AD 2003-01-04 Airworthiness Directives; Bell Helicopter Textron, Inc. Model 204B, 205A, 205A-1, 205B and 212 Helicopters

The following model helicopters with the listed part number (P/N) installed, certificated in any category:   Model With main rotor grip (Grip) P/N (1) 205B 204-011-121-005, −009, −113, −117, or −121. (2) 212 204-011-121-009 or −121. (3) 204B 204-011-121-005 if the grip was ever installed on a Model 205B helicopter. (4) 205A and 205A-1 204-011-121-005 or −113 if the grip was ever installed on a Model 205B helicopter. (5) 204B, 205A, and 205A-1 204-011-121-117. (6) 205A-1 204-011-121-009 or −121 modified in accordance with Supplemental Type Certificate (STC) SH5132NM. 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 (h) 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.

Required as indicated, unless accomplished previously. To prevent failure of a grip, separation of a main rotor blade, and subsequent loss of control of the helicopter, accomplish the following: (a) Within 10 hours time-in-service (TIS), create a component history card or equivalent record and determine and record the total hours TIS for each grip. If the total hours TIS cannot be determined from the helicopter records, assume and record 900 hours TIS for each year the grip has been installed on any helicopter. Continue to count and record the hours TIS and begin to count and record the number of times the helicopter engine(s) are started (engine start/stop cycles). (b) Within 10 hours TIS, and thereafter at intervals not to exceed 25 hours TIS, without removing the main rotor blades: (1) Clean the exposed surfaces of the upper and lower tangs of each grip with denatured alcohol. Wipe dry. (2) Using a 10-power or higher magnifying glass, visually inspect the exposed surfaces of the upper and lower tangs of each grip for a crack. Pay particular attention to the lower surface of each lower grip tang from the main rotor blade bolt-bushing flange to the leading and trailing edge of each grip tang. See Figure 1 as follows: BILLING CODE 4910-13-P ER15JA03.023 (c) Ultrasonic (UT) inspect each grip shown in the following table of this AD in accordance with the Bell Helicopter Textron, Inc. (BHTI) Nondestructive Inspection Procedure, Log No. 00-340, Revision E, dated April 9, 2002. Table 1 UT Inspect Grip P/N Within 30 days, for a Grip with the following or more hours TIS Thereafter, at intervals not to exceed the following hours TIS or the engine start/stop cycles, whichever occurs first Hours TIS Engine start/stop cycles (1) 204-011-121-009 4000 400 1600 (2) 204-011-121-121 500 150 600 (3) 204-011-121-005, or −113 if the grip was EVER installed on a Model 205B helicopter 4000 400 1600 (4) 204-011-121-117 if the grip was NEVER installed on a Model 205B helicopter 4000 150 600 (5) 204-011-121-117 if the grip was EVER installed on a Model 205B helicopter 500 150 600 (6) 204-011-121-009 if the grip is installed on a Model 205A-1 helicopter modified in accordance with STC SH5132NM 4000 400 1600 (7) 204-011-121-121 if the grip is installed on a Model 205A-1 helicopter modified in accordance with STC SH5132NM 500 150 600 The UT inspection of the grip must be performed by a Non-Destructive Testing (NDT) UT Level I Special, Level II, or Level III inspector who is qualified under the guidelines established by MIL-STD-410E, ATA Specification 105, AIA-NAS-410, or an FAA-accepted equivalent for qualification standards of NDT Inspection/Evaluation Personnel. Note 2: You can find the Nondestructive Inspection Procedure attached to BHTI Alert Service Bulletin (ASB) 205B-02-39, Revision B, dated November 22, 2002, or BHTI ASB 212-02-116, Revision A, dated October 30, 2002. (d) At intervals not to exceed 1200 hours TIS or 24 months, whichever occurs first: (1) Remove each main rotor blade, and (2) Inspect each grip buffer pad on the inner surfaces of each grip tang for delamination (see Figure 1 of this AD). If there is any delamination, remove the buffer pad and inspect the grip surface for corrosion or other damage. Note 3: This inspection interval coincides with the main rotor tension-torsion strap replacement times. (e) Within 2400 hours TIS or at the next overhaul of the main rotor hub, whichever occurs first, and thereafter at intervals not to exceed 2400 hours TIS: (1) Remove each main rotor blade. (2) Remove each grip buffer pad (if installed) from the inner surfaces of each grip tang. (3) Inspect the grip surfaces for corrosion or other damage. (4) Fluorescent-penetrant inspect (FPI) the grip for a crack, paying particular attention to the upper and lower grip tangs. When inspecting grips, P/N 204-011-121-005, -09, and -113, pay particular attention to the leading and trailing edges of the grip barrel. Note 4: FPI procedures are contained in BHTI's Standard Practices Manual, BHT-ALL-SPM. (f) Before further flight: (1) Replace with an airworthy grip any grip with a crack. (2) Replace with an airworthy grip or repair, if within maximum repair damage limits, any grip with any corrosion or other damage. Note 5: The maximum repair damage limitations are found in the applicable Component and Repair Overhaul Manual. Note 6: BHTI Operations Safety Notice 204-85-6, 205-85-9 and 212-85-13, all dated November 14, 1985, and BHTI ASB 212-94-92, Revision A, dated March 13, 1995, also pertain to the subject of this AD. (g) Within 24 hours for any grip found with a crack and within 7 days for any grip inspected per paragraph (e) of this AD, report to the FAA Rotorcraft Certification Office the information requested in Appendix 1 to this AD. The information collection requirements of this AD have been approved by the Office of Management and Budget (OMB) under the provisions of the Paperwork Reduction Act of 1980 (44 U.S.C. 3501 et seq. ) and have been assigned OMB Control Number 2120-0056. (h) 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 Certification Office, Rotorcraft Directorate, FAA. Operators shall submit their requests through an FAA Principal Maintenance Inspector, who may concur or comment and then send it to the Manager, Rotorcraft Certification Office. Note 7: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Rotorcraft Certification Office. (i) Special flight permits may be issued in accordance with 14 CFR 21.197 and 21.199 to operate the helicopter to a location where the requirements of this AD can be accomplished. (j) The inspections shall be done in accordance with the Bell Helicopter Textron Nondestructive Inspection Procedures of Log No. 00-340, Rev. E, dated April 9, 2002. 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. (k) This amendment becomes effective on January 30, 2003. Appendix 1 to AD 2003-01-04 AD Compliance Inspection Report (Sample Format) Provide the following information and mail or fax it to: Manager, Rotorcraft Certification Office, Federal Aviation Administration, Fort Worth, Texas, 76193-0170, USA, Fax: 817-222-5783. Aircraft Registration No: Helicopter Model: Helicopter Serial Number: Owner and Operator of the Helicopter: Contact Phone Number: Grip Part Number: Grip Serial Number: Grip Total Hours Time-in-Service (TIS) at Inspection: Grip Hours TIS since Overhaul: Grip Start/Stop Cycles and Associated Hours TIS since Last Reported: Description of Findings Who performed the inspection? Date and location the inspection was performed: Crack Found (Y/N)? If yes, describe the crack size, location, orientation (provide a sketch or pictures with the grip part and serial numbers). Which inspection was being performed when the crack was discovered? Has the grip ever been installed on another model helicopter? If so, provide the models and associated hours. Provide any other comments. Issued in Fort Worth, Texas, on December 31, 2002. David A. Downey, Manager, Rotorcraft Directorate, Aircraft Certification Service. [FR Doc. 03-328 Filed 1-14-03; 8:45 am] BILLING CODE 4910-13-P