EC135 

ALERT SERVICE BULLETIN 

Fuselage - Cable Channel - Inspection of wire harnesses and 

modification of side channel covers 

1. Planning Information 

A. 

B. 

c. 

Effectivity 

(1) Helicopters affected: 

(2) Components affected: 

(3) Spare parts affected: 

Concurrent Requirements 

Not applicable. 

Reason 

EC135/EC635, all models S/N 0005 up to and including I 

S/N 0576. 

Wire harnesses in the LH and RH cable channel. 

Not applicable. 

During a flight a burning odor could be smelt in the cabin. Its reason was a short circuit in 

the LH cable channel, which was caused by a damaged wire harness. The wire harness was 

damaged by the side channel cover's attachment hardware. 

For this reason, a modified attachment of the side channel cover is introduced with this Alert 

Service Bulletin. 

D. Description 

Inspect wire harnesses in the LH and RH cable channel for chafing, remove screws and 

anchor nuts from the area where the side channel covers overlap and replace by a 

double-sided adhesive tape. 

E. Compliance 

Inspection of the wire harnesses and accomplishment of the chafing protection measures 

must be accomplished within the next 25 fh after receipt of this Alert Service Bulletin, but by 

28.02.2007 at the latest. 

F. Approval 

The technical content of this document is approved under the authority of 

DOA No. EASA.21 J.034. 

2007-01-18 EC135-53A-017 

REVISION 01, 2007-06-22 PAGE 1 of 10 
~~[2fopter EC135 

ALERT SERVICE BULLETIN 

G. Manpower 

EFFECTIVITY Helicopters with collective lever cover (copilot). 

Approx. 5 man- hours. 

EFFECTIVITY Helicopters without collective lever cover (copilot). 

Approx. 4 man-hours. 

H. Weight and Balance 

Not applicable. 

I. Electrical Load Data 

Not applicable. 

J. Software Accomplishment Summary 

Not applicable; 

K. References 

AMM EC135 

AMM EC135/635 T1/T2 (CPOS). 

L Other Publications affected 

The changes to AMM EC135, AMM EC135/635 T1/T2 (CPOS) and to IPC EC135, IPC 

EC635 wich are required as a result of thie Alert Service Bulletin will be incorporated with 

one of the next revisions. 

M. Interchangeability of Parts 

Not applicable. 

2. Material Information 

A. Material - Price and Availability 

Information on cost and availability of required retrofit kit SB-135-53A-017 -2C1 or 

SB-135-53A-017-2C2 will be provided by ECD, Dept. Spares Order Administration on 

request. 

B. Support Information 

Not applicable. 

EC135-53A-017 

PAGE 2 of 10 

2007-01-18 

REVISION 01, 2007-06-22 
EC135 

ALERT SERVICE BULLETIN 

C. Material Necessary for Each Helicopter 

No. 

1 

2 

EFFECTIVITY Helicopters without collective lever cover (copilot). 

Retrofit kit SB-135-53A-017 -2C1 

New P/N Keyword Old P/N 

- Adhesive tape (double-sided) - (CM 6049) 

- Acetone (CM 203) -

*a.n. =as needed 

No. 

1 

2 

3 

4 

EFFECTIVITY Helicopters with collective lever cover (copilot). 

Retrofit kit SB-135-53A-017 -2C2 

New P/N Keyword Old P/N 

15147.{)5-20Farbe1002 Hook tape -

Klettostar·Haftband (0.6m) 

15244-05-20Farbe1 002 Pile tape - Klettostar -Fiauschband (0.6m) 

- Adhesive tape (double-sided) - (CM 6049) 

- Acetone (CM 203) -

*a.n. = as needed 

Disposition: 

A= New, included in kit. 

Qty Disposition 

a.n.* B 

a.n.* B 

Qty Disposition 

1 A 

1 A 

a.n.• B 

a.n.• B 

B = Consumable material, to be ordered from the lnterturbine company as needed. 

CM item number i.a.w. list of consumable materials in the AMM. 

D. Material Necessary for Each Spare 

Not applicable. 

