EASA SIB CASA-2019-05-Issue-2: Bell 206L Helicopters - Cracks in Fuselage

What to do

Operators and maintainers of Bell 206L helicopters should conduct thorough inspections of the internal fuselage structure from FS142.7 to FS155.00 whenever the left and right door assemblies (items 24, 24A, and 24B) are removed. Use mirrors and flashlights to aid inspections in areas with limited access. Follow Bell's approved maintenance and structural repair manuals for repairs and replacements, and contact Bell for guidance on cracks outside approved criteria. Report all service difficulties to Transport Canada as required by Canadian Aviation Regulations.

Summary

Transport Canada Civil Aviation Safety Alert CASA 2019-05 is a safety alert addressing the discovery of cracks in the fuselage frame and bulkhead of Bell 206L series helicopters, specifically around fuselage stations FS142.7 to FS155.00. The alert highlights multiple occurrences of cracks and rivet issues in the upper fuselage area, including stiffener part number 206-033-107-055. It aims to raise awareness among owners, operators, and maintainers of Bell 206L helicopters about this structural concern.

What changed

This revision of CASA 2019-05 corrects an error in the French version of the original document related to the background and recommended action sections. It clarifies inspection requirements and emphasizes the need for thorough visual inspections when door assemblies are removed, as well as the use of approved Bell manuals for repairs. No new mandatory service bulletins or notices currently exist for this inspection area.

Why it matters

The alert is critical for aviation professionals because undetected cracks and loose rivets in the fuselage structure can compromise the structural integrity of Bell 206L helicopters, potentially leading to safety risks. Operators and maintenance personnel must be vigilant during scheduled inspections to identify and address these issues early. Proper compliance helps prevent structural failures and ensures continued airworthiness of affected helicopters.