroft has changed, please, forword to new owner.

P::::im::. 1 nf 1 A.
 ~~LEONARDO
~ HRICDPTERS

1. PLANNING INFORMATION

A. EFFECTIVITY
AII the A 109S helicopters.

B. COMPLIANCE
► For helicopter having accumulated less than 3000 (three thousand) landings:
at- reaching of 3000 landings or within the next 200 landings whichever
comes later and subsequently each 1500 landings.
► For helicopter having accumulated more than 3000 (three thousand) landings:
within the next 200 landings and subsequently each 1500 lahdings.

C. CONCURRENT REQUIR~MENTS
N.A.

D.REASON
This Service Bulletin is issued in order to introduce an inspection to the LH and RH
countertorque crossbeam fitting plate assemblies P/N 109-0330-17 (made of
aluminum alloy) to verify the presence of cracks near the bossed holes of the plate.

E. DESCRIPTION
Product lmprovement - Cases of cracks of the aluminum alloy 7475 LH and RH
countertorque crossbeam_fitting plate assemblies P/N 109-0330-17 around the bossed
holes of the plates have been reportad on AW109 series helicopters. In no case these
cracks had any effect on the conduit of flight.
The performed investigation concluded that the cracks reported on the fitting plates
are due to a marginality of the design, associated with the peculiar installation process
and that the cracks do not affect the Safety of the Flight.
This Service Bulletin is issued with the purpose to provide the necessary instructions
to perform an eddy current non-destructive inspection to verify the presence of cracks
on the LH and RH countertorque crossbeam fitting plate assemblies P/N 109-0330-17
in the area highlighted in the Figure1.

F.APPROVAL
The content of this Service Bulletin is approved under the authority of D0A nr.
EASA.21.J.005. For helicopters registered under other Aviation Authorities, before
applying the Service Bulletin, applicable Aviation Authority approval must be óhecked
within Leonardo Helicopters customer portal.
),

S.B. Nº109S-078
DATE: March 6, 2018
DC\/IQll"\11.1• /
 ~~LEONARDO
~ HEl/COPTERS

E.AS.A. states mandatory compliance with inspections, modifications or technical

directives and related time of compliance by means of relevant Airworthiness
Directives.
lf an aircraft listed in the effectivity embodies a modification or repair not LHD 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 befare incorporation of the present Service
Bulletin.

G. MANPOWER
To comply with this Service Bulletin approximately sixteen (16) Maintenance-Man-
Hours are deemed necessary.
Maintenance-Man-Hours are based on hands-on time and can change with personnel
and facilities available.

H. WEIGHT ANO BALANCE

N.A.

l. REFERENCES

1) PUBLICATIONS
DATA MODULE DESCRIPTION
DM01 0B-A-00-20-00-00A-120A-A Make the helicopter safe for
maintenance

2)ACRONYMS
DOA Design Organization Approval
EASA European Aviation Safety Agency
LHD Leonardo Helicopters Division
LH Left
LS Local Supply
N.A. Not Applicable
P/N Part Number
RH Right
SB Service Bulletin
S/N Serial Number

S.B. Nº109S-078
DATE: March 6, 2018
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 -¡~LEONARDO
~ HELJCOPTERS

3) ANNEX
Annex A EDDY CURRENT WORK INSTRUCTIONS

J. PUBLICATIONS AFFECTED
Air vehicle maintenance planning information (EASA).
Air vehicle maintenance planning information (FAA).

K. SOFTWARE ACCOMPLISHMENT SUMMARY

N.A.

S.B. Nº109S-078
DATE: March 6, 2018
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 ~~LEONARDO
~ HEUCOPTERS

2. MATERIAL INFORMATION

A. REQUIRED MATERIALS

1) PARTS
N.A.

