87-11-05 R4: Components Fatigue Failure

87-11-05 BOEING VERTOL COMPANY (VERTOL) AND KAWASAKI HEAVY INDUSTRIES, LTD.: Amendment 39-5591. Applies to Model 107-II helicopters and Kawasaki Model KV107-II and IIA helicopters, certificated in any category. Compliance is required within the next 100 hours' time in service after the effective date of this AD, unless already accomplished. (a) To prevent hazards in flight associated with the fatigue failure of life limited components, the following retirement lives are imposed: LIFE LIMIT COMPONENT PART PART NUMBER HOURS APPENDIX Alum Synch 107D3141 9,940 Shaft Assembly 107D3341 9,940 Steel Synch 107D3140 7,850 Shaft Assembly 107D3340 7,850 A15D3840-1 24,750 Synchronizing 107D3154-2 500 No. 1 Shaft Splined 107D3154-3, -4 3,000 Adapter 107D3144-1 14,615 Mix Box 107D2066-10 11,075 Collector Gear thru -28 Fwd Rotor Shaft A02D1259-3 2,100 and Carrier Assy A02D1269-1 2,100A07D1269-1 2,100 A02D1259-3SP 13,580 A02D1269-1SP 13,580 A07D1269-1SP 13,580 A02D1269-2 13,580 Quill Shaft 107D2067-1, 5,620 No. 2 -3, -5 Aft Transmission 107D2419 or 8,700 Planet Carrier A02D2419 Aft Rotor Drive Shaft upper extension A02D3147 7,200 Aft Rotor Shaft 107D3171-2, -3, -4, -5 15,860 Lower Section A2D3171-3, -4, -6 15,860 Aft Rotor Shaft 107D3151 19,140 Center Section A02D3151 19,140 Fwd Hub 107R2550 2,500/1,200 No. 3 Aft Hub 107R2550 10,460/3,000 Fwd and Aft 107R2551-1 or 6,610 Connecting Link A02R2551-8 Fwd and Aft Hub A02R2589-3 25,140 Horizontal Hinge Pin 107R2589-3 25,140 Fwd and Aft Lag Damper Piston 107R2601-1 4,670 Rod End APPENDICES: No. 1. Synchronizing shaft splined adapter, Part Number (P/N) 107D3154-2, shall be repetitively inspected as specified in Boeing Vertol (BV) Service Bulletin 107-116 (R-1), Revision B, dated February 21, 1983, or FAA-approved equivalent. P/N 107D3154-3 and -4 require repetitive visual and dye check inspections as specified in the BV107-6 Maintenance Schedule, Section 2, dated February 7, 1986, and Service Bulletin 107-116 (R-1)B. No. 2. Quill shaft, P/N 107D2067-1, has a life limit of 120 hours unless the modifications specified in paragraph (e) of AD 63-24-04 revised October 15, 1964, Amendment 648 of Part 507 (28 FR 12614) as amended by Amendment 821 of Part 507 (29 FR 14169) are accomplished. (Also, reference Boeing Service Bulletins 107-113, Revision A, dated November 22, 1963, and 107-182, Revision B, dated July 26, 1965.) No. 3. The life limit for the forward rotor hub spline is 2,500 hours. After 2,500 hours of service, the hub is to be magnetic particle inspected. If found to be free of cracks and not having a wear step on the profile face of the spline in excess of 0.002 inch, the hub may be inverted and installed on the aft rotor head for an additional 3,000 hours of use. On completion of the additional 3,000 hours, the hub is to be retired from service. The life limit for the aft rotor hub spline is 10,460 hours. After 10,460 hours of use, the hub is to be magnetic particle inspected. If found to be free of cracks and not having a wear step on the profile face of the spline in excess of 0.002 inch, the hub may be inverted and installed on the forward rotor head for an additional 1,200 hours of use. On completion of the additional 1,200 hours, the hub is to be retired from service. (An acceptable procedure for measuring the 0.002-inch step wear is contained in Boeing Vertol Overhaul Manual 107-5, Chapter 60-20-1.) Inverting and switching of main rotor hubs are permitted to the life limit stated above any number of times provided accurate records are maintained of the total hours the hubs are installed on an aft head and on a forward head. (b) An alternate method of compliance or adjustment of the compliance time, which provides an equivalent level of safety, may be used when approved by the Manager, New York Aircraft Certification Office, FAA, New England Region, 181 South Franklin Avenue, Room 202, Valley Stream, New York 11581. (c) Aircraft may be ferried to a base in accordance with FAR Sections 21.197 and 21.199 where compliance can be accomplished. The repair and inspection procedures in Boeing Vertol (BV) Service Bulletin (SB) 107- 113, Revision A, dated November 22, 1963; BV SB 107-116 (R-1), Revision B, dated February 21, 1983; BV SB 107-182, Revision B, dated July 26, 1965, and BV 107-6 Maintenance Schedule, Section 2, temporary Revision 31, dated February 7, 1986, incorporated by reference in this directive were approved by the Director of the FEDERAL REGISTER pursuant to 5 U.S.C. 552(a)(1). Copies may be obtained from Boeing Vertol Company, Boeing Center, P.O. Box 16858, Philadelphia, Pennsylvania 19142. These documents may be examined at the Office of the Regional Counsel, FAA, Southwest Region 4400 Blue Mound Road, Fort Worth, Texas 76106 or the Office of the Federal Register, 1100 L Street, NW., Room 8401, Washington, D.C. This amendment supersedes the following: Amendment 656 of Part 507 (28 FR 13931) as amended by Amendment 39-107 (30 FR 8963), AD 63-26-04; Amendment 39-2993 (42 FR 38803), AD 77-16-03; Amendment 39-3746 (45 FR 25050), AD 80-08-11; Amendment 39-4522 (47 FR 57484), AD 82-27-06; and Amendment 39-4757 (48 FR 50069), AD 83-22-02. This amendment, 39-5591, becomes effective May 14, 1987.