EASA AD No.: 2012-0085R5

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EASA AIRWORTHINESS DIRECTIVE

AD No.: 2012-0085R5

Date: 30 October 2012

Note: This Airworthiness Directive (AD) is issued by EASA, acting in accordance with 

Regulation (EC) No 216/2008 on behalf of the European Community, its Member States and of 

the European third countries that participate in the activities of EASA under Article 66 of that 

Regulation.

This AD is issued in accordance with EC 748/2012, Part 21.A.3B. In accordance with EC 2042/2003 Annex I, Part M.A.301, the 

continuing airworthiness of an aircraft shall be ensured by accomplishing any applicable ADs. Consequently, no person may operate 

an aircraft to which an AD applies, except in accordance with the requirements of that AD, unless otherwise specified by the Agency 

[EC 2042/2003 Annex I, Part M.A.303] or agreed with the Authority of the State of Registry [EC 216/2008, Article 14(4) exemption].

Design Approval Holder’s Name:

EUROCOPTER DEUTSCHLAND GmbH

Type/Model designation(s):

EC 135 and EC 635 helicopters

TCDS Number: EASA.R.009

Foreign AD: Not applicable

Revision: This AD revises EASA AD 2012-0085R4 dated 04 October 2012. The original 

EASA Emergency AD 2012-0085-E dated 17 May 2012 superseded EASA AD 

2012-0041R1 dated 15 March 2012.

ATA 62 Main Rotor System – Main Rotor Hub – Inspection / Replacement

Manufacturer(s): Eurocopter Deutschland GmbH (ECD), Eurocopter España S.A.,

Eurocopter S.A.

Applicability: EC 135 P1(CDS), EC 135 P1(CPDS), EC 135 P2(CPDS), EC 135 P2+,

EC 135 T1(CDS), EC 135 T1(CPDS), EC 135 T2(CPDS), EC 135 T2+, 

EC 635 T1(CPDS), EC 635 P2+ and EC 635 T2+ helicopters, all serial 

numbers.

Reason: During a periodical inspection of an EC 135 helicopter, a crack was detected 

on the lower hub-shaft flange of a main rotor hub (MRH) shaft. The 

investigation into the cause(s) of the cracking is still ongoing. 

This condition, if not detected, could lead to further crack propagation, possibly 

resulting in main rotor hub failure and consequent loss of the helicopter.

To address this condition, EASA issued Emergency AD 2012-0041-E, which 

was later revised for clarification. Since issuance of AD 2012-0041R1, further 

cracks were detected on the lower hub shaft flange of three other helicopters 

(now in total four helicopters) during accomplishment of the pre-flight checks. 

In addition, it has been determined that the identification of deformed safety 

pins may not be sufficient to detect the cracks on the MRH shaft.

Prompted by these findings, ECD developed new inspection procedures and 

EASA issued Emergency AD 2012-0085-E, superseding AD 2012-0041R1, to

require repetitive pre-flight visual inspections of the main rotor blade

attachment area in the upper and lower MRH shaft flanges, and repetitive 

visual inspection on the upper and lower MRH shaft flanges and the blade bolt 
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area and, in case cracks are detected, replacement of the MRH. That AD also 

required reporting of any findings to ECD.

After that AD was issued, further investigation results showed that the 

repetitive visual inspections of the blade bolt area, as described in Part 3 of 

ECD Alert Service Bulletin (ASB) No. EC135-62A-029 Revision 1, were no 

longer required to ensure safe operation. ECD ASB EC135-62A-029 Revision 

3 was published to provide the amended instructions.

Consequently, EASA issued AD 2012-0085R1 to delete the relevant required 

actions from paragraph (2) of the AD and, at the same time, to correct the 

Note for paragraph (1), providing further clarification.

Prompted by results of full scale component testing which demonstrated that 

the interval for the repetitive visual inspections of the upper and lower hub

shaft flanges could be extended from 10 to 15 flight hours (FH), EASA issued 

AD 2012-0085R1. In addition, rework procedures had been developed by ECD 

to allow deference of the next inspection to 400 FH after rework.

Since AD 2012-0085R2 was issued, based on results of further full scale 

component testing which demonstrated that the interval for the repetitive visual 

inspections of the upper and lower hub shaft flanges could be extended, EASA 

issued EASA 2012-0085R3 to extend the inspection intervals in paragraph (2) 

of the AD from 15 to 25 FH. Thereafter, based on further test results, EASA 

issued AD 2012-0085R4 to extend the inspection intervals in paragraph (2) of 

the AD from 25 to 40 FH.

Since AD 2012-0085R4 was issued, based on results of further full scale 

component testing, it has been determined that the interval for the repetitive 

visual inspections of the upper and lower hub shaft flanges can be extended 

from 40 to 50 FH.

For the reason described above, this AD is revised to amend the inspection 

intervals in paragraph (2) of the AD and make reference to ECD ASB EC135-

62A-029 Revision 7 for related information.

This AD is still considered to be an interim action and further AD action may 

follow.

