AD 2002-06-52

[Federal Register Volume 67, Number 74 (Wednesday, April 17, 2002)]
[Rules and Regulations]
[Pages 18815-18817]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 02-9173]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-SW-08-AD; Amendment 39-12711; AD 2002-06-52]
RIN 2120-AA64


Airworthiness Directives; Bell Helicopter Textron Canada Model 
407 Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

-----------------------------------------------------------------------

SUMMARY: This document publishes in the Federal Register an amendment 
adopting Airworthiness Directive (AD) 2002-06-52, which was sent 
previously to all known U.S. owners and operators of Bell Helicopter 
Textron Canada (BHTC) Model 407 helicopters by individual letters. This 
AD requires a one-time replacement of certain bearings and, before 
further flight, adding a limitation and caution to the rotorcraft 
flight manual (RFM) and at specified intervals, inspecting, replacing, 
and lubricating certain oil cooler blower bearings. This AD is prompted 
by several occurrences of failure of an oil cooler blower bearing. The 
actions specified by this AD are intended to prevent failure of an oil 
cooler blower bearing, loss of tail rotor drive, and a subsequent 
forced landing.

DATES: Effective May 2, 2002, to all persons except those persons to 
whom it was made immediately effective by Emergency AD 2002-06-52, 
issued on March 15, 2002, which contained the requirements of this 
amendment.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of May 2, 2002.
    Comments for inclusion in the Rules Docket must be received on or 
before June 17, 2002.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Office of the Regional Counsel, Southwest Region, 
Attention: Rules Docket No. 2002-SW-08-AD, 2601 Meacham Blvd., Room 
663, Fort Worth, Texas 76137. You may also send comments electronically 
to the Rules Docket at the following address: <a href="/cdn-cgi/l/email-protection#e7deca869490ca868384888a8a82899394a7818686c9808891"><span class="__cf_email__" data-cfemail="40796d2133376d2124232f2d2d252e3433002621216e272f36">[email&#160;protected]</span></a>.
    The applicable service information may be obtained from Bell 
Helicopter Textron Canada, 12,800 Rue de l'Avenir, Mirabel, Quebec 
J7J1R4, telephone (450) 437-2862 or (800) 363-8023, fax (450) 433-0272. 
This information may be examined at the FAA, Office of the Regional 
Counsel, Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth, 
Texas; or at the Office of the Federal Register, 800 North Capitol 
Street, NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Paul Madej, Aviation Safety Engineer, 
FAA, Rotorcraft Directorate, Rotorcraft Standards Staff, Fort Worth, 
Texas 76193-0110, telephone (817) 222-5125, fax (817) 222-5961.

SUPPLEMENTARY INFORMATION: On February 10, 2000, the FAA issued Final 
Rule AD 2000-02-12 (65 FR 8032, February 17, 2000), to require 
inspecting each oil cooler blower bearing (bearing) for roughness and 
replacing any rough bearing before further flight. That AD was prompted 
by reports of failure of the bearing. Since the issuance of that AD, 
continued bearing failures and identifications of effects of engine 
exhaust gas ingestion have been reported. On March 15, 2002, the FAA 
issued superseding Emergency AD 2002-06-52 for BHTC Model 407 
helicopters. That emergency AD requires a one-time replacement of 
certain bearings within 100 hours time-in-service, and before further 
flight, adding a limitation and caution to the RFM and at specified 
intervals, inspecting and, if necessary, replacing certain bearings and 
lubricating certain bearings. That action was prompted by several 
occurrences of failure of an oil cooler blower bearing. Particular 
tailwind conditions during flight can result in engine exhaust gas 
ingestion by the oil cooler blower and deterioration of the bearing 
grease. This condition, if not corrected, could result in bearing 
failure, loss of tail rotor drive, and a subsequent forced landing.
    The FAA has reviewed Bell Helicopter Textron Alert Service Bulletin 
(ASB) Nos. 407-01-44, Revision A, dated October 25, 2001; 407-01-47, 
dated November 9, 2001; and 407-02-49, dated January 7, 2002. ASB 407-
01-44, Revision A, dated October 25, 2001, specifies replacing specific 
oil cooler blower bearings and clarifies and expands the bearing 
lubrication procedure and schedule. ASB 407-01-47, dated November 9, 
2001, updates the inspection and lubrication procedures and schedule 
for specified bearings at all oil cooler blower and tail rotor 
driveshaft locations. ASB 407-02-49, dated January 7, 2002, introduces 
a new limitation and a new caution for tailwind operations in the RFM 
and maintenance actions for exceeding the limitations.
    Transport Canada, which is the airworthiness authority for Canada, 
notified the FAA that an unsafe condition may exist on this helicopter 
model. Transport Canada advises that testing indicates premature 
failure of an oil cooler blower bearing can occur, under certain 
conditions, due to ingesting exhaust gases into the aft fairing inlet 
resulting in elevated temperatures. Also, Transport Canada advises that 
research indicates that over-greasing the bearing can result in 
elevated bearing temperatures and failure of a bearing. Transport 
Canada classified the service bulletins as mandatory and issued AD No. 
CF-2002-18, dated March 4, 2002, to ensure