2) CONSUMABLES
The following consumable materials, or equivalent, are necessary to accomplish this
Service Bulletin:
# P/N DESCRIPTION Q.TY NOTE
TT-N-95
(cod. 531055030) Aliphatic naphtha AR
CCC-C-46
2 Soft lint-free cloth AR
(cod. 590210190)

3) LOGISTIC MATRIX
LOGISTIC P/N Q.TY (PER HELO) NOTE PART
N/A N/A N/A

B. SPECIAL TOOLS
The following special tools, or equivalent, are necessary to accomplish this Service
Bulletin:
# P/N DESCRIPTION Q.TY NOTE PART
3 MIZ-21SR Eddy Current instrument 1 (1-3-5)
4 VM229F-6 45º absolute shielded probe 100+500 kHz 1 (2-3-5)
5 VM99FBN-21 Adapter 1 (2-3-5)
6 VM99BM Cable assy (2-3-5)
7 Commercial Flat calibration reference block in AL-AL Y 1 (5)
7475, with notch 0,5 mm deep
8 Commercial PTFE adhesive tape 1 (5)

SPECIAL TOOLS NOTE

(81) Manufactured by Zetec lnc.
(82) Manufactured by VM Products lnc.
(83) Other instruments and/or probes can be used on mandatory condition that:
a. the probe is absolute and shielded type with frequency range 100-SOOkHz;
b. the system "instrument plus probe" shall obtain equivalent results from the
calibration;
c. the setup is at least carried out by a Level 2 in accordance with
EN4179/NAS41 O and the relevant Work lnstruction is approved by the Level 3
in accordance with EN4179/NAS41 O.
(84) Please contact Leonardo Helicopter Division order administration point of contact to

S.8. Nº109S-078
DA TE: March 6, 2018
DC\/IC'l"IU• /
 ~~LEONARDO
~ HELICOl'TERS

request the tools supply on loan. As soon as the present Service Bulletin is
implemented the tools supplied on loan shall be promptly returned to LHD.
(85) Local supply.

C. INDUSTRY SUPPORT INFORMATION

N/A

S.B. Nº109S-078
DATE: March 6, 2018
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 ~tLEONARDO
~ HELICOPrfRS

3. ACCOMPLISHMENT INSTRUCTIONS

GENERAL NOTES
a) The following procedures are applicable to left
countertorque crossbeam fitting plate assy P/N
109-0330-17 and to the right countertorque
crossbeam fitting plate assy P/N 1 09-0330-17.
b) Place an identification tag on ali 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.

1. In accordance with DM 0B-A-00-20-00-00A-120A-A, prepare the helicopter on ground

for a safe maintenance. Disconnect the battery, ali electrical power sources and/or the
externa! power supply.
2. Remove the passenger cabin roof panel liners to gain access to the left and right
countertorque crossbeam fitting plate assemblies PIN 109-0330-17.
3. Accurately clean the inspection area of the left and right countertorque crossbeam fitting
plate assy PIN 109-0330-17 by means of a soft lint-free cloth soaked in aliphatic
naphtha.
4. In accordance with the instructions given in Annex A perfórm the eddy current
non-destructive inspection of the countertorque crossbeam fitting plate assy
P/N 109-0330-17 along the connecting areas between plate and attacks as highlighted
in the Figure 1, in order to verify the presence of cracks.
4.1 lf no damages are found on the left and right countertorque crossbeam fitting
plate assemblies P/N 109-0330-17, proceed as described in step 5 and following.
4.2 lf one or both the countertorque crossbeam fitting plate assy P/N 109-0330-17
are found cracked, the fitting plate assy must be replaced before the next flight.
Contact Leonardo Helicopters Customer Support to the following mail box, in
order to arrange the shipment of the materials required to perform the
replacement of the plate assy.
aw109.mbx.aw@leonardocompany.com
5. Return the helicopter to a ready to flight configuration and record for compliance with this
Service Bulletin on the helicopter logbook.
6. Send the attached compliance form to the following mail box:
aw109.mbx.aw@leonardocompany.com

S.B. Nº109S-078
DATE: March 6, 2018
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 7~LEONARDO
~ HEUCOPTfRS

As an alternative, gain access to My Communications section on Leonardo WebPortal

and compile the "Service Bulletin Application Communication".

