T.F.S. No. 00000523 

Approved under EASA DOA No. 21J.056 Page 1/20 

2009.04.23

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

EUROCOPTER 

DIRECTION TECHNIQUE SUPPORT

13725 MARIGNANE CEDEX FRANCE

EMERGENCY

ALERT SERVICE BULLETIN 

SUPER PUMA NUMBER VERSIONS 

EC225 05A017 Civil: LP 

EC725 05A016 Military: AP 

SUBJECT: TIME LIMITS – MAINTENANCE CHECKS 

Check of the magnetic plug on the main gearbox (MGB) epicyclic 

module 

Main module chip collector modification

ATA: 63 

Corresponds to MOD 0752522 

REVISION No. DATE OF APPROVAL DATE OF ISSUE 

 

Revision 0 On: April 10, 2009 2009.04.10 

Revision 1 On: April 18, 2009 2009.04.18

Revision 2 On: April 23, 2009 2009.04.23 
T.F.S. No. 00000523 

Approved under EASA DOA No. 21J.056 Page 2/20 

2009.04.23

1. PLANNING INFORMATION 

1.A. EFFECTIVITY 

1.A.1. Helicopters/installed equipment 

On main gearboxes (MGB), all part numbers pre MOD 0752522. 

NOTE 1

Helicopters which have MOD 0752522 embodied, 

are not concerned by the directives of the present 

ALERT SERVICE BULLETIN. 

NOTE 2

Refer to the log-card (FM) of the main reduction module. 

NOTE 3

MOD 0752522 is intended to improve the detection of 

metallic particles generated by possible deterioration of 

the epicyclic stage by removing the magnets and the 

flanged edge from the chip collector on the top part of the 

main reduction module. 

1.A.2. Non-installed equipment 

1) On main gearboxes (MGB), all part numbers pre MOD 0752522. 

2) On main reduction modules for Main Gearboxes (MGB) of all part numbers pre MOD 0752522. 

1.B. ASSOCIATED REQUIREMENTS 

Not applicable. 
T.F.S. No. 00000523 

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2009.04.23

1.C. REASON 

To ensure the integrity of the Epicyclic Module by removal of the epicyclic module and inspection of 

the chip collector following detection of particles at the electrical magnetic plug on the epicyclic 

module. 

Revision 0 of the present ALERT SERVICE BULLETIN resulted in issue of EASA Airworthiness 

Directive No. 2009-0087-E 

Revision 1 of the present ALERT SERVICE BULLETIN was intended: 

- to add embodiment of MOD 0752522, 

- to inform operators that embodiment of MOD 0752522 renders the directives of revision 0 of the 

present ALERT SERVICE BULLETIN null and void. 

- to inform operators that embodiment of MOD 0752522 modifies the measures to be taken in the 

event of particle detection at the Epicyclic Module magnetic plug defined at revision 0. 

Following embodiment of MOD 0752522, the particles collection procedure applicable following 

detection at the Epicyclic Module magnetic plug, no longer requires removal of the Epicyclic Module 

from the MGB. Only the procedure described under Task 05-53-00-218 need be applied. 

Moreover, considering that this modification deletes the segregation of particles between the main 

module and the epicyclic module, if the criteria specified in Work Card 20.08.01.601 of the Standard 

Practices Manual (MTC) are met, the complete MGB must be removed. 

Revision 1 of the present ALERT SERVICE BULLETIN did not form the subject of an EASA 

Airworthiness Directive. 

Revision 2 of this ALERT SERVICE BULLETIN is intended to inform you that the EASA approval has 

been obtained. 

Revision 2 of this ALERT SERVICE BULLETIN does not affect compliance with Revision 1. 

Revision 2 of this ALERT SERVICE BULLETIN will form the subject of an EASA Airworthiness 

Directive. 
T.F.S. No. 00000523 

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2009.04.23

1.D. DESCRIPTION 

Revision 0:

Following the accident to helicopter AS332 L2 registration G-REDL, which occurred on 1st April 2009, 

the investigation is still in progress under the authority of the British AAIB, with the participation of the 

French BEA, EASA and EUROCOPTER. 

At this stage, the cause of the accident appears to be linked to the deterioration of the epicyclic stage 

of the main gearbox, the reason for which has yet to be determined. In the light of this information, 

detection of any pollution of the main gearbox is of the very highest importance. 

