AD 2011-06-07

To prevent an uncommanded in-flight deployment of the emergency flotation gear, unexpected deceleration and pitch down movement of the helicopter, and subsequent loss of control of the helicopter, do the following:

(a) Determine whether the 1G unit has an asterisk (*) after the P/N displayed on the 1G unit panel as shown in Figure 4 of Eurocopter Emergency Alert Service Bulletin No. 25A037, dated April 27, 2010 (EASB).

(b) If there is an asterisk after the P/N displayed on the 1G unit panel, determine if there is a rubber extrusion installed on the stringer as shown in Figure 6 of the EASB.

(1) If no rubber extrusion is installed on the stringer, remove the 1G unit by following the Accomplishment Instructions, paragraph 2.B.2.a. of the EASB.

(2) Bond a rubber extrusion onto the stringer using Bostik 1400 or an equivalent adhesive. Bostik 1400 is ready for use; if using an equivalent adhesive, follow the manufacturer's directions for preparation and application.

(i) Thoroughly clean the bonding surfaces of the stringer; remove all traces of grease.

(ii) Apply a uniform adhesive film on the bonding surfaces.

(A) For Bostik 1400, allow to dry until tack free (about 15 minutes).

(B) For equivalent adhesive, follow the manufacturer's procedures.

(iii) After adhesive application, assemble the bonding faces and press firmly to eliminate air bubbles. Maintain the pressure throughout the hardening period as described for the adhesive being used. For Bostik 1400, the adhesive hardens in about 48 hours at room temperature.

(3) Reinstall the 1G unit by following the Accomplishment Instructions, paragraph 2.B.2.b., of the EASB. Functionally test the emergency flotation gear control system.

(c) If there is no asterisk displayed after the P/N on the 1G unit panel, remove the 1G unit by following the Accomplishment Instructions, paragraph 2.B.2.a., of the EASB.

(1) Inspect the 1G unit for interference:

(i) If you find interference between the harness wires and the stringer, install a sheath, P/N EN6049-006-08-5, on all the harnesses in the area of the interference, and secure the sheath with cable ties as depicted in Figure 5 of the EASB.

(ii) If you find interference between the harness wires and the inside surface of the 1G unit or with any of the 1G unit's internal components, remove the installed cable ties, P/N E0043-1A0P, and spacer(s), P/N E0688-01, as required, to allow repositioning or routing of the harness to eliminate interference. Secure repositioned harnesses using new cable ties, P/N E0043-1A0P, and new spacers, P/N E0688-01.

(iii) If you find interference between the harness and the helicopter structural stringer, install a sheath, P/N EN6049-006-08-5, on all the harnesses located at the stringer as depicted in Figures 5 and 6 of the EASB. Secure the sheath with cable ties, P/N E0043-1A0P, so that no interference between the sheathed harness and the structural stringer exists.

(iv) Bond a black rubber extrusion, P/N BT4, on the stringer as shown in Figure 6 by following the requirements of paragraph (b)(2) of this AD.

(2) Inspect the attachment screw of cable 1GR19E for orientation and arrangement that matches the Post EASB detail, as shown in insert D of Figure 5 of the EASB, and determine if it is covered with heat shrink, P/N VG95343T05E004A, or equivalent. If orientation and arrangement of the attachment screw cable 1GR19E are not as shown in insert D of Figure 5 or the attachment screw is not covered with heat shrink, modify the attachment screw by following the Accomplishment Instructions, paragraph 2.B.5.b., of the EASB.

Note 1. Figure 5 of the EASB does not show the heat shrink installed for clarity of screw head and lug detail.

(3) Inspect for damage to a wire of the harness inside the 1G unit as depicted in Figure 7 of the EASB. Replace any damaged wire using the correct wire and contact information listed in the Appendix, paragraph 4, of the EASB.

(4) Mark an asterisk “*” after P/N 350A63256300 on the 1G unit panel using indelible ink to indicate compliance with this AD.

(5) Reinstall the 1G unit by following the Accomplishment Instructions, paragraph 2.B.2.b., of the EASB, and functionally test the emergency flotation gear control system.

(d) Installing an airworthy 1G unit that has been modified and identified as required by this AD is terminating action for the requirements of this AD.

(e) To request a different method of compliance or a different compliance time for this AD, follow the procedures in 14 CFR 39.19. Contact the Manager, Safety Management Group, FAA, Attn: George Schwab, Aviation Safety Engineer, Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, Texas 76137, telephone (817) 222-5114, fax (817) 222-5961, for information about previously approved alternative methods of compliance.

(f) The Joint Aircraft System/Component (JASC) Code is 2497: Electrical Power System Wiring.

(g) Remove and install the 1G unit, determine the correct wire and contact information, and do the inspections by following the specified portions of Eurocopter Emergency Alert Service Bulletin No. 25A037, dated April 27, 2010. The Director of the Federal Register approved this incorporation by reference in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from American Eurocopter Corporation, 2701 Forum Drive, Grand Prairie, TX 75053-4005, telephone (800) 232-0323, fax (972) 641-3710, or at http://www.eurocopter.com. 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 National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.