E. Reidentified Parts 

Not applicable. 

F. Special Tooling 

Not applicable. 

2007-01-18 

REVISION 01, 2007-06-22 

EC135-53A-017 

PAGE 3 of 10 
-~~[8fOPter EC135 

ALERT SERVICE BULLETIN 

3. Accomplishment Instructions 

A. Preliminary work steps: 

(1} De-energize helicopter electrical system i.a.w. AMM, 24-00-00, 2-1. 

(2) If present, remove floor cover from the area of the LH and RH side channel covers i.a.w. 

AMM, 25-10-00, 4-2. 

(3} If present, remove cover from collective lever (copilot) i.a.w. AMM, 67-12-00, 4-8. 

(4) Remove LH and RH side channel covers i.a.w. AMM, 52-50-00, 4-3. 

B. Inspection of wire harnesses in the LH and RH cable channel: 

(1) Inspect wire harnesses i.a.w. Figure 1 for chafing and damage and, while doing so, 

especially inspect the area beneath the attachment screws of the side channel covers. 

If wire harnesses are damaged, contact the ECD customer service before the next flight 

for further instructions. 

(2) If additional items of optional equipment are installed on the side channel covers, 

inspect beneath lying wire harnesses and contact the ECD customer service in case 

of doubt. 

(3} If no signs of damage can be detected in the wire harnesses, proceed i.a.w. Section 3.C 

of this Alert Service Bulletin. · 

C. Modification of the side channel covers: 

NOTE The following instructions are effective for the LH cable channel. The 

instructions for the RH cable channel are identical. 

(1) If present, remove foam rubber (5, Figure 2). 

(2) Drill out countersunk rivets (1 , Figure 2} using drill bit dia. 2.4 mm. 

(3) Remove two anchor nuts (4, Figure 2) and sheet (3). 

(4) Affix double-sided adhesive tape (6, Figure 2) onto side channel cover (2). By doing 

so, remove protective backing film not until side channel cover (2} and side channel 

cover (7) are installed. 

Clean areas to be affixed before affixing of the double-sided adhesive tape with 

acetone (CM 203}. 

EC135-53A-017 

PAGE 4 of 10 

2007-01-18 

REVISION 01, 2007-06-22 
EC135 

ALERT SERVICE BULLETIN 

EFFECTIVITY For helicopters with collective lever cover (copilot). 

D. Modification of the attachment of the collective lever cover (copilot): 

(1) Drill out rivets (6) from the side channel cover (4, Figure 3} using drill bit dia. 

2.4 mm. 

(a) Remove the two anchor nuts (5, Figure 3}. 

(b) Attach hook-and-pile tape (8, 10, Figure 3) onto the cover (3): 

1 Clean bonding surfaces of the side channel cover (4, Figure 3) with 

acetone (CM 203}. 

2. Mark position of the pile tape (1 0, Figure 3) onto the side channel cover (4). 

;1 Peel off protective backing strip of the pile tape (1 0, Figure 3} and affix pile 

tape (1 0) to the side channel cover (4) . 

.1. Clean bonding surfaces of the cover (3, Figure 3) of the collective lever 

(copilot) with acetone (CM 203). 

Q. Peel off protective backing strip of the hook tape (8, Figure 3} and affix hook 

tape (8) to the cover (3). 

EFFECTIVITY All. 

E. Attach chafing protection (e.g. ROUNDIT2000NX, chafing protection must correspond to 

Aviation Standard) over the wire harnesse in the RH and LH cable channel. Inspect 

installation position of the wire harnesses and, if necessary, correct: 

(1) Attach chafing protection (7, Figure 4) over the wire harnesses (2) which are next to the 

anchor nuts (3) and attach by means of ty-raps (5). 

(2) If the clearance between anchor nuts (3, Figure 4), screws (4) and the wire 

harnesses (2) is less than 4 mm, route wire harnesses until the specified minimum 

clearance of 4 mm is reached and then fix wire harnesses (2) by means of ty- raps (5). 

