Airworthiness Directive · Amendment 39-17865 · Main rotor head
Bell Helicopter Textron, Inc. (BHTI) Helicopters
This AD applies to the model helicopters listed in Table 1 to Paragraph (a) of this AD with the listed part-numbered main rotor grips installed, certificated in any category:
| Model | With the following grip part number (P/N) |
|---|---|
| 204B | 204-011-121-005 if the grip was ever installed on a Model 205B helicopter. |
| 204B, 205A, and 205A-1 | 204-011-121-009, -117, -121 or ASI-4011-121-9. |
| 205A and 205A-1 | 204-011-121-005 or -113 if the grip was ever installed on a Model 205B helicopter. |
| 205B | 204-011-121-005, -009, -113, -117, or -121. |
| 210 | 204-011-121-009 or -121. |
| 212 | 204-011-121-009, -121, or ASI-4011-121-9. |
We are superseding Airworthiness Directive (AD) 2003-01-04 for BHTI Model 204B, 205A, 205A-1, 205B, and 212 helicopters. AD 2003-01-04 required inspecting the main rotor grip (grip) and reporting certain inspection results to the FAA. AD 2003-01-04 also required performing additional inspections, repair, or replacement depending on whether a crack or delamination was found, and determining and recording the hours time-in-service (TIS) and the engine start/stop cycles for each grip on a component history card or equivalent record. This new AD requires the same actions as AD 2003-01-04 but adds a retirement life to certain grips and expands the applicability to include the Model 210 helicopter and additional part-numbered grips. This AD was prompted by the discovery of additional cracked grips. We are issuing this AD to prevent failure of a grip, separation of a main rotor blade, and subsequent loss of control of the helicopter.
You are responsible for performing each action required by this AD within the specified compliance time unless it has already been accomplished prior to that time.
(1) 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 50 hours TIS for each month for which the hours cannot be determined. 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).
(2) Within 10 hours TIS, and thereafter at intervals not to exceed 25 hours TIS, without removing the main rotor blades:
(i) Clean the exposed surfaces of the upper and lower tangs of each grip with denatured alcohol, and wipe dry.
(ii) 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 as depicted in Figure 1 to Paragraphs (f)(2)(ii) and (f)(4)(ii) of this AD.
(3) At the intervals shown in Table 2 to Paragraph (f)(3) of this AD, ultrasonic (UT) inspect each grip in accordance with the Bell Helicopter Textron Nondestructive Inspection Procedure, Log No. 00-340, Revision E, dated April 9, 2002. 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.
| Within 30 days, or the following hours TIS for the grip, whichever occurs later: | Thereafter, at intervals not to exceed the following hours TIS or engine start/stop cycles, whichever occurs first: | Hours TIS | Engine start/stop cycles |
|---|---|---|---|
| 204-011-121-009 or ASI-4011-121-9 | 4,000 | 400 | 1,600 |
| 204-011-121-121 | 500 | 150 | 600 |
| 204-011-121-005 or -113, if the grip was EVER installed on a Model 205B helicopter | 4,000 | 400 | 1,600 |
| 204-011-121-117, if the grip was NEVER installed on a Model 205B helicopter | 4,000 | 150 | 600 |
| 204-011-121-117, if the grip was EVER installed on a Model 205B helicopter | 500 | 150 | 600 |
Note 1 to Paragraph (f)(3) of this AD: You can find the Nondestructive Inspection Procedure attached to BHTI Alert Service Bulletin (ASB) No. 205B-02-39, Revision B, dated November 22, 2002, or BHTI ASB No. 212 02-116, Revision A, dated October 30, 2002.
(4) At intervals not to exceed 1,200 hours TIS or 24 months, whichever occurs first:
(i) Remove each main rotor blade, and
(ii) Inspect each grip buffer pad on the inner surfaces of each grip tang for delamination as depicted in Figure 1 to Paragraphs (f)(2)(ii) and (f)(4)(ii) of this AD. If there is any delamination, remove the buffer pad and inspect the grip surface for corrosion or other damage.
Note 2 to Paragraph (f)(4) of this AD: This inspection interval coincides with the main rotor tension-torsion strap replacement times.
(5) Within 2,400 hours TIS, or at the next overhaul of the main rotor hub, whichever occurs first, and thereafter at intervals not to exceed 2,400 hours TIS:
(i) Remove each main rotor blade.
(ii) Remove each grip buffer pad (if installed) from the inner surfaces of each grip tang.
(iii) Visually inspect the grip tang surfaces for corrosion or other damage.
(iv) Fluorescent-penetrant inspect the grip for a crack, paying particular attention to the upper and lower grip tangs. When inspecting any grip, P/N 204-011-121-005, -009, -113, or ASI-4011-121-9, pay particular attention to the leading and trailing edges of the grip barrel.
(6) Before further flight:
(i) Replace any cracked grip with an airworthy grip.
(ii) Replace any grip with any corrosion or other damage with an airworthy grip, or repair the grip if the corrosion or other damage is within maximum repair damage limitations.
(iii) Replace any grip, P/N 204-011-121-009 or ASI-4011-121-9, which has been in service for 15,000 or more hours TIS.
(iv) Replace any grip, P/N 204-011-121-121, which has been in service for 25,000 or more hours TIS.
(7) Revise the Airworthiness Limitations sections of the applicable maintenance manuals or the Instructions for Continued Airworthiness (ICAs) by establishing a new retirement life of 15,000 hours TIS for grip P/N 204-011-121-009 or ASI-4011-121-9, and 25,000 hours TIS for grip P/N 204-011-121-121, by making pen and ink changes or inserting a copy of this AD into the applicable maintenance manual or ICAs.
(8) Record a 15,000 hours TIS life limit for each grip P/N 204-011-121-009 or ASI-4011-121-9, and a 25,000 hours TIS life limit for each grip P/N 204-011-121-121, on the applicable component history card or equivalent record.
The aircraft, engines and makers this AD names, by the model designations in its text. A model listed here may still be outside the AD's serial ranges.
