AD 2021-07-05 Airworthiness Directives; Leonardo S.p.a. (Type Certificate Previously Held by Agusta S.p.A.) (Leonardo) Helicopters

Models named: A109C, A109E, A109K2. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to Leonardo Model A109C, A109E, and A109K2 helicopters, certificated in any category, with a main rotor blade (MRB) part number (P/N) 709-0103-01-all dash numbers installed.

Comply with this AD within the compliance times specified, unless already done.

(1) For an MRB with a serial number that has a prefix of either “EM-” or “A5-”, except an MRB with a tip cap P/N 709-0103-29-109 installed, within 10 hours time-in-service (TIS) after the effective date of this AD, unless accomplished previously, and thereafter at intervals not to exceed 25 hours TIS: (i) Tap inspect the upper and lower sides of each tip cap for bonding separation between the metal shells and the honeycomb core using a steel hammer P/N 109-3101-58-1 or a coin (quarter) in the area indicated as honeycomb core on Figure 1 of Agusta Alert Bollettino Tecnico (BT) No. 109-106, BT No. 109K-22, or BT No. 109EP-1, each Revision B and each dated December 19, 2000 (BT No. 109-106, BT No. 109K-22, or BT No. 109EP-1), as applicable to your helicopter model. Also, tap inspect for bonding separation in the tip cap to blade bond area (no bonding voids are permitted in this area). (ii) Visually inspect the upper and lower sides of each blade tip cap for swelling or deformation. (iii) Dye-penetrant inspect the tip cap leading edge along the welded joint line of the upper and lower tip cap skin shells for a crack in accordance with the Compliance Instructions, steps 3. through 3.2.6., of BT No. 109-106, BT No. 109K-22, or BT No. 109EP-1, as applicable to your helicopter model. (iv) If there is any swelling, deformation, or crack; or bonding separation that exceeds allowable limits, remove the blade from service before further flight. (v) If there is no swelling, deformation or crack; or if bonding separation does not exceed allowable limits, continue to perform the inspections required by this AD. (2) For an MRB with a tip cap P/N 709-0103-29-109 installed, perform the following at the specified intervals: (i) For each tip cap with less than 600 hours TIS, before reaching 600 hours TIS, and thereafter, at intervals not to exceed 50 hours TIS or (ii) For each tip cap with 600 or more hours TIS, within the next 5 hours TIS or 30 days after the effective date of this AD, whichever occurs first, and thereafter at intervals not to exceed 50 hours TIS. (A) Dye-penetrant inspect the welded bead on the tip cap leading edge (joint line between the two metal shells) for a crack in accordance with the Accomplishment Instructions, steps 3.1 through 3.6, of Leonardo Helicopters Alert Service Bulletin (ASB) No. 109-125, ASB No. 109EP-085, or ASB No. 109K-048, each at Revision A and each dated October 19, 2020, as applicable your helicopter model. (B) If there is a crack, remove the tip cap from service before further flight. (3) As of the effective date of this AD, do not install any MRB with tip cap P/N 709-0103-29-109 on any helicopter unless it has been inspected in accordance with the inspection requirements of this AD.

This AD was prompted by reports of the in-flight loss of tip caps. The FAA is issuing this AD to prevent loss of a tip cap from an MRB. The unsafe condition, if not addressed, could result in an increase in MRB vibration and subsequent loss of control of the helicopter.

This AD replaces AD 2007-26-52, Amendment 39-15519 (73 FR 26316, May 9, 2008).