The epicyclic module on EC225 aircraft is equipped with an electrical magnetic plug which is 

connected to an alarm in the cockpit, which is activated in the event of pollution. 

EUROCOPTER re-iterates and emphasises, as a precaution, the procedure which is applicable when 

a particle is detected by the alarm, in accordance with the procedures described in the present ALERT 

SERVICE BULLETIN. 

This precautionary measure is mandatory. 

Revision 1:

Since issue of Revision 0 of the present ALERT SERVICE BULLETIN, the studies in progress 

investigating the possibility of improving the metallic particles detection system monitoring the Main 

Gearbox elements, have resulted in a modification to the chip collector located at the interface 

between the Epicyclic module and the Main module. 

The detector currently fitted enables segregation of the particles generated in the possible event of 

deterioration of the epicyclic module and so avoids their contaminating and damaging the main 

module. However in-service experience has shown that this chip collection device may delay the 

detection of particles. 

In order to improve the flow of particles towards the detection devices (gearbox sump and epicyclic 

module magnetic plugs), EUROCOPTER has called up: 

Removal of the magnetic elements installed on the chip collector 

• Removal of the magnetic elements installed on the chip collector 

• Removal of the flanged edge from the chip collector. 

EUROCOPTER has made the measures defined in Revision 1 of the present ALERT SERVICE 

BULLETIN mandatory. 

It must be underlined however that the cause of the reported event still remains to be determined. 

EUROCOPTER will inform you of any new developments. 

Revision 2: 

EUROCOPTER issued Revision 1 of this ALERT SERVICE BULLETIN to rapidly provide the users 

with the technical information, enabling them to embody MOD 0752522 and EAD directives 

No. 2009-0095-E concurrently. 

The present Revision 2 whose technical content is identical to that of Revision 1 is issued to inform the 

operators of the EASA agreement. 
T.F.S. No. 00000523 

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2009.04.23

1.E. COMPLIANCE 

EUROCOPTER renders compliance with the present ALERT SERVICE BULLETIN mandatory. 

1.E.1. Compliance at the works 

1.E.1.a. On Helicopters 

Comply with paragraph 1.E.2.a. before delivery. 

1.E.1.b. On non-installed equipment 

Apply paragraph 2.B.3. before installation on an aircraft. 

1.E.2. Compliance in service: By the operator: 

1.E.2.a. On helicopters/installed equipment 

1) Comply with paragraph 2.B.2. after every detection of particles by the electric magnetic plug on 

the epicyclic module, 

Then, 

2) For Main Gearboxes (MGB) which have not had their epicyclic module removed following a 

visually confirmed detection of one or more particles on the epicyclic module magnetic plug and 

if the detection was recorded at least 200 flight hours previously: 

- Apply paragraph 2.B.2. before the next flight. 

3) Apply paragraph 2.B.3 of the present ALERT SERVICE BULLETIN within 150 flight hours, 

without exceeding 3 months following receipt of Revision 1 of the present ALERT SERVICE 

BULLETIN, issued on April 18, 2009. 

After embodiment of MOD 0752522, the measures 

to be taken in the event of detection of one or 

more particles at the epicyclic module magnetic 

plug became again conform to sub-task 

60-00-00-212-001 (check of MGB metallic particles 

detectors) of MMA task 60-00-00-212. 

1.E.2.b. On non-installed equipment 

1) For MGBs which had already logged some flight hours since new, or overhaul, on receipt of 

revision 0 of the present ALERT SERVICE BULLETIN: 

- Apply paragraph 2.B.1. before installation on the aircraft. 

2) On Main Gearboxes (MGB) : 

- Apply paragraph 2.B.3. before installation on the aircraft. 

3) On Main Gearbox (MGB) main reduction modules : 

- Apply paragraph 2.B.3. before installation on the aircraft 

CAUTION
T.F.S. No. 00000523 

Approved under EASA DOA No. 21J.056 Page 6/20 

2009.04.23

1.F. APPROVAL 

Approval is limited to civil version helicopters subject to an Airworthiness Certificate. 

The technical information contained in revision 0 of this ALERT SERVICE BULLETIN was approved 

on April 10th, 2009 under the authority of EASA Design Organisation Approval No. 21J.056. 

The information or instructions referring to modification MOD 0752522 Edition 2 were approved on 

April 22, 2009 under the authority of EASA Design Organisation Approval No. 21J.056. 

