# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 1 of 14 2008-04-28 REVISION 03, 2009-12-16 

## Rotor Flight **Controls – Tail Rotor, Cyclic and Collective Controls – Check bearings for correct attachment and retrofit of bushings and**  **washers**
**1. Planning Information A. Effectivity**  (1) Helicopters affected: EC135/EC635 all models, excluding S/N 0028. (2) Components affected: Tail rotor controls: LH lever L672M2802205 RH lever L672M1012212 Cyclic control: Lever L671M1005250 Collective Control: Lever assy L671M2020108 Plate L671M5040207 (3) Spare parts affected: Tail rotor controls: LH lever L672M2802205 RH lever L672M1012212 Cyclic control: Lever L671M1005250 Collective control: Lever assy L671M2020108 Plate L671M5040207 **B. Concurrent Requirements** Not applicable. **C. Reason** During accomplishment of an inspection on a MBB BK117 C-2, bearings were detected which had not been correctly bondend. Not properly bonded bearings may cause the respective lever to shift in the axial direction. Under unfavourable circumstances, the lever might get into contact with the helicopter structure and thus impair the controls’ freedom of movement. As the affected bearings of the EC135 are bonded in the same procedure, they must be checked for correct attachment with this Alert Service Bulletin. Furthermore, with this Alert Service Bulletin the retrofit of bushings and washers is described. Thus, the bearings are prevented from shifting in the axial direction. **D. Description** Check attachment of bearings. If necessary, rebond bearings. Retrofit of bushings and washers.

This document is available on the internet: www .eurocopter.com/techpub

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 2 of 14 REVISION 03, 2009-12-16 2008-04-28 **E. Compliance** (1) The following deadlines had been set in the first issue of this Alert Service Bulletin: **EFFECTIVITY** All EC135 on which no periodical inspection has been accomplished up to now. (a) The inspection and the possibly necessary repair of the levers i.a.w. Section 3.B must be accomplished within the next 50 fh after receipt of this Alert Service Bulletin, but by 31.05.2008 at the latest. **EFFECTIVITY** Helicopters S/N 0005 up to and including S/N 0829 **before**retrofit of the washers and bushings i.a.w. Section 3.C. (b) Check of the bearing in the LVDT plate i.a.w. Section 3.B.(5) must be repeated together wi th the periodical inspection or with the 12–month inspection, depending upon whichever occurs first. (2) The following deadlines are set for the Revisions 01, 02 and **03** of this Alert Service Bulletin: **EFFECTIVITY** Helicopters S/N 0005 up to and including S/N 0829. (a) The retrofit of the washers and the bushings must be accomplished within the next 12 months after receipt of Revision 1 of this Alert Service Bulletin i.a.w. Section 3.C. **EFFECTIVITY** Helicopters with washers and bushings i.a.w. Section 3.C. (b) After the retrofit of the bushings and washers i.a.w. Section 3.C. of this Alert Service Bulletin, the check of the levers must be repeated with the periodical inspection at 800 Fh or 36 months (what ever comes first). **EFFECTIVITY** Inspection after replacement of one of the components given in Section 1.A.(3) which was delivered **before**receipt of Revision 3 of this Alert Service Bulletin. (c) The replaced component must be inspected i.a.w. Section 3.B not before 10 fh have been reached but not later than 50 fh after its replacement. **F. Approval** The information or instruction contained in this document refer to change no. 1670. The technical content of this document is approved under the authority of DOA No. EASA.21J.034. **G. Manpower** Approx. 6.5 man–hours for the check. Approx. 32 man–hours for retrofit of bushings and washers.

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 3 of 14 2008-04-28 REVISION 03, 2009-12-16 **H. Weight and Balance** Weight: 0.032 kg Moment: 67.60 kgmm **I. Electrical Load Data** Not applicable. **J. Software Accomplishment Summary** Not applicable. **K. References** AMM EC135 and AMM EC135/635. **L. Other publications affected** The changes to AMM EC135, AMM EC135/635, IPC EC135, IPC EC135/635, MSM EC135 and MSM EC135/635 which are required as a result of this Alert Service Bulletin will be incorporated with one of the next revisions. **M. Interchangeability of Parts** With accomplishment of Revision 1 of this Alert Service Bulletin the P/Ns of the following componts change: Guidance unit RH from L672M1012101 to L672M1012103 from L672M1012102 to L672M1012103 Guidance unit LH from L672M2802101 to L672M2802103 from L672M2802102 to L672M2802103 Cyclic shaft from L671M1005102 to L671M1005104 from L671M1005103 to L671M1005104



### 2. Material Information **A. Material – Price and Availability** Information on cost and availability of required retrofit kit SB-135-67A-019-2C will be provided by ECD, Dept. Spares Order Administration on request. **B. Support Information** Not applicable.

