MANDATORY SERVICE BULLETIN

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AF-SB-1102 MANDATORY SERVICE BULLETIN Page 1 of 5 EFFECTIVITY: BELL 206 & 206L SERIES HELICOPTERS EQUIPPED WITH AIRFILM CAMERA SYSTEMS G1 UTILITY MOUNT SUBJECT: MANDATORY INSPECTION AND MODIFICATION OF NOSE CONSOLE AT G1 MOUNT FASTENERS DATE: 1/05/2015 1.0 REASON Mandatory inspection for cracks on the Nose Console Flange at the forward G1 mount fasteners. 2.0 DESCRIPTION Instances of cracking have been found on the Bell 206 airframe at the Airfilm G1 Utility Mount forward fasteners location. This bulletin describes the internal airframe inspection and subsequent repair and modification required for continued safe operation of the G1 Mount. 3.0 COMPLIANCE MANDATORY – Within the next 40 flight hours 4.0 MANPOWER Inspection: Estimated 3 man-hours Repair: Estimated 20 man-hours 5.0 WEIGHT AND BALANCE N/A 6.0 MATERIALS Inspection: ½” Socket, Flashlight, Inspection Mirror, 10X Magnifying Lens, Measuring Device (Scale, or Calipers) Capable of 2 Place (X.XX inch) Dimensional Accuracy. Repair/Modification: Standard sheet metals tools, standard riveting tool, marking pen, #30 Drill, #4 Clecos, Airfilm modification kit P/N G1-201-1 7.0 REFERENCES STC No. SR01654LA – G1 Utility Mount, Airfilm Camera Systems AF-G1-006 – Installation Instructions, G1 Utility Mount. AF-G1-008 – Instructions for Continued Airworthiness, G1 Utility Bracket AF-G1-300 - Repair Drawing, Bell 206 Nose Console AF-G1-400 - Modification Drawing, Bell 206 Nose Console G1-201 – Modification Kit FAA APPROVED AF-SB-1102 MANDATORY SERVICE BULLETIN Page 2 of 5 8.0 ACCOMPLISHMENT INSTRUCTIONS (1) Remove G1-1 Utility Mount to gain access to the Internal Nose Console (airframe) by removing the 8 AN3 mounting bolts on the outboard upper flanges of the G1 Mount. Reference Install Instruction (AF-G1-006) for detailed description of removal procedures. Figure 1 G1 Mount Fastener Locations NOTE Washers may be present as shims between G1 mount and airframe. Note the location and quantity of the shims for reinstallation. NOTE Ensure that standard practices per AC43.13-1B and manufacturer’s manuals are complied with. AN3 mount bolts (8 places). Washers may be present between mount and the airframe. FWD Nose Mount Fasteners (2X) FAA APPROVED AF-SB-1102 MANDATORY SERVICE BULLETIN Page 3 of 5 (2) Once the G1 Mount is removed, gain access to the internal nose console structure near the forward G1’s forward fasteners location. Figure 2 View (looking Down) Showing the LH Side Forward Fastener with Crack Damage (3) Inspect for cracks in the Nose Console area at the G1 mount forward fastener nutplates (RH & LH sides). Figure 3 shows a typical crack near the nutplate at the radius of the formed flange. Use 10X magnified visual inspection or fluorescent penetrant inspection (per ASTM E1417) to inspect for cracks in the areas noted. FWD Nose Mount Fastener Nutplate. (most forward nutplate) 6013-T6 Skin .02 thick Crack FWD INBD FAA APPROVED AF-SB-1102 MANDATORY SERVICE BULLETIN Page 4 of 5 (4) If no cracks are found, proceed to step 5. If cracks are present, repair in accordance with Airfilm Drawing AF-G1-300. Figure 3 View Showing the Repair Fitting Installed (RH Side) (5) If no cracks are found, install Airfilm modification kit P/N G1-201-1 in accordance with Airfilm Drawing AF-G1-400. (6) Before reinstalling the G1 Utility Mount, perform 1000 hr inspection on the G1 Mount Assembly in accordance with AF-G1-008 (ICA) as noted below. CAUTION If the damage is outside the maximum damage criteria defined in the repair drawing, contact Airfilm Camera Systems for Engineering Support. WARNING If any cracks or loose rivets are found during this inspection, the aircraft must be repaired before returning to service. Forward FAA APPROVED AF-SB-1102 MANDATORY SERVICE BULLETIN Page 5 of 5 The mount must be removed from the helicopter and disassembled. FITTING INSPECTIONS Inspect. Interval Hours Inspection Maintenance Personnel Initial 1000 Visually inspect bolt holes for damage | Visually inspect brackets for cracks, nicks or deep scratches INSPECTION LIMITS The G1-1 Universal Mount is to be removed from service and returned to Airfilm Camera Systems if the following inspection limits are exceeded. Cracks: Any indication Bolt hole elongation: Any Indication Dents, scratches or nicks: Greater than 0.010 inches (7) Reinstall the G1 Utility Mount in accordance with Airfilm Camera Systems Installation Instructions AF-G1-006. 9.0 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS The structural repair/modification and adjacent structure identified in this Bulletin should be visually inspected 100 flight-hours after installation. After the initial inspections, the repair should be inspected in the same interval as the STC’ed Airfilm Nose Mount. The inspection should verify that there are no cracks, or loose rivets in the repair and the adjacent structure. Special attention should be given to the formed radius in the original skin, forward of the repair. Airfilm Camera Systems Support Contact: (530) 333-0193 info@airfilm.com FAA APPROVED .25 2.0 MAX .75 MAX SECTION D-D INSTALL SHIM A/R TO ALLOW DOUBLER TO INSTALL ON TOP OF STIFFENER FLANGE SHOW DAMAGE LIMITS DOUBLER FITTING REMOVED TO SECTION B-B DAMAGE AREA FORWARD C J. MUELLER D C B A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 F E F A DO NOT SCALE DRAWING TREAT EFFECTED AIRFRAME AND REPAIR COMPONENTS FOR CORROSION PREVENTION IAW BTH-ALL-SPM. SHEET 1 OF 1 12. www.airfilm.com Georgetown CA 12/1/2015 AF-G1-300 N/C Airfilm Camera Systems INSTALL SHIMS, REPAIR FITTING, AND RIVETS WET WITH CORROSION INHIBITING SEALANT (P/S 890 OR EQUIVALENT). 13. INCHES SCALE 1:3 REV DWG. NO. SIZE TITLE: NAME DATE APPROVED CHECKED DRAWN DIMENSIONS ARE IN NOTED ALL UNLESS OTHERWISE .X USE MS20426AD4 RIVETS FOR FLUSH INSTALLATION ON THE EXTERIOR AND MS20470AD4 (OR CR3213-4) RIVETS IN WEB. 14. TOLERANCES: .XX .1 .03 PROPRIETARY NOTICE .5 ANGULAR: .010 OR ITEMS DISCLOSED. BASIS FOR MANUFACTURING OR SALE OF THE ITEM