S.B. Nº109S-078
DATE: March 6, 2018
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 ~~LEONARDO
~ HELICOPTERS

ANNEXA
EDDY CURRENT WORK INSTRUCTIONS

S.B. Nº109S-078
DATE: March 6, 2018
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 ..•

ANNEX A
-¡~LEONARDO
~ HEUCOPTfRS

THE OPERA TIVE WORK INSTRUCTION SHALL BE APPROVED IN ANY CASE BY EDDY

CURRENT LEVEL 3

SCOPE
This Work lnstruction defines the non-destructive inspection procedure by eé:tdy current (ET) in
accordance with AWPS008X, of the A109 Plates Assy, Fitting Countertorque Crossbeam PIN 109-
0330-17.
The scope of the inspection is to detect possible cracks.

EQUIPMENT
For the inspection the following equipment shall be available:

• an Eddy Current "MIZ-21SR" instrument (manufactured by Zetec lnc. in USA) (see Note);
• a 45º absolute shielded probe 100-;-500 kHz, PIN VM229F-6 (manufactured by VM Products
lnc. with adapter VM99FBN-21 for Zetec instrument) and the relevant cable VM99BM;
• a flat calibration reference block in aluminium, with notch 0,5 mm deep;
• sorne adhesive PTFE tape to protect the tip of the probe from wear damage and to simulate
the paint thickness on the reference block.

Note
Other instruments and/or probes can be used on mandatory condition that:
·a. the probe is absolute and shielded type with frequency range 100-500kHz;
b. the system "instrument plus probe" shall obtain equivalent results from the calibration;
c. the setup is at least carried out by a Level 2 in accordance with EN4179/NAS41 O and the
relevant Work lnstruction is approved by the Level 3 in accordance with EN4179/NAS410.

INSPECTION AREAS
The areas to be inspected are the connecting areas between plate and attacks, as highlighted
in the Figure 1.

SURFACES PREPARATION
The whole surfaces to be inspected shall be free from any grease, scale, conductive sealants or
other excessive contaminants that can interfere with the inspections.
The surfaces shall be inspected both painted and unpainted provided that a proper calibration
reference block is used.

EXAMINATION
WARNING!
1. THE PROBE SHALL BE KEPT AS PERPENDICULAR AS POSSIBLE TO THE
SURFACE IN ALL PHASES OF THE INSPECTION.
2. DURING THE SCANNING, IT IS VERY IMPORTANT TO MOVE THE PROBE SLOWLY
ANO UNIFORML Y.

S.B. Nº109S-078
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DATE: March 6, 2018
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 ANNEXA
~~LEONRRDO
~ Hfl/COl'TERS

3. TAKE CARE TO THE SIGNAL FROM THE EDGE EFFECT.

The calibration and the subsequent inspection shall be carried out in accordance with the
following sequence.

SET UP OF THE EQUIPMENT

Connect the probe on the instrument by relevant cable, switch on the instrument and set up the
parameters listed below:

45º absolute shielded probe VM229F-6

EC F1 TEST DISP1 SRCF1 ALM SRC D1

SETUP# neglect MODE X-Y ALARM IN
CONFIG neglect V SCALE D1 02 CHNG CENT
FREQ1 400K H SCALE D1 09 CHNG SIZE
DIFF F1 008 PHASE D1 as necessary (352) OUTPUT s
GAIN F1 63 POSITION D1 neglect STOR SCN0
MARK/CLR #O LPS 000 250 RULER OFF
AUTOSET F1 AUTOCLEAR ON LCD ADJ

CALIBRA TION
The calibration shall be carried out before the inspection and rechecked after the end of the
inspection; it shall be periormed on the reference block detailed in the Par. - Equipment - in
accordance with the following sequence:
• put the sensor of the probe on the reference standard, press the compensation key and adjust
the phase of the instrument in a way that the lift-off signal results in horizontal deflection from
the centre to the left so that it is clearly distinguished from the defect indication (see trace A on
Figure 3),
• perform the scanning inspection on the reference standard to verify that, in correspondence of
the reference notch 0,5 mm deep, a deflection positioned at 45º clockwise about respect to the
lift-off signal, at least of three (3) main divisions of the screen (see trace B on Figure 3).

