ALERT SERVICE BULLETIN 407-21-123

6 July 2021

MODEL AFFECTED: 407

SUBJECT: TAILBOOM ASSEMBLY, NEW AIRWORTHINESS

LIMITATION SCHEDULE (ALS) INSPECTION
REQUIREMENT.

HELICOPTERS AFFECTED: Serial number 53000 through 53900, 53911

through 54166, and 54300 and subsequent.

COMPLIANCE: PART I: Within 50 flight hours or 30 days, whichever

comes first, following the release date of this bulletin.

PART II: At the next tailboom assembly scheduled

inspection, and every 100 flight hours for tailboom
assemblies identified in Table 1 or every 300 flight
hours for tailboom assemblies identified in Table 2,
thereafter.

DESCRIPTION:

Bell has received a field report indicating an in-service crack on a tailboom lower skin.
The crack was found on the lower aft corner of the left-hand cutout of the horizontal
stabilizer, at Boom Station 120.75. Following analysis, it was determined that the crack
was the result of fatigue which originated from the fastener hole for a nut plate.
This Alert Service Bulletin (ASB) is being published to provide initial and recurring
inspection requirements of the affected tailboom assemblies, which will be incorporated
to Chapter 4 of the 407-MPI Maintenance Planning Information in the Airworthiness
Limitations Schedule (DMC-407-A-04-00-00-00A-288A-A).
PART I of this ASB requires identification of the affected tailboom assembly.
PART II of this ASB provides the requirements for a recurring inspection of affected
tailboom assemblies.
Applicability of this bulletin to any spare part shall be determined prior to its installation
on an affected helicopter.

ASB 407-21-123
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APPROVAL:

The engineering design aspects of this bulletin are Transport Canada Civil Aviation
(TCCA) approved.

CONTACT INFO:

For any questions regarding this bulletin, please contact:

Bell Product Support Engineering

Tel: 1-450-437-2862 / 1-800-363-8023 / [email protected]

MANPOWER:

Approximately 0.25 man-hours are required to complete PART I of this bulletin.

Approximately 1 man-hour is required to complete PART II of this bulletin.
Man-hours are based on hands-on time and may vary with personnel and facilities
available.

WARRANTY:

There is no warranty credit applicable for parts or labor associated with this bulletin.

MATERIAL:

Required Material:

None required.

Consumable Material:

The following material is required to accomplish this bulletin, but may not require
ordering, depending on the operator’s consumable material stock levels. This material
may be obtained through your Bell Supply Center.

Part Number Nomenclature Qty (Note) Reference *

2100-00006-00 Cleaning Compound 5 GAL (1) C-318

* C-XXX numbers refer to the consumables list in the BHT-ALL-SPM, Standard Practices Manual

NOTE 1: Quantity indicated is the format that the product is delivered in. Actual quantity
required to accomplish the instructions in this bulletin may be less.

SPECIAL TOOLS:

For PART II: 10X Magnifying Glass.

ASB 407-21-123
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WEIGHT AND BALANCE:

Not affected.

ELECTRICAL LOAD DATA:

Not affected.

REFERENCES:

407-MPI Maintenance Planning Information, Chapter 4.

407-MM Maintenance Manual, Chapter 53.
BHT-ALL-SRM Structural Repair Manual, Chapter 3.

PUBLICATIONS AFFECTED:

407-MPI Maintenance Planning Information, Chapter 4.

ACCOMPLISHMENT INSTRUCTIONS:

PART I: Identification of affected tailboom assemblies

1. Verify the helicopter historical service records to determine the part number of
tailboom assembly installed. The tailboom assembly part number can also be
confirmed by removing the aft tail rotor driveshaft cover (DMC-407-A-53-04-00-05A-
520A-A) and looking at the identification data plate located near Boom Station (BS)
129 (Figure 1).

-NOTE-

If the tailboom assembly has been modified from its

original configuration, the part number on the
identification data plate may have been re-identified, or
the part number of the current configuration may be
identified on a modification identification data plate
which will be located near Boom Station (BS) 129
(Figure 1).

a. If the tailboom assembly part number identified in step 1 is listed in Table 1 of

this bulletin, accomplish the inspection of the tailboom assembly as defined in
PART II of this bulletin at the next tailboom assembly scheduled inspection, and
every 100 flight hours thereafter.