F. Conclusive work: 

CAUTION PAY ATTENTION THAT THE SPECIFIED SCREWS ARE USED FOR 

INSTALLATION OF THE SIDE CHANNEL COVERS, AS TOO LONG 

SCREWS MAY DAMAGE THE BENEATH LYING WIRE HARNESSES. 

(1) Install LH and RH side channel covers i.a.w. AMM , 52-50-00, 4-3. By doing so, pay 

attention to the modified attachment of the side channel covers by a double-sided 

adhesive tape i.a.w. Section 3.C. 

If other screws than screws LN9136-05012 are used in the places of Figure 4 which are 

marked with an "X", replace screws accordingly. 

EFFECTIVITY For helicopters with collective lever cover (copilot). 

(2) Install collective lever cover (copilot) i.a.w. AMM, 67-12-00, 4-8. By doing so, pay 

attention to the modified attachment of the cover by hook-and-pile tapes i.a.w. Section 

3.0 and replace the two remaining screws with screws LN9139M4X16. 

2007-01-18 

REVISION 01 , 2007-06-22 

EC135-53A-017 

PAGE 5 of 10 
-~~ra~,s::opter EC135 

ALERT SERVICE BULLETIN 

EFFECTIVITY All. 

(3) If removed, install floor cover i.a.w. AMM, 25-10-00, 4-2. 

G. Confirm accomplishment of this Alert Service Bulletin by an entry in the historical record of 

the helicopter. 

4. Appendix 

Not applicable. 

EC135-53A-017 

PAGE 6 of 10 

2007-01-18 

REVISION 01, 2007-06-22 
-~~LSvcopter EC135 

ALERT SERVICE BULLETIN 

dLIGHT DIRECTION 

& Inspect wire harnesses for chafing and damage. By doing so, especially 

inspect the area where the side channel covers are screwed. 

2007-01-18 

REVISION 01, 2007-06-22 

Inspection of Wire Harnesses 

Figure 1 

EC135·53A-o17 

PAGE 7 of 10 
EC135 

ALERT SERVICE BULLETIN 

7 

1 Countersunk rivet 

2 Side channel cover& 

3 Sheet 

4 Anchot nut 

5 Foam rubber 

View A 

6 Double-sided adhesixe tape (CM 6049) 

7 Side channel cover ~ 

& only LH side channel cover is shown. 

EC135-53A-017 

PAGE 8 of 10 

Modification of Side Channel Cover 

Figure 2 

2007-01-18 

REVISION 01, 2007-06-22 
EC135 

ALERT SERVICE BULLETIN 

Before modification. 

4 

After modification. 

1 Screw & 

2 Washer& 

3 Cover 

4 Side channel cover 

5 Anchor nut& 

6 Rivet & 

7 Screw 

8 Hook tape £ 

9 Washer 

1 0 Pile tape & 

ffi Before modification. 

ffiAtter modification. 

& Establish screw holes into the pile tape. 

Modification of Collective Lever Cover (Copilot) 

· Figure 3 

2007-01-18 

REVISION 01, 2007-06-22 

9X2 

10 

EC135-53A-Q17 

PAGE 9 of 10 
·~~fo~n?opter EC135 

ALERT SERVICE BULLETIN 

Cable channel 

2 Wire harness & 

3 Anchor nut 

4 Screw & 

5 Ty-rap & 

6 Side channel cover 

7 Chafing protection 

(e.g. ROUNDIT2000NX) & 

Section A-A 

3 

ill Typical routing of the wire harnesses in the cable channel. 7 

& The minimum clearance between wire harnesses and anchor nuts/screws must be 4 mm. 

& If necessary, route wire harnesses by additionally fixing them with ty-raps. 

ffi Attach a chafing protection over wire harnesses. 

& If other screws than screws LN9136-05012 are used in the places of Figure 4 which are 

marked with an "X", replace screws accordingly. 

EC135-53A-017 

PAGE 10 of 10 

Installation Position of Wire Harnesses 

Figure 4 

2007-01-18 

REVISION 01 I 2007-06-22