FAA Issues AD for Leonardo AW139 Helicopters Citing Fire Risk

The U.S. Federal Aviation Administration (FAA) has issued a final rule and Airworthiness Directive (AD) for all Leonardo S.p.A. Model AB139 and AW139 helicopters. The directive addresses an unsafe condition related to electrical wiring in the overhead panel, which could lead to an in-flight fire and subsequent loss of helicopter control.

The AD mandates that operators perform repetitive detailed inspections of specific electrical cable bundles for any signs of chafing. If damage is found, the directive requires modifications to be made. This action is a critical step in ensuring the continued operational safety of a widely used rotorcraft platform in both civilian and governmental roles.

Directive Details and Safety Implications

The unsafe condition was identified as the potential for electrical cables located in the overhead control panel to chafe against the helicopter's structure. According to the FAA, this chafing could damage the wire insulation, leading to electrical arcing or a short circuit. Such an event could ignite nearby flammable materials, resulting in a fire within the cockpit. The potential consequences include the loss of critical helicopter control systems, posing a significant risk to the aircraft and its occupants.

The AD, filed under Docket No. FAA-2021-0461, requires operators to inspect the clearance between electrical wiring and the surrounding structure. It also mandates checks on the condition and installation of protective sleeves on the wires. If any chafing, damage, or inadequate clearance is discovered, the directive specifies corrective actions, which may include rerouting wires, repairing damaged sections, or installing additional protective material.

Affected Fleet and Operations

The directive applies to all Leonardo Model AB139 and AW139 helicopters. The AW139, a 15-seat twin-engine helicopter, is a global workhorse in various sectors, including offshore transport, emergency medical services, search and rescue, and executive transport. According to manufacturer data, the AW139 is operated by over 300 customers in more than 90 nations.

The global fleet size is significant, with over 1,200 units produced as of mid-2024. These helicopters have collectively accumulated over 4.5 million flight hours since the model's certification in 2004, underscoring the widespread impact of this safety mandate. Operators must now incorporate these new inspection requirements into their maintenance schedules to remain in compliance and ensure airworthiness.

Regulatory Background and International Harmonization

This FAA action follows a similar directive issued by the European Union Aviation Safety Agency (EASA). The FAA's final rule is based on EASA AD 2021-0044, which addressed the same unsafe condition for helicopters under its jurisdiction. The FAA's adoption of the EASA-identified safety concern is a common practice that reflects the trend of international cooperation and harmonization of aviation safety standards between major regulatory bodies.

By aligning its regulations with EASA, the FAA ensures a consistent safety standard is applied to the global AW139 fleet, simplifying compliance for international operators. Airworthiness Directives are a standard and proactive regulatory tool used to correct identified safety deficiencies across an entire aircraft fleet before they can lead to accidents.

Why This Matters

This Airworthiness Directive represents a crucial, proactive safety measure for one of the most successful medium-lift helicopters in modern aviation. For operators, it mandates immediate attention to maintenance protocols to mitigate a serious fire risk. The action underscores the importance of international regulatory alignment in maintaining global aviation safety standards for widely used aircraft platforms.

flying.flights is your source for accurate commercial aviation news and global aviation updates. For reporting on UAP sightings, investigations, and aviation-related encounters, see the UAPs section at flying.flights/uaps.