Page 1/19

2012.07.13

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

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

Revision 3 On: July 13, 2012 2012.07.13Page 2/19

2012.07.13 

### 1. PLANNING INFORMATION

1.A. EFFECTIVITY

1.A.1. Helicopters/installed equipment

On main gearboxes (MGB), all part numbers pre MOD 0 752522.



### 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 mo dule.



### NOTE 3

MOD 0752522 is intended to improve the detection of

metallic particles generated by possible deteriorat ion of

the epicyclic stage by removing the magnets and the

flanged edge from the chip collector on the top par t of the

main reduction module.

1.A.2. Non-installed equipment

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

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



### 1.B. ASSOCIATED REQUIREMENTS

Not applicable.Page 3/19

2012.07.13 

### 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 re sulted in issue of EASA Airworthiness

Directive No. 2009-0087-E

Revision 1 of the present ALERT SERVICE BULLETIN wa s intended:

- to add embodiment of MOD 0752522,

- to inform operators that embodiment of MOD 075252 2 renders the directives of revision 0 of the

present ALERT SERVICE BULLETIN null and void.

- to inform operators that embodiment of MOD 075252 2 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 Ta sk 05-53-00-218 need be applied.

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

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

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

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

Airworthiness Directive.

Revision 2 of this ALERT SERVICE BULLETIN was inten ded to inform you that the EASA approval

had been obtained.

Revision 2 of this ALERT SERVICE BULLETIN did not a ffect compliance with Revision 1.

The purpose of Revision 3 of this ALERT SERVICE BUL LETIN is:

- To remind operators that it is forbidden to fly w ith Main Gearboxes pre MOD 07 52522

since July 18, 2009.

- To introduce the deadline of December 01, 2012, f or embodiment of modification 07 52522 on

non-installed equipment.Page 4/19

2012.07.13 

### 1.D. DESCRIPTION

Revision 0:

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

the investigation is still in progress under the au thority 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 st age

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

detection of any pollution of the main gearbox is o f 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 acti vated in the event of pollution.

EUROCOPTER re-iterates and emphasises, as a precaut ion, 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 SERV ICE BULLETIN, the studies in progress

investigating the possibility of improving the meta llic particles detection system monitoring the Main

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

between the Epicyclic module and the Main module.

The detector currently fitted enables segregation o f 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 tha t this chip collection device may delay the

detection of particles.

In order to improve the flow of particles towards t he 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 flanged edge from the chip collecto r.

EUROCOPTER has made the measures defined in Revisio n 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 em body MOD 0752522 and EAD directives

No. 2009-0095-E concurrently.

Revision 2, whose technical content is identical to that of Revision 1, was issued to inform the

operators of the EASA agreement.Page 5/19

2012.07.13 Revision 3:

The purpose of Revision 3 of this ALERT SERVICE BUL LETIN is:

- To remind operators that it is forbidden to fly w ith Main Gearboxes pre MOD 07 52522

since July 18, 2009.

- To introduce the deadline of December 01, 2012, f or embodiment of modification 07 52522 on

non-installed equipment.



### 1.E. COMPLIANCE

EUROCOPTER renders compliance with the present ALER T SERVICE BULLETIN mandatory.

1.E.1. Compliance at the works

1.E.1.a. On Helicopters

Not applicable.

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

Not applicable.

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

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

REMINDER:

Revision 1 of this ALERT SERVICE BULLETIN required mandatory embodiment of modification

MOD 07 52522 before July 18, 2009.

Consequently, it is forbidden to fly with MGBs pre MOD 07 52522 (See paragraph 2.B.1.)

since July 18, 2009.

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

1) On Main Gearboxes (MGB):

- Comply with paragraph 2.B.1. before installation on the aircraft, and at the latest

by December 01, 2012.

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

- Comply with paragraph 2.B.1. before installation on the aircraft, and at the latest

by December 01, 2012.Page 6/19

2012.07.13 

### 1.F. APPROVAL

Approval is limited to civil version helicopters su bject to an Airworthiness Certificate.