[[Page 18816]]

the continued airworthiness of these helicopters.
    This helicopter model is manufactured in Canada and is type 
certificated for operation in the United States under the provisions of 
14 CFR 21.29 and the applicable bilateral agreement. Pursuant to the 
applicable bilateral agreement, Transport Canada has kept the FAA 
informed of the situation described above. The FAA has examined the 
findings of Transport Canada, reviewed all available information, and 
determined that AD action is necessary for products of this type design 
that are certificated for operation in the United States.
    This unsafe condition is likely to exist or develop on other BHTC 
Model 407 helicopters of the same type design registered in the United 
States. Therefore, the FAA issued Emergency AD 2002-06-52 to prevent 
failure of an oil cooler blower bearing, loss of tail rotor drive, and 
a subsequent forced landing. The AD requires:
    <bullet> Before further flight, adding the tailwind limitation and 
caution contained in Temporary Revision 9 (the temporary revision is 
attached to ASB 407-02-49, dated January 7, 2002) to the RFM.
    <bullet> At specified intervals, inspecting the oil cooler blower 
bearings; and if a bearing is rough, a seal is torn, the expelled 
grease has turned black, or metal particles are visible in the expelled 
grease, replacing the affected bearing before further flight.
    <bullet> At a specified time-in-service, replacing certain 
bearings.
    <bullet> At specified intervals, lubricating the bearings.
    The actions must be accomplished in accordance with the ASBs 
described previously. The short compliance time involved is required 
because the previously described critical unsafe condition can 
adversely affect the structural integrity and controllability of the 
helicopter. Therefore, the actions previously described are required at 
the specified time intervals, and this AD must be issued immediately.
    Since it was found that immediate corrective action was required, 
notice and opportunity for prior public comment thereon were 
impracticable and contrary to the public interest, and good cause 
existed to make the AD effective immediately by individual letters 
issued on March 15, 2002, to all known U.S. owners and operators of 
BHTC Model 407 helicopters. These conditions still exist, and the AD is 
hereby published in the Federal Register as an amendment to 14 CFR 
39.13 to make it effective to all persons.
    The FAA estimates that 281 helicopters of U.S. registry will be 
affected by this AD. It will take approximately 1 work hour for each 
RFM revision; 2 work hours per helicopter for the initial inspection; 
0.5 hour for each repetitive inspection; 0.5 hour to lubricate the oil 
cooler blower bearing; and 4 work hours per helicopter to replace the 
oil cooler blower bearing. Required parts will cost approximately 
$1,926 per helicopter. Based on these figures, the total cost impact of 
the AD on U.S. operators is estimated to be $996,426, assuming 20 
repetitive inspections and 20 bearing lubrications on each helicopter 
and bearing replacement on all the helicopters in the fleet.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available in the Rules Docket for examination by interested persons. A 
report that summarizes each FAA-public contact concerned with the 
substance of this AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their mailed 
comments submitted in response to this rule must submit a self-
addressed, stamped postcard on which the following statement is made: 
``Comments to Docket No. 2002-SW-08-AD.'' The postcard will be date 
stamped and returned to the commenter.
    The regulations adopted herein will not have a substantial direct 
effect on the States, on the relationship between the national 
Government and the States, or on the distribution of power and 
responsibilities among the various levels of government. Therefore, it 
is determined that this final rule does not have federalism 
implications under Executive Order 13132.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and that it is not a ``significant regulatory 
action'' under Executive Order 12866. It has been determined further 
that this action involves an emergency regulation under DOT Regulatory 
Policies and Procedures (44 FR 11034, February 26, 1979). If it is 
determined that this emergency regulation otherwise would be 
significant under DOT Regulatory Policies and Procedures, a final 
regulatory evaluation will be prepared and placed in the Rules Docket. 
A copy of it, if filed, may be obtained from the Rules Docket at the 
location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by adding a new airworthiness directive 
to read as follows:

2002-06-52  Bell Helicopter Textron Canada: Amendment 39-12711. 
Docket No. 2002-SW-08-AD. Supersedes AD 2000-02-12, Docket No. 99-
SW-79-AD, Amendment 39-11579.

    Applicability: Model 407 helicopters, with oil cooler blower 
bearing, part number (P/N) 406-040-339-ALL, 407-340-339-101 or -103, 
installed, certificated in any category.