INSPECTION
When the instrument is calibrated, then inspect as follows:
• put the probe in a flat area far away from the edges, periorm the compensation and adjust
the phase in a way that the lift-off signal results in horizontal deflection;
• perform detailed examination scanning in order to cover the whole areas to be inspected
using circular path directions (see Figure 2) with indexing not greater than 3 mm and
covering a tilting of the sensor from 90º up to 45º;
• in case relevant linear indications are identified, periorm also a scanning perpendicular the
its main direction;
• recheck the instrument calibration as described before.

S.B. Nº109S-078
DATE: March 6, 2018
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 ANNEXA ~~LEONARDO
~ HElJCOPTERS

EVALUT ATION
Any vertical deflection equal or greater than the set threshold (see red trace on Figure 3),
unless it can be attributed to change in geometry or due to edge effect, shall be considered
relevant indication andas such processed.
In this case, it shall be verified the instrument calibration and the inspection repeated to confirm
the crack.

PERSONNEL
The inspections performed in accordance with this procedure shall be carried out by personnel
qualified at least Level 2 in the Eddy Current Method in accordance with EN4179 or NAS41 O
international standards.

S.B. N°109S-078
n--- ,f"') -.& -f A DATE: March 6, 2018
OC\ /IC'lr\1\1- /
 ANNEXA
~~LEONARDO
~ HEL/COPTERS

• SIN 7208
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o

A109 Piastra Supporto Antic~ppia \

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• • •
•
Figure 1 - lnspection areas connecting plate and attacks.

Figure 2 - Sean paths for the sensor to the surface, 90º and 45º. The arrows show the
scanning directions

S.B. Nº109S-078
DATE: March 6, 2018
O C \ /IC ll"\~1- /
 ,r,,.
ANNEX A ,~ LEONARDO HEUCOPTERS

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THRESHOLD

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Figure 3.Typical signal from the calibration phase (A= lift-off, B = indication from reference notch
0,5mm deep). The red hatched-line shows the acceptance/rejection threshold.

S.B. Nº109S-078
n AA -~ A A
DATE: March 6, 2018
~~LEONARDO
~ HELICOPTERS AgustaWest/and Products

Please send to the following address:

SERVICE BULLETINCOMPLIANCE FORM Date:
LEONARDO S.p.A.
CUST0MER SUPP0RT & SERVICES - ITALY Number:

PRODUCT SUPPORT ENGINEERING & LICENSES DEPT.

Via Giovanni Agusta, 520
21017 Caseína Costa di Samarate (VA) - ITAL Y Revision:
Tel.: +39 0331 225036 Fax: +39 0331 225988

Customer Name and Address:

Telephone:

Fax:

B.T. Compliance Date:

Helicopter Model S/N Total Number Total Hours T.S.O.

Remarks:

lnformation:

We request your cooperation in filling this form, in arder to keep out statistical data relevan! to aircraft configuration up-to-date. The form should be filled in ali
its parts and sen! to !he above address or you can communicate the application also vía Technical Bulletin Application Communication Section placed in
Leonardo AW Customer Portal - MvCommunications Area. We thank vou beforehand for !he information aiven.
 ERRATA CORRIGE

Please find here attached the page that has to be replaced in the basic Service Bulletin
n°109S-078.

• PAGE 7 "Step Nº 4.1"

Was:

lf no damages are found on the left and right countertorque crossbeam fitting plate assemblies
P/N 109-0330-17, proceed as described in step 11 and following.

Becomes:

lf no damages are found on the left and right countertorque crossbeam fitting plate assemblies
P/N 109-0330-17, proceed as described in step 5 and following.