### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 1/14

2009.08.03
This document is available on the Internet: www.eurocopter.com/techpub EUROCOPTER

DIRECTION TECHNIQUE SUPPORT

13725 MARIGNANE C EDEX F RANCE



# EMERGENCY 

# ALERT SERVICE BULLETIN

PUMA NUMBER VERSIONS

Civil : F,G,J 

# SA330 67.18 Military : B,Ba,C,Ca,Ea,H,L,S1, Jm,Sm



### SUBJECT: ROTOR FLIGHT CONTROLS

Inspection and reconditioning of pilot and copilot pedal unit adjustment system

Corresponds to MOD: 330A779820.00

REVISION No. DATE OF APPROVAL DATE OF ISSUE

Revision 0 On: July 31, 2009 2009.08.03

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 2/14

2009.08.03 

### 1. PLANNING INFORMATION

1.A. EFFECTIVITY

1.A.1. Helicopters/installed equipment

All SA330 helicopters that have embodied MOD 07. 10.304 (pedal position adjustment system) but

have not embodied MOD 330A779820.00.



### NOTE

Refer to the Individual Inspection Record (RIC AMS), the Equipment Log Cards (FMs) or the aircraft logbook to identify the act ual configuration of the helicopter.

1.A.2. Non-installed equipment

On all pedal units that have embodied MOD 07.10. 304 (pedal position adjustment system) but have

not embodied MOD 330A779820.00.



### 1.B. ASSOCIATED REQUIREMENTS

Not applicable.



### 1.C. REASON

To prevent the risk of losing the yaw contro l provided by the pilot and copilot pedal unit.

This ALERT SERVICE BULLETIN will be the s ubject of an EASA Airwor thiness Directive.



### 1.D. DESCRIPTION

While adjusting the position of the pedal unit on a SA330 helicopter, the copilot set the position beyond the end limit ("tall pilot" position). This l ed to the separation of the pedal adjustment system and the pedals rocking forward.

It was determined after investigation that the Loc tite bond on the "tall pilot" stop nut was damaged, most likely due to aging of the adhesive. The nut came loose and could no longer perform its stop function. The threaded rod of the adjustment system separated from the system.

The separation of the adjustment system could result in the loss of control of the pedal units, causing the helicopter to begin rotating.

EUROCOPTER has defined an inspection procedure to determine the effectiveness of the "tall pilot" stop. The safetying on the stop nut must also be reworked on customer premises.

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 3/14

2009.08.03 

### 1.E. COMPLIANCE

EUROCOPTER renders compliance with th is ALERT SERVICE BULLETIN mandatory.

1.E.1. Compliance at the works

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

Not applicable.

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

Comply with paragraphs 2.B.2., 2.B. 3. and 2.B.5. prior to delivery.

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

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

Perform the inspection defined in paragraph 2.B.1. within 10 flight hours at the latest following receipt of this ALERT SERVICE BULLETIN issued on the date indicated at the foot of the page.

Result Analysis :

- If a non-conformity is found in paragraph 2.B.1., co mply with paragraphs 2.B.2., 2.B.3. or 2.B.4.

and 2.B.5. before resuming flights

.

- If no non-conformity is found in paragraph 2.B.1., co mply with paragraphs 2.B.2., 2.B.3. and 2.B.5.

within 3 months at the latest following receipt of this ALERT SERVICE BULLETIN issued on the date indicated at the foot of the page.

When complying with paragraph 2.B.3. or 2.B.4., it is temporarily permitted not to install the half-bushings. Consequently, flights without th e half-bushings can be resumed for one year

from the date of issue of this ALERT SERVICE BULLETIN.

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

Comply with paragraphs 2.B.2., 2.B.3. and 2.B.5. prior to installation on helicopter and at the

latest within 3 months following receipt of this ALERT SERVICE BULLETIN issued on the date indicated at the foot of the page.



### 1.F. APPROVAL

1.F.1. Approval of the modifications

The information or instructions relate to MO D 330A779820.00 approved on July 30, 2009 by the EASA for civil version helicopters subject to an airworthiness certificate.

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 4/14

2009.08.03 1.F.2. Approval of the ALERT SERVICE BULLETIN

The technical information contained in Revision 0 of this ALERT SERVICE BULLETIN was approved on July 31, 2009 under th e authority of EASA Design Organization Approval No. 21J.056 for civil version helicopters subject to an airworthiness certificate.

The technical information contained in Revision 0 of this ALERT SERVICE BULLETIN was approved on July 31, 2009 by the EUROCOPTER Airworthine ss Department for military version helicopters.



### 1.G. MANPOWER

1.G.1. Qualification

1 mechanic.

1.G.2. Time for the operations

3 hours.

1.G.3. Estimated helicopter grounding time

3 hours.



### 1.H. WEIGHT AND BALANCE

Not applicable.



### 1.I. EFFECT ON ELECTRICAL LOADS

Not applicable.