The technical information contained in Revision 1 of this ALERT SERVICE BULLETIN was approved 

on April 18, 2009 by EUROCOPTER Airworthiness Department, but did not form the subject of an 

EASA agreement. 

The technical information provided in Revision 1 of the present ALERT SERVICE BULLETIN provided 

the possibility to embody MOD 0752522 at the same time as EAD 2009-0095-E, in order to avoid a 

second epicyclic module removal. 

The technical information provided in Revision 2 of this ALERT SERVICE BULLETIN was approved 

on April 23, 2009, under the authority of EASA Design Organisation Approval No. 21J.056. 

1.G. MANPOWER 

1.G.1. Qualification 

Mechanical Technician 

1.G.2. Time for the operations 

10 minutes for the check, without removal of the epicyclic module. 

Approximately 10 hours for the inspection in the event of removal of the epicyclic module. 

Approximately 14 hours to embody MOD 0752522. 

1.H. WEIGHT AND BALANCE 

Not applicable. 

1.I. EFFECT ON ELECTRICAL LOADS 

Not applicable. 

1.J. SOFTWARE MODIFICATION EMBODIMENT RECORD 

Not applicable. 
T.F.S. No. 00000523 

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2009.04.23

1.K. REFERENCES 

Aircraft Maintenance Manual (MMA) Tasks: 

- 05-53-00-218 

- 60-00-00-212 

- 63-22-00-062 

Standard Practices Manual (MTC) Work Cards: 

- 20.08.01.601 

- 20.03.01.102 

- 20.08.05.101 

- 20.08.05.103 

1.L. OTHER DOCUMENTS AFFECTED 

Aircraft Maintenance Manual (MMA). 

1.M. TOOLING AFFECTED 

Not applicable. 

1.N. INTERCHANGEABILITY OR MIXABILITY OF PARTS 

Not applicable. 
T.F.S. No. 00000523 

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2009.04.23

2. ACCOMPLISHMENT INSTRUCTIONS 

2.A. GENERAL 

NOTE 1

When removing the Epicycle reduction gear it is not necessary 

to remove entirely the emergency MGB lubrication system. 

Only the items hampering the epicycle reduction gear removal 

require to be removed. 

NOTE 2

EUROCOPTER are ready to provide you with any further 

information or support you may require to comply with the 

instructions described in the present ALERT SERVICE 

BULLETIN especially in case of systematic exchanges or any 

problem with tools in relation with paragraph 2.B.3.: 

Contact the EUROCOPTER Customer Service Technical 

Support Department (SVTM) 

On: Tel: +33 (0)4.42.85.20.51

Fax: +33 (0)4.42.85.99.66

Email: DynComp.Technical-Support@eurocopter.com

Or Customer Assistance (24/24 – 7/7) 

On : Tel : +33 (0)4.42.85.97.97 

Fax : +33 (0)4.42.85.99.96 

Email : Customer.Assistance@eurocopter.com

2.B. OPERATIONAL PROCEDURE 

2.B.1. Checking the magnetic plug on the epicyclic module 

Refer to Figure 1

- Check the magnetic plug (a) in accordance with Sub-Task 60-00-00-212-001 of MMA 

Task 60-00-00-212. 

If no particles are found on the magnetic plug (a): 

- Leave it as it is. 

If one or more particles are found on the magnetic plug: 

- Apply paragraph 2.B.2. 
T.F.S. No. 00000523 

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2009.04.23

2.B.2. Checking the absence of particles on the chip collector 

Refer to Figure 1

2.B.2.a. Procedure 

- Remove the epicyclic module as per MMA Task 63-22-00-062. 

- Using a magnet, collect any particles that may be found in the chip collector (b). 

- Apply Sub-Task 05-53-00-218-001 of Task 05-53-00-218 in order to check the contamination of 

the flared housing and main gearbox (MGB) and collect all the particles contaminating the MGB 

and its lubrication system. 

- Determine the number and type of particles, including all the particles found during the previous 

operations and refer to the criteria defined in the Standard Practices Manual (MTC) Work Card 

20.08.01.601. 

2.B.2.b. Measures to be taken 

. If the replacement criteria are not met: 

- Thoroughly clean the area concerned. 

- Install the epicyclic module as per MMA Task 63-22-00-062. 

- Return the helicopter to flight configuration. 

