ALERT SERVICE BULLETIN

EC135

CHANGE INSTRUCTION NO. 3 FOR EC135-67A-019

2009-12-16 PAGE 1 of 1

Date: First issue: 2008-04-28

Revision 01: 2009-09-29

Revision 02: 2009-10-07

Revision 03: 2009-12-16

Please replace Revision 02 of Alert Service Bulletin EC 135-67A-019 with Revision 03.

With the first issue of this Alert Service Bulletin, an inspection of the bearings for correct

attachment i.a.w. 3.B. of this Alert Service Bulletin has been specified for all EC135/EC635.

With Revision 01 the installation of bushings and washers was specified that prevents shifting

of the bearings in the axial direction.

With Revision 02 the references to the AMM have been corrected. The retrofit of the guidance

unit with yaw brake was deleted as it is not required.

With Revision 03 an inspection is introduced which must be accomplished after one of the

affected components (Section 1.A.(3)) has been replaced. 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.

ALERT SERVICE BULLETIN

EC135

EC135-67A-019

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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
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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 with 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.
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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.
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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.
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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 .
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(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.
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(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.
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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
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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
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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
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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)
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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
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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

1 After modification.

Detail D (Overview see Figure 1) After modification

4 5 6

4

6
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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:___________________

Helicopter P/N* 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