### 1.J. SOFTWARE MODIFICATION EMBODIMENT STATE

Not applicable.



### 1.K. REFERENCES

Standard Practices Manual (MTC):

Work Card: 20.02.05.404

Work Card: 20.02.06.406

Work Card: 20.02.06.409

### T.F.S. No. 00000528

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2009.08.03 

### 1.L. OTHER DOCUMENTS AFFECTED

Not applicable.



### 1.M. TOOLING AFFECTED

Not applicable.



### 1.N. INTERCHANGEABILITY OR MIXABILITY OF PARTS

Not applicable.

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 6/14

2009.08.03 

### 2. ACCOMPLISHMENT INSTRUCTIONS

2.A. GENERAL

Not applicable.



### 2.B. OPERATIONAL PROCEDURE

NOTE 1

The procedure is to be followed on both the pilot and copilot sides.

2.B.1. Functional test of pedal unit adjustment system (Figure 1)

2.B.1.a. Check for presence of "tall pilot" stop function

- Turn grip (o) to slowly bring the pedal unit to "tall pilot" limit stop. - Check that the "tall pilot" limit stop functions correctly. - Check that the fixed sleeve (j) ha s not separated from the cap (k). - Check that the half-bushings (s) are in place. - Check that the sliding sleeve (i) can freely mo ve forward approximately 2 mm with the pedal unit at the "tall pilot" limit stop (see Figure 1 - DETAIL A).



### NOTE 2

If the half-bushings (s) are not present, do not check the movement on the sliding sleeve (i).

2.B.1.b. Result Analysis

- If the following is detected: . absence of "tall pilot" limit stop,

or . separation of fixed sleeve (j) and cap (k),

or . no freedom of movement on sliding sleeve (i) with the half-bushings (s) in place, Comply with paragraphs 2.B.2., 2.B.4. and 2.B.5.

- If only the following is detected: . absence of the half-bushings (s) Comply with paragraphs 2.B.2., 2.B.3. and 2.B.5.

When complying with paragraph 2.B.3. or 2.B.4 ., it is temporarily permitted not to install the half-bushings. Consequently, flights without the half-bushings can be resumed for one year from the date of issue of this ALERT SERVICE BULLETIN.

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 7/14

2009.08.03 2.B.2. Removal of pedal unit adjustment system (Figure 2)

WHEN REMOVING THE ADJUSTMENT SYSTEM,

BLOCK THE PEDALS TO AVOID DAMAGING ANY

SURROUNDING ELEMENTS.

- Remove and discard the taper pin (a). - Loosen and remove the nut (b), washer (c) and threaded pin (d). - Remove and discard the 2 taper pins (f). - Loosen and remove the 2 screws (g) and 2 washers (h). - Remove the entire pedal unit adjus tment system and place on workbench.

2.B.3. Upgrade of safetying on pedal unit adjustment system (Figures 2, 3 and 4)

- Remove and discard the cotter pin (n). - Remove the grip (o). - Remove and discard the cotter pin (q). - Move the threaded rod (r) to bring the stop nut (p ) towards the "small pilot" position in order to gain access to the stop nut (p) in the nut tube (m).

- Check that at least one thread of the stop nut (p) protrudes as indicated on Figure 3 - DETAIL B or Figure 4 - DETAIL C.

. If less then one thread is visible:

.. Perform rework of safetying as per paragraph 2.B.4.

. If at least one thread is visible:

.. Use a punch to make 3 marks (x) on the end of the threaded rod (r) to provide additional

safetying for the nut as per Figure 4 and MT C Work Card 20.02.06.406 (do not perform sampling tests for improper safetying). - If the half-bushings are found to be missing, install new half-bushings (4) inside the sliding sleeve (i) and bond them with epoxy adhesive (12). - Install cotter pin (3a) to the nut tube (m). - Install grip (o) and cotter pin (3b).



### NOTE 3

The two cotter pins (3a) and (3b) must be flush and peened on installation. 

### CAUTION

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 8/14

2009.08.03 2.B.4. Rework of safetying on pedal unit adjustment system (Figures 2, 3 and 4)

- Remove and discard the taper pin (n) if it was not removed in paragraph 2.B.3. - Remove the grip (o) if it was not removed in paragraph 2.B.3. - Remove and discard the taper pin (q) if it was not removed in paragraph 2.B.3. - Heat the assembly to 120°C in order to disassemble the components bonded with Loctite (MTC Work Card 20.02.06.409). - If half-bushings (s) are present, unbond and remove the half-bushings (s) as needed following

the instructions in MTC Work Card 20.02.06.409.



### NOTE 4

The half-bushings are bonded with epoxy adhesive and may be damaged when removed. If so, they must

be discarded.