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 4 of 14 REVISION 03, 2009-12-16 2008-04-28 **C. Material Necessary for Each Helicopter** Retrofit kit SB-135-67A-019-2C i.a.w. design documents L671M1005104, L672M2802103, L670M2003057 and L672M1012103. No. New P/N Keyword Old P/N Qty Disposition

1 L671M1005260 Washer

− 1 A 2 L672M1012260 Bushing

− 2 A 3 L221M1042208 Washer

− 2 A 4 RSN46 Retaining ring RSN46 1 A, B Disposition: A = New, included in kit. B = Part with old P/N is discarded. **D. Material Necessary for Each Spare** Not applicable. **E. Reidentified Parts** Not applicable. **F. Special Tooling** Not applicable.


### 3. Accomplishment instructions A. Preliminary Work Steps: (1) De–energize helicopter electrical system i.a.w. AMM, 24-00-00, 2-1. (2) Remove middle cover i.a.w. AMM, 52-40-00, 4-4. (3) If installed, remove equipment plate i.a.w. AMM, 25-70-00, 4-2. (4) Remove forward access cover i.a.w. AMM, 52-40-00, 4-3.

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 5 of 14 2008-04-28 REVISION 03, 2009-12-16 B. Check bearing for correct attachment: **CAUTION** BEFORE STARTING WORK, AFFIX A PLACARD IN THE COCKPIT WHICH SAYS THAT THE CONTROLS MUST NOT BE MOVED. OPERATING THE CONTROLS DURING THE CHECK MAY CAUSE SERIOUS INJURIES. **NOTE** The check requires a flashlight and a mirror. (1) Check bearing in LH guidance unit (Detail A, Figure 2) for correct attachment. (a) Check, whether bearing (1, Figure 2) is correctly installed in lever (2) as shown in Section A–A. (b) Manually check, whether bearing (1) is tightly fitted in lever (2). To do so, manually try to move lever in axial direction

. (c) If a loose bearing is detected, copy reply form sheet on page 14, fill out and send to ECD customer support. Rebond bearing i.a.w. AMM, 20-00-00, 2-14. (2) Check bearing in RH guidance unit (Detail B, Figure 2) for correct attachement. (a) Check, whether bearing (1, Figure 2) is correctly installed in lever (3) as shown in Section B–B. (b) Manually check, whether bearing (1) is tightly fitted in lever (3). To do so, manually try to move lever (3) in axial direction

. (c) If a loose bearing is detected, copy reply form sheet on page 14, fill out and send to ECD customer support. Rebond bearing i.a.w. AMM, 20-00-00, 2-14. (3) Check bearing of cyclic control (Detail C, Figure 3) for correct attachment. (a) Check, whether bearing (1, Figure 3) is correctly installed in lever (2) as shown in Section C–C. (b) Manually check, whether bearing (1, Figure 3) is tightly fitted in lever (2). To do so, manually try to move lever in axial direction

. (c) If a loose bearing is detected, copy reply form sheet on page 14, fill out and send to ECD customer support. Rebond bearing i.a.w. AMM, 20-00-00, 2-14. (4) Check bearing of upper guidance unit (Detail D, Figure 3) for correct attachment. (a) Check, whether bearing (3, Figure 3) is correctly installed in lever (4) as shown in Section D–D. (b) Manually check, whether bearing (3, Figure 3) is tightly fitted in lever (4). To do so, manually try to move connected forked end in axial direction

.

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 6 of 14 REVISION 03, 2009-12-16 2008-04-28 (c) If a loose bearing is detected, copy reply form sheet on page 14, fill out and send to ECD customer support. Rebond bearing i.a.w. AMM, 20-00-00, 2-14. (5) Check bearing in LVDT plate (Detail E, Figure 4) for correct attachment. (a) Check, whether bearing (1, Figure 4) is correctly installed in plate (2) as shown in Section E–E. (b) Manually check, whether bearing (1, Figure 4) is tightly fitted in plate (2). To do so, manually try to move plate (2) in axial direction

. (c) If a loose bearing is detected, copy reply form sheet on page 14, fill out and send to ECD customer support. Rebond bearing i.a.w. AMM, 20-00-00, 2-14. C. Retrofit of bushings and washers: (1) Remove LH guidance unit i.aw. AMM, 67-20-00, 4-4. (2) Disassemble LH guidance unit i.aw. AMM, 67-20-00, 4-5. (3) Assemble LH guidance unit i.a.w. AMM, 67-20-00, 4-5. While doing so, additionally install bushing (1, Figure 5) between bearing block (2) and lever (3) (see Detail A, Figure 5) – notwithstanding the instructions given in the AMM. (4) Install LH guidance unit i.a.w. AMM, 67-20-00, 4-4. **EFFECTIVITY** Helicopters **S/N 0005** up to and**including S/N 0829 without**  yaw brake. (5) Remove RH guidance unit i.a.w. AMM, 67-20-00, 4-4. (6) Disassemble RH guidance unit i.a.w. AMM, 67-20-00, 4-5. (7) Assemble RH guidance unit i.a.w. AMM, 67-20-00, 4-5. While doing so, additionally install bushing (1, Figure 5) between bearing block (4) and lever (5) (see Detail B, Figure 5) – notwithstanding the instructions given in the AMM. (8) Install RH guidance unit i.a.w. AMM, 67-20-00, 4-4. **EFFECTIVITY** Helicopters **S/N 0005** up to and**including S/N 0829.** (9) Remove cyclic shaft i.a.w. AMM, 67-11-00, 4-5. (10) Disassemble the cyclic shaft i.a.w. AMM, 67-11-00, 4-6. While you do so, disassemble the cyclic shaft only as far as necessary for the retrofit of the washer (2, figure 6). (11) Assemble cyclic shaft i.a.w. AMM, 67-11-00, 4-6. While doing so, additionally install washer (2, Figure 6) between bearing block (3) and lever (1) (see Detail C, Figure 6) – notwithstanding the instructions given in the AMM. (12) Install cyclic shaft i.a.w. AMM, 67-11-00, 4-5.