Table 1: List of tailboom part number (P/N) that requires PART II of this
bulletin accomplished

407-030-801-107 407-530-014-101 407-530-014-103

ASB 407-21-123
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 b. If the tailboom part number identified in step 1 is listed in Table 2 of this bulletin,
accomplish the inspection of the tailboom assembly as defined in PART II of this
bulletin at the next tailboom scheduled inspection, and every 300 flight hours
thereafter.

Table 2: List of tailboom part number (P/N) that require PART II of this
bulletin accomplished

407-030-801-201 407-030-801-203 407-030-801-205

407-030-801-217 407-030-801-219 407-030-801-221
407-030-801-221FM 407-530-013-105

2. If tail rotor driveshaft cover was removed in step 1, install driveshaft cover (DMC-
407-A-53-04-00-05A-720A-A).

3. Make an entry in the helicopter logbook and historical service records indicating
compliance with PART I of this Alert Service Bulletin.

PART II: Recurring inspection requirement for tailboom assemblies listed in Table
1 and Table 2 of this bulletin

1. Prepare the helicopter for maintenance.

2. Wash the area of the tailboom assembly to inspect (Figure 2) with cleaning
compound (C-318) and water prepared in accordance with the manufacturer’s
recommendations to remove all traces of dirt, stains, exhaust residues and oil. Rinse
thoroughly and wipe dry.

3. Perform a detailed visual inspection (DVI) of the left side of the tailboom assembly
skins and lower left closure plate of the horizontal stabilizer for signs of cracks and
loose fasteners as follows:

a. If any fasteners are found loose, remove them per standard practices and inspect
edges of holes for cracks using a 10X magnifying glass. If no crack is found,
install correct diameter fasteners (BHT-ALL-SRM, Chapter 3, Section 3-3 and
Table 3-28). Same type and size as the original fasteners removed shall be
installed, oversizing of the hole diameter or rivet substitution is not allowed.

(1) If fasteners cannot be replaced per instructions in step 3.a. or a crack is found,
contact Bell Product Support Engineering ([email protected]) for
recommended actions. Once corrective actions have been provided go to step
3.b.

b. Using a 10X magnifying glass and bright light source, carry out a DVI of the
tailboom assembly skins for cracks just below the edge of mating horizontal
stabilizer lower attachment support (Figure 2, Area X).

ASB 407-21-123
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 (1) If a crack is found on the tailboom skins, replace the tailboom assembly with
a serviceable tailboom assembly that meets the intent of this ASB prior to
next flight, and report findings to Bell Product Support Engineering
([email protected]). Go to step 4.

(2) If no crack is found on the tailboom assembly skins, but a crack is found on
the lower left closure plate, do the following:

(a) Remove cracked lower left closure plate and discard (DMC-407-A-53-02-
00-00A-921A-A). The closure plate is considered unserviceable.

(b) Using a 10X magnifying glass and bright light source carry out a DVI of
the tailboom assembly skins that are located under the closure plate for
any cracks (Figure 2, Area X).

1. If no cracks are found, install a serviceable lower left closure plate

(DMC-407-A-53-02-00-00A-921A-A) and go to step 4.

2. If a crack is detected, replace the tailboom assembly with a

serviceable tailboom assembly that meets the intent of this ASB.

(c) Report all findings to Bell Product Support Engineering

([email protected]).

(3) If no cracks or loose fasteners are found, go to step 4.

4. Make an entry in the helicopter logbook and historical service records indicating
compliance with this Alert Service Bulletin.

5. Perform PART II of this bulletin every 100 flight hours for affected tailboom
assemblies identified in Table 1 of PART I or every 300 flight hours for affected
tailboom assemblies identified in Table 2 of PART I.

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Figure 1 – Location of Identification Data Plate and Modification Identification Data
Plate, Tailboom Assembly

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Figure 2 – Inspection Area on Tailboom Assembly (Sheet 1 of 3)

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Figure 2 – Inspection Area on Tailboom Assembly (Sheet 2 of 3)

ASB 407-21-123
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Figure 2 – Inspection Area on Tailboom Assembly (Sheet 3 of 3)

ASB 407-21-123
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