The MGB must be checked and monitored in 

accordance with Sub-Tasks 05-53-00-218-001 

and 05-53-00-218-003 of Task 05-53-00-218 even 

if the particles found are within the acceptable 

criteria.

. If the replacement criteria are met: 

- Send the epicyclic module to an approved repair centre for investigation. 

- Install an epicyclic module as per MMA Task 63-22-00-062. 

NOTE 3

If, following application of the measures described 

above, the replacement criteria are met and if no 

particle has been found on the magnetic plug in the 

MGB sump: only the epicyclic module need be 

replaced. 

- If one or more particles are found, contact the EUROCOPTER Technical Support department as 

indicated in paragraph 2.A. 

CAUTION
T.F.S. No. 00000523 

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2009.04.23

2.B.3. Embodiment of MOD 0752522 

2.B.3.a. Preliminary checks: 

- Apply the directives defined in paragraph 2.B.2.a. 

. If the replacement criteria are not met: 

- Thoroughly clean the area concerned. 

The MGB must be checked and monitored in 

accordance with Sub-Tasks 05-53-00-218-001 

and 05-53-00-218-003 of Task 05-53-00-218 even 

if the particles found are within the acceptable 

criteria.

NOTE 4

If any damage is found, contact the EUROCOPTER 

Technical Support department as indicated in 

paragraph 2.A. 

. If the replacement criteria are met: 

- Send the epicyclic module to an approved repair centre for investigation. 

NOTE 5

If, following application of the measures described 

above, the replacement criteria are met and if no 

particle has been found on the magnetic plug in the 

MGB sump: only the epicyclic module need be 

replaced. 

- If one or more particles are found, contact the EUROCOPTER Technical Support department as 

indicated in paragraph 2.A. 

CAUTION
T.F.S. No. 00000523 

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2009.04.23

2.B.3.b. Modification of the chip collector 

1) Removal of the chip collector (b) as shown in Figure 2: 

- Remove the nuts (c). 

- Remove the top collector (d). 

- Remove the chip collector (b) together with its magnetic elements (e). 

NOTE 6

Take care not to damage the seal (f) located at the 

periphery of the chip collector (b). 

2) Removal of the magnetic elements (e) as shown in Figure 3: 

- Remove the rivets (g) attaching the magnetic elements (e) to the chip collector (b) as per MTC 

Work Card 20.03.01.102 paragraph 3. 

- Remove the magnetic elements (e). 

- Carefully deburr the bore of all the rivet holes (g). 

NOTE 7

Take care not to distort and/or warp the chip collector 

(b) during application of this procedure. 

3) Modification of the chip collector (b) as shown in Figure 4: 

- Gradually remove the flanged edges (h) from the chip collector (b) by successive passes with 

a milling machine. 

- Blend with a 5 mm radius. 

- Carefully deburr the areas cut away. 

NOTE 8

Take care not to distort and/or warp the chip collector 

(b) during application of this procedure. 

4) Re-identify the chip collector (b) in accordance with paragraph 2.C. as per MTC Work Cards 

20.08.05.101 and 20.08.05.103 and in accordance with Figure 5: 

- Cross out the part number of the chip collector (b) with indelible ink. 

- Mark the new part number on the chip collector (1) with indelible ink as per MTC Work Card 

20.08.05.103. 

- Clean the chip collector (1). 

NOTE 9

Take care not to distort and/or warp the chip collector 

(b) during application of this procedure. 
T.F.S. No. 00000523 

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2009.04.23

5) Installation of the chip collector (1) in accordance with Figure 2: 

- Fit the seal (f) on the chip collector (1). 

NOTE 10

If the seal (f) has been damaged (torn, cut etc.) during 

removal, replace it with a new seal (2) after adjusting 

its length. 

- Lubricate the seal (f) with gearbox running oil. 

- Install the chip collector (1) together with its seal (f) but without its magnetic elements (e). 

- Install the top collector (d). 

- Fit the nuts (c). 

- Apply torque. 

- Install the epicyclic module in accordance with MMA Task 63-22-00-062. 

Due to the presence of the O-ring (MMA Task 

63-22-00-062, item 5) inside the bevel gearwheel, 

high load may be required for removal or 

installation of the 1st stage sun gear. 

Correct installation is ensured by complying with 

dimension L (MMA Task 63-22-00-062). 