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

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

The information or instructions referring to modifi cation MOD 0752522 Edition 2 were approved

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

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

on April 18, 2009 by EUROCOPTER Airworthiness Depar tment, 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 t ime 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 Desi gn Organisation Approval No. 21J.056.

The technical information contained in this ALERT S ERVICE BULLETIN Revision 3 was approved

on July 13, 2012 under the authority of EASA Design Organization Approval No. 21J.056 for

helicopters of civil versions subject to an Airwort hiness Certificate.

The technical information contained in this ALERT S ERVICE BULLETIN Revision 3 was approved

on July 13, 2012 under the prerogatives of the reco gnition of design capability FRA21J-002-DGA for

French Government helicopters.



### 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 ep icyclic module.

Approximately 10 hours for the inspection in the ev ent 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.Page 7/19

2012.07.13 

### 1.J. SOFTWARE MODIFICATION EMBODIMENT RECORD

Not applicable.



### 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.Page 8/19

2012.07.13 

### 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 sy stem.

Only the items hampering the epicycle reduction gea r removal

require to be removed.



### NOTE 2

EUROCOPTER are ready to provide you with any furthe r

information or support you may require to comply wi th 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.1 .:

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. Embodiment of MOD 07 52522

2.B.1.a. Preliminary checks

Refer to Figure 1

- 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).

- Comply with 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 gearbo x (MGB) and collect all the particles

contaminating the MGB and its lubrication system.

- Determine the number and type of particles, inclu ding 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.

. If the replacement criteria are not met:

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

indicated in paragraph 2.A.

- Thoroughly clean the area concerned.Page 9/19

2012.07.13 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:

- Contact the EUROCOPTER Technical Support departme nt as indicated in paragraph 2.A.

- Send the epicyclic module to an approved repair c entre for investigation

.



### NOTE 4

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.

2.B.1.b. Modification of the chip collector:

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

- Remove the nuts (c).

- Remove the top collector (d).

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



### NOTE 5

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 elem ents (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 6

Take care not to distort and/or warp the chip

collector (b) during application of this procedure.



### CAUTIONPage 10/19

2012.07.13 3) Modification of the chip collector (b) as shown in Figure 4:

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

a milling machine.

- Blend with a 5 mm radius.

- Carefully deburr the areas cut away.



### NOTE 7

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 accordan ce 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 8

Take care not to distort and/or warp the chip

collector (b) during application of this procedure.

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

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



### NOTE 9

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

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

its length.Page 11/19

2012.07.13 - 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 M MA 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 1 st stage sun gear.

Correct installation is ensured by complying with

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



### REMINDERPage 12/19

2012.07.13 Figure 1 

### a bPage 13/19

2012.07.13 Figure 2 

### f

2

b

1 d c e



## 62-75 lbf.in 0.7 – 0.85 daN.m 0.156Page 14/19

2012.07.13 Figure 3 

### b

1

b

1 b

1 g

g ePage 15/19

2012.07.13 Figure 4 

### h Chip collector (b) before deletion of the flanged e dges.

Chip collector (1) after deletion of the flanged ed ges and

the magnetic elements (e)

Clearance holes for the attachment rivets (g) for t he

magnetic elements (e) b

1Page 16/19

2012.07.13 Figure 5 

### Mark the new part number in

indelible inkPage 17/19

2012.07.13 

### 2.C. IDENTIFICATION

After application of paragraph 2.B.1. record embodi ment of MOD 0752522 on the log-card for the

MGB main reduction module.

- Re-identification of the chip collector after emb odiment of MOD 0752522.

Old part number

(item b) New part number

(item 1)

3 32A32

- 5160

- 00 332A32

- 5196

- 21



### 2.D. OPERATING AND MAINTENANCE INSTRUCTIONS

Not applicable.Page 18/19

2012.07.13 

### 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/C OMPONENT

3.C.1. Kits or components to be ordered for one hel icopter 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 c ompliance with the Tasks and/or

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

company.

Website: http://www.interturbine.com

Telephone: +49.41.91.809.300

AOG: +49.41.91.809.444Page 19/19

2012.07.13 

### 3.D. PROCUREMENT CONDITIONS

Order the required quantity (unless otherwise speci fied)

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.