Effective Date: Revision 5: 30 October 2012

Revision 4: 04 October 2012

Revision 3: 11 September 2012

Revision 2: 24 August 2012

Revision 1: 10 August 2012

Original issue: 18 May 2012

Required Action(s) 

and Compliance 

Time(s):

Required as indicated, unless already accomplished:

(1) Within 3 days after 18 May 2012 [the effective date of the original issue of 

this AD] and thereafter, before each flight, accomplish a pre-flight visual 

inspection in accordance with the instructions of section 3.B.Part 1 of ECD 

Alert Service Bulletin (ASB) No. EC135-62A-029 Revision 1 (or later 

revision).

The flight duration between 2 pre-flight inspections must not exceed 6 FH.

Note 1: The repetitive pre-flight inspections of this AD may be accomplished 

by the flight crew or the pilot-owner if they hold a certifying staff authorization 

issued by the corresponding approved maintenance organisation in 

accordance with the provisions of Part M.A.606 paragraph (h)1, or Part 

145.A.30 paragraph (j)3, as applicable. After completion of each pre-flight 

inspection as required by paragraph (1) of this AD, this person should issue 

the corresponding Certificate of Release to Service in the log book of the 
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helicopter.

Prior authorizations, given to the flight crew by the corresponding approved 

maintenance organisation based on EASA AD 2012-0041 (including R1) or 

EASA AD 2012-0085-E, remain valid for actions accomplished as required by 

this AD.

(2) Upon accumulation of 400 FH by the MRH (see below and Appendix 1 of

this AD) since first MRH installation on a helicopter (specified as time 

since new (TSN) in the ECD ASB), or within 50 FH, whichever occurs later 

after 18 May 2012 [the effective date of the original issue of this AD], and, 

thereafter, at intervals not to exceed 50 FH, accomplish a visual 

inspection of the upper and lower hub shaft flanges in accordance with the 

instructions of section 3.B.Part 2 of ECD ASB No. EC135-62A-029

Revision 1 (or later revision).

For a MRH which has been reworked in accordance with the instructions 

of ECD SB No. EC135-62-030 or SB No. EC135-62-032 (or later 

revisions), the next inspection can be deferred until 400 FH accumulated 

by the MRH after that rework has been accomplished.

After that inspection, repetitive inspections are required at intervals not to 

exceed 50 FH. Appendix 1 of this AD provides detailed information.

(3) If, during any inspection as required by paragraph (1) and (2) of this AD, 

cracks are detected, before next flight, replace the MRH with a 

serviceable unit.

(4) Replacement of a MRH as required by paragraph (3) of this AD does not 

constitute terminating action for the repetitive inspections as required by 

paragraph (1) and (2) of this AD.

(5) Within 1 week after replacement of the MRH as required by paragraph (3) 

of this AD, report the findings and send the removed MRH for further 

investigation to ECD.

(6) From 18 May 2012 [the effective date of the original issue of this AD], do 

not install a MRH that has accumulated more than 400 FH since first 

installation on a helicopter unless that MRH has passed an inspection as 

required by paragraph (2) of this AD.

Ref. Publications: Eurocopter Deutschland ASB No. EC135-62A-029 Revision 1, dated 16 May

2012, Revision 2 dated 17 May 2012, or Revision 3 dated 09 August 2012, or 

Revision 4 dated 23 August 2012, or Revision 5 dated 10 September 2012, or 

Revision 6 dated 02 October 2012, or Revision 7 dated 22 October 2012.

Eurocopter Deutschland SB No. EC135-62-030 dated 16 August 2012, or 

Revision 1 dated 31 August 2012, or Revision 2 dated 15 October 2012.

Eurocopter Deutschland SB No. EC135-62-032 dated 04 September 2012, or 

Revision 1 dated 15 October 2012.

The use of later approved revisions of these documents is acceptable for 

compliance with the requirements of this AD.

Remarks: 1. If requested and appropriately substantiated, EASA can approve 

Alternative Methods of Compliance for this AD.

2. Based on the required actions and the compliance time, EASA have 

decided to issue a Final AD with Request for Comments, postponing the 

public consultation process until after publication.

3. Enquiries regarding this AD should be referred to the Safety Information 

Section, Executive Directorate, EASA. E-mail: ADs@easa.europa.eu.

4. For any question concerning the technical content of the requirements in 

this AD, please contact Eurocopter Deutschland GmbH,

Industriestrasse 4, 86607 Donauwörth, Federal Republic of Germany

Telephone: + 49 (0)151-1422 8976; Facsimile: + 49 (0)906-71 4111.
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Appendix 1 – Required Actions on MRH

MRH FH and condition Part 1 of ASB Part 2 of ASB

Less than 400 FH TSN Yes No

Less than 400 FH time since rework 

(TSR) in accordance with ECD SB

EC135-62-030 or SB EC135-62-032 

(or later revisions)

Yes No

400 FH TSN or more Yes Yes

400 FH or more TSR in accordance 

with ECD SB EC135-62-030 or SB 

EC135-62-032 (or later revisions)

Yes Yes

Note 2: At the time of issuance of AD 2012-0085R2, the MRH rework of SB No. EC135-62-030 can be 

applied by ECD or in-service by the operator after training and authorization by ECD, while the MRH rework 

of SB No. EC135-62-032 can only be applied by an authorized (by ECD) overhaul station.