    Note 1: This AD applies to each helicopter identified in the 
preceding applicability provision, regardless of whether it has been 
otherwise modified, altered, or repaired in the area subject to the 
requirements of this AD. For helicopters that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in

[[Page 18817]]

accordance with paragraph (f) of this AD. The request should include 
an assessment of the effect of the modification, alteration, or 
repair on the unsafe condition addressed by this AD; and if the 
unsafe condition has not been eliminated, the request should include 
specific proposed actions to address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent oil cooler blower bearing failure, loss of tail rotor 
drive, and a subsequent forced landing, accomplish the following:
    (a) Before further flight, insert the tailwind limitation and 
caution, contained in Temporary Revision (TR) 9, dated January 15, 
2002, into the Bell Model 407 Rotorcraft Flight Manual (RFM), dated 
February 9, 1996.

    Note 2: TR 9 is attached to Bell Helicopter Textron (BHT) Alert 
Service Bulletin (ASB) 407-02-49, dated January 7, 2002.

    (b) Within 10 hours time-in-service (TIS), inspect the forward 
and aft oil cooler blower bearings by hand-rotating the driveshaft 
with the oil cooler driveshaft connected. If a bearing is rough, a 
seal is torn, the expelled grease has turned black, or metal 
particles are visible in the expelled grease, replace the affected 
bearing before further flight.
    (c) At intervals not to exceed 25 hours TIS, for oil cooler 
blower bearings, P/N 406-040-339-ALL and 407-340-339-103:
    (1) Inspect the bearings by hand-rotating the driveshaft in 
accordance with the Accomplishment Instructions, Part I, paragraph 
2, of BHT ASB 407-01-47, dated November 9, 2001 (ASB 407-01-47). If 
a bearing is rough, a seal is torn, the expelled grease has turned 
black, or metal particles are visible in the expelled grease, 
replace the affected bearing before further flight.
    (2) Lubricate the bearings in accordance with the Accomplishment 
Instructions, Part II, paragraph 2, of ASB 407-01-47.
    (d) For oil cooler blower bearings, P/N 407-340-339-101:
    (1) At intervals not to exceed 25 hours TIS, inspect the 
bearings by hand-rotating the driveshaft in accordance with the 
Accomplishment Instructions, Part II, paragraph 1, of BHT ASB 407-
01-44, Revision A, dated October 25, 2001 (ASB 407-01-44, Revision 
A). If a bearing is rough, a seal is torn, the expelled grease has 
turned black, or metal particles are visible in the expelled grease, 
replace the affected bearing before further flight.
    (2) At intervals not to exceed 100 hours TIS, lubricate the 
bearings in accordance with the Accomplishment Instructions, Part 
III, paragraphs 1 and 2, of ASB 407-01-44, Revision A.
    (e) Within 100 hours TIS, replace the forward and aft oil cooler 
blower bearings, P/N 406-040-339-ALL and 407-340-339-103, if 
installed, with airworthy bearings, P/N 407-340-339-101. Continue to 
inspect and lubricate the bearings in accordance with paragraph (d) 
of this AD.
    (f) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Regulations Group, Rotorcraft 
Directorate, FAA. Operators shall submit their requests through an 
FAA Principal Maintenance Inspector, who may concur or comment and 
then send it to the Manager, Regulations Group.

    Note 3: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Regulations Group.

    (g) Special flight permits will not be issued.
    (h) The inspections and lubrication of the oil cooler blower 
bearings shall be done in accordance with the Accomplishment 
Instructions, Part I, paragraph 2, of Bell Helicopter Textron Alert 
Service Bulletin 407-01-47, dated November 9, 2001 and Part II, 
paragraph 1, of Bell Helicopter Textron Alert Service Bulletin 407-
01-44, Revision A, dated October 25, 2001. This incorporation by 
reference was approved by the Director of the Federal Register in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be 
obtained from Bell Helicopter Textron Canada, 12,800 Rue de 
l'Avenir, Mirabel, Quebec J7J1R4, telephone (450) 437-2862 or (800) 
363-8023, fax (450) 433-0272. Copies may be inspected at the FAA, 
Office of the Regional Counsel, Southwest Region, Attention: Rules 
Docket No. 2002-SW-08-AD, 2601 Meacham Blvd., Room 663, Fort Worth, 
Texas 76137; or at the Office of the Federal Register, 800 North 
Capitol Street, NW., suite 700, Washington, DC.
    (i) This amendment becomes effective on May 2, 2002, to all 
persons except those persons to whom it was made immediately 
effective by Emergency AD 2002-06-52, issued March 15, 2002, which 
contained the requirements of this amendment.

    Note 4: The subject of this AD is addressed in Transport Canada 
AD CF-2002-18, dated March 4, 2002.


    Issued in Fort Worth, Texas, on April 4, 2002.
David A. Downey,
Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 02-9173 Filed 4-16-02; 8:45 am]
BILLING CODE 4910-13-U