After embodiment of MOD 0752522, the measures 

to be taken in the event of detection of one or 

more particles at the epicyclic module magnetic 

plug became again conform to sub-task 

60-00-00-212-001 (check of MGB metallic particles 

detectors) of MMA task 60-00-00-212. 

REMINDER

CAUTION
T.F.S. No. 00000523 

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2009.04.23

Figure 1 

a 

b 
T.F.S. No. 00000523 

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2009.04.23

Figure 2 

f 

2 

b 

1 

d c 

e 

62-75 lbf.in 

0.7 – 0.85 daN.m 

0.156 
T.F.S. No. 00000523 

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2009.04.23

Figure 3 

b 

1

b 

1 b 

1

g 

g 

e 
T.F.S. No. 00000523 

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2009.04.23

Figure 4 

h 

Chip collector (b) before deletion of the flanged edges. 

Chip collector (1) after deletion of the flanged edges and 

the magnetic elements (e) 

Clearance holes for the attachment rivets (g) for the 

magnetic elements (e) 

b 

1 
T.F.S. No. 00000523 

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2009.04.23

Figure 5 

Mark the new part number in 

indelible ink 
T.F.S. No. 00000523 

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2009.04.23

2.C. IDENTIFICATION 

- Record compliance with this ALERT SERVICE BULLETIN on the log-card (FME) of the main 

gearbox (MGB) epicyclic module. 

and 

- After application of paragraph 2.B.3. record embodiment of MOD 0752522 on the log-card for the 

MGB main reduction module. 

- Re-identification of the chip collector after embodiment of MOD 0752522. 

Old part number 

(item b) 

New part number 

(item 1) 

 

332A32-5160-00 332A32-5196-21 

 

2.D. OPERATING AND MAINTENANCE INSTRUCTIONS 

Not applicable. 
T.F.S. No. 00000523 

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2009.04.23

3. MATERIAL INFORMATION 

3.A. MATERIAL: PRICE AND AVAILABILITY 

3.A.1. Cost 

For any information on the kits and/or components, contact the EUROCOPTER Network Sales & 

Customer Relations Department. 

3.A.2. Availability 

The industrial delivery lead-time will be notified to the user, on request, by the Sales & Customer 

Relations Department. 

3.B. INFORMATION CONCERNING INDUSTRIAL SUPPORT 

Not applicable. 

3.C. MATERIAL REQUIRED FOR EACH HELICOPTER/ENGINE/COMPONENT 

3.C.1. Kits or components to be ordered for one helicopter or one assembly 

Material P/N Qty Item Key Word Former P/N Instructions

 

332A32-5021-01 A/R - Epicyclic module 

706A39-821-003 A/R 2 Seal 

 

3.C.2. Material to be ordered separately 

Items marked with an asterisk "*" or required for compliance with the Tasks and/or 

Work Cards listed in paragraph 1.K. can be ordered from the INTERTURBINE 

company. 

Website: http://www.itlogistics.de

Telephone: +49.41.91.809.300 

AOG: +49.41.91.809.444 
T.F.S. No. 00000523 

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2009.04.23

3.D. PROCUREMENT CONDITIONS 

Order the required quantity (unless otherwise specified) 

from 

EUROCOPTER 

Etablissement de Marignane 

Direction Ventes et Relations Client 

ECR. 

13725 MARIGNANE CEDEX 

FRANCE 

NOTE 1 

For ALERT SERVICE BULLETINS, order by: 

Telex: HELICOP 410 969F. 

Fax: +33 (0)4.42.85.99.96 

NOTE 2

On the purchase order, please specify the mode of 

transport, the destination, and the serial numbers of the 

helicopters to be modified. 

4. APPENDIX 

Not applicable. 

T.F.S. No. 00000523 

Approved under EASA DOA No. 21J.056 Page 20/20 

2009.04.23

3.D. PROCUREMENT CONDITIONS 

Order the required quantity (unless otherwise specified) 

from 

EUROCOPTER 

Etablissement de Marignane 

Direction Ventes et Relations Client 

ECR. 

13725 MARIGNANE CEDEX 

FRANCE 

NOTE 1 

For ALERT SERVICE BULLETINS, order by: 

Telex: HELICOP 410 969F. 

Fax: +33 (0)4.42.85.99.96 

NOTE 2

On the purchase order, please specify the mode of 

transport, the destination, and the serial numbers of the 

helicopters to be modified. 

4. APPENDIX 

Not applicable.