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 7 of 14 2008-04-28 REVISION 03, 2009-12-16 (13) Remove collective control rod (4, Figure 6) from bellcrank i.a.w. AMM, 67-10-00, 4-2. While doing so, remove the collective control rod (4) only as far as necessary for the retrofit of the washers (5). (14) Install collective control rod (4, Figure 6) at the bellcrank i.a.w. AMM, 67-10-00, 4 2. While doing so, additionally install washers (5) between collective control rod (4) and bellcrank (6) (see Detail D, Figure 6) – notwithstanding the instructions given in the AMM. D. Conclusive work: (1) Accomplish inspection for foreign objects and for foreign matter. (2) Install forward access cover i.a.w. AMM, 52-40-00, 4-3. (3) If removed, install equipment plate i.a.w. AMM, 25-70-00, 4-2. (4) Install middle cover i.a.w. AMM, 52-40-00, 4-4. E. Confirm accomplishment of this Alert Service Bulletin by an entry in the historical record of the helicopter.


### 4. Appendix Not applicable.

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 8 of 14 REVISION 03, 2009-12-16 2008-04-28 1 LH guidance unit – Detail A, Figure 2 2 RH guidance unit – Detail B, Figure 2 3 Lever, cyclic control – Detail C, Figure 3 4 Upper guidance unit – Detail D, Figure 3 5 LVDT – Detail E, Figure 4 1

1 

## B

2 3 4

5

Arrangement of Levers Figure 1

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 9 of 14 2008-04-28 REVISION 03, 2009-12-16

1 Double grooved ball bearing (bonded) AG12EG81 2 LH lever L672M2802205 3 RH lever L672M1012212 1 2

Lever must free of play in axial direction. 3 

### Detail **A** (Overview see Figure 1) **Before** modification

1 Section

**A–A**



### Detail **B** (Overview see Figure 1) **Before** modification

Section

**B–B**

Detail A and B of Figure 1 Figure 2

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 10 of 14 REVISION 03, 2009-12-16 2008-04-28 Detail C and D of Figure 1 Figure 3 1 Double grooved ball bearing AGF12BCE 2 Lever L671M1005250 3 Spherical bearing MBBN3068–06U 4 Collective lever assy L671M2020108 2

Lever must be free of play in axial direction. Forked lever must be free of play in axial direction. 1 Section

**C–C** 

### Detail **C** (Overview see Figure 1) **Before** modification



### Detail **D** (see Figure 1) **Before** modification
Section **D–D** 3

4

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 11 of 14 2008-04-28 REVISION 03, 2009-12-16 Detail E of Figure 1 Figure 4 1 Spherical bearing LN9367GE6N2 2 Plate L671M5040208 2 Plate (2) must be free of play in axial direction. 1 Section

**E–E** 

### Detail **E** (see Figure 1)

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 12 of 14 REVISION 03, 2009-12-16 2008-04-28 1 Bushing L672M1012260 2 Bearing block of LH guidance unit 3 LH lever L672M2802205 4 Bearing block of RH guidance unit 5 RH lever L672M1012212 3

4 

### Detail **A** (Overview see Figure 1) **After** modification

1 Section **A–A**



### Detail **B** (Overview see Figure 1) **After** modification
Section

**B–B**

Detail A and B of Figure 1 Figure 5 2

5

After modification. 1

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 13 of 14 2008-04-28 REVISION 03, 2009-12-16 Detail C and D of Figure 1 Figure 6 1 Lever L671M1005250 2 Washer L671M1005260 3 Bearing block 4 Control rod 5 Washer L221M1042208 6 Bellcrank 2 1 Section **C–C** 

### Detail **C** (Overview see Figure 1) **After** modification

3

After modification. 1 

### Detail **D** (Overview see Figure 1) **After** modification 4 5 6

4 6

# ALERT SERVICE BULLETIN **EC135**

**EC135-67A-019** PAGE 14 of 14 REVISION 03, 2009-12-16 2008-04-28 

# Telefax

To Eurocopter Deutschland GmbH Customer Support FAX 0049 906 714111 Address of operator: **Reply form sheet for ASB EC135-67A-019 ”check bearings of correct attachment”** Please completely fill out reply form sheet and send to the given FAX No.

Date:__________ Signature:___________________ P/N* Helicopter S/N: 1 2 3 4 Important data regarding lever Production order number ** TT (Fh)

**Please copy page! Original page remains in Alert Service Bulletin!** Disposition: L672M1012212 S01 ECD500 10001397284 07.09.05 *

** Example