- Unbond the fixed sleeve (j) from the cap (k). - Remove the fixed sleeve (j) and the sliding sleeve (i). - Loosen and remove the cap (k) from the nut tube (m). - Remove the retention sleeve (l). - Move the threaded rod (r) to bring the stop nut (p ) towards the "small pilot" position so that the nut protrudes from the nut tube (m) in order to gain access to the nut. - Loosen, remove, clean and set aside the stop nut (p) for later use.



### NOTE 5

Prior to installation, check the condition of each element removed previously.

- Degrease only the section of the thread ed rod (r) that receiv es the stop nut (p). - Perform safetying on stop nut (p) by applying Lo ctite (10) as per MTC Work Card 20.02.06.409 and torque tighten nut as indicated in MTC Work Card 20.02.05.404. - Use a punch to make 3 marks (x) on the end of the threaded rod (r) to provide additional safetying for the nut as per Figure 3 - DETAIL B or Figure 4 - DETAIL C and MTC Work Card 20.02.06.406 (do not perform sampling tests for improper safetying). - Wait for Loctite to cure (10) as per MTC Work Card 20.02.06.409. - Lubricate threaded rod (r) with grease (11). - Move the threaded rod (r) to bring the stop nut (p) to mid-travel position (see Figure 3 – DETAIL B). - Install the retention sleeve (l). - Tighten the cap (k) on the nut tube (m). - Install the sliding sleeve (i) t ogether with the fixed sleeve (j). - Bond the fixed sleeve (j) and the cap (k) with epoxy adhesive (12). - Install the half-bushings (4) inside the slid ing sleeve (i) and bond them with epoxy adhesive (12). - Install cotter pin (3a) to the nut tube (m). - Install grip (o) and cotter pin (3b).



### NOTE 6

The two cotter pins (3a) and (3b) must be flush and peened on installation.

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 9/14

2009.08.03 2.B.5. Installation of pedal unit adjustment system (Figure 2)

- Offer up the pedal unit adjustment system assembly. - Install the 2 washers (h) and tighten the 2 screws (g) on the retention sleeve (l). - Install the 2 pins (2). - Install the threaded pin (d) and wash er (c) and tighten the nut (b). - Install pin (1). - Use the grip (o) to return the pedal unit to the mid-position.



### 2.C. IDENTIFICATION

- Record compliance with this ALERT SERVICE BULLETIN in the aircraft documentation on final

completion of the operational procedure, i. e. afte r having checked that the half-bushings (s) or (4) are present or have been installed. - Indelibly mark the MOD number on the nut tube (m) as shown on Figure 4.



### 2.D. OPERATING AND MAINTENANCE INSTRUCTIONS

Not applicable.

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 10/14

2009.08.03 Figure 1: Inspection of pedal unit adjustment system Stop nut (p) in the “tall pilot” position



# DETAIL A p o



# SECTION A - A

k j s i

i s j

k

≈ 2 mm

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 11/14

2009.08.03 Figure 2: Inspection and removal/insta llation of pedal unit adjustment system 

### f - 2

g
h d

c
b

a - 1



# SECTION B - B o l

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 12/14

2009.08.03 Figure 3: Rework of safetying on pedal unit adjustment system 

# SECTION C - C

DETAIL B Stop nut (p) in the mid-travel position



### x

Presence of at least one thread 

### 11

r s
4 j

k m i

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 13/14

2009.08.03 Figure 4: Embodiment of MOD 330A779820.00 Presence of at least one thread 

### m Indelible marking of MOD

No. 330A779820.00

### T.F.S. No. 00000528

Approved under EASA DOA No. 21J.056 Page 14/14

2009.08.03 

### 3. MATERIAL INFORMATION

3.A. MATERIAL: PRICE AND AVAILABILITY

3.A.1. Cost

The components listed in paragraph 3.C.1. will be delivered free of charge upon receipt of an order from the operator.

3.A.2. Availability

The operator will be notified of the delivery lead time by User Service Sales Directorate.



### 3.B. INFORMATION CONCERNING INDUSTRIAL SUPPORT

Not applicable.



### 3.C. EQUIPMENT REQUIRED FOR EACH HELICOPTER/ENGINE/COMPONENT

3.C.1. Kit or component(s) to be ordered for one helicopter or one assembly

Material P/N Qty Item Key Word Instructions

MP/N SAP

23310CA015015 740025 2 1 Pin

53301-20-15BCL 1155051 4 2 Pin

53301-20-25BCL 1173580 4 3a Pin

53301-20-25BCL 1173580 4 3b Pin

3.C.2. Material to be ordered separately

Material P/N Qty Item Key Word Instructions

MP/N SAP

330A77-4088-20 330A77408820 AR 4 Half-bushing

3.C.3. Products to be ordered separately

Material P/N Qty Item Key Word Instructions

MP/N SAP

ASNA4019 1055389 AR 10 Adhesive

AIR 4210B 1061310 AR 11 Grease CN-EC2216B/A 1104301 AR 12 Epoxy adhesive



### 3.D. PROCUREMENT CONDITIONS

Not applicable.



### 4. APPENDIX

Not applicable.