Eurocopter EC145/BK117 Technical Briefing

Eurocopter
EC145/BK117
Technical Briefing
Heli-Expo 2009
February 2009
EC145/BK117 – The Team!
Team Contacts
Manager Technical Support
James JB Kincaid
Phone: 972-641-5068
Fax:
972-641-3710
Mobile: 214-701-5094
[email protected]
Product Manager
EC135/EC145/ BK117/BO105
Michael Morters
Phone: 972-641-3587
Fax:
972-641-3710
Product Manager
EC135/EC145/ BK117/BO105
Chris Carter
Phone: 972-641-3734
Fax:
972-641-3710
[email protected]
[email protected]
Product Manager
EC135/EC145/BK117/BO105
Dave Vogel
Phone: 972-641-3573
Fax:
972-641-3710
Mobile: 817-201-1196
[email protected]
Customer Support Improvements
• Office Hours
ƒ Grand Prairie office now open for technical assistance from 7:00AM until 5:00PM fully staffed.
- After-hours support maintained 24/7 through closed-loop answering service supported by technicians
‘on call’
• Additional Staff
ƒ Experienced German factory technicians added to Grand Prairie staff
- Dieter Schmidt – Avionics / autopilot expertise
- Manfred Wimmer – EC145 / EC135 expertise
• Additional Technical Representatives
-
Mike May – AS 350 expertise
Kelly Haller – LUH support, SW region
Les Weatherhead – LUH support East region
Erich Crossin – Super Puma support
Brent Butterworth – Autopilot / Avionics
Ronald Caulkins – HUMS Specialist
John Sharski – EC120
• Customer Support Newsletter
ƒ Monthly newsletter to inform of technical tips, service improvements, publication updates, spare
parts topics, etc. Distributed by email and posted on AE’s website.
In-House Representatives
Assistance at American Eurocopter
Help Desk 1-800-232-0323
Ken Arnold
350/355/130
Cory Shippen
350/355/130
Mike May
350/355/130
Dave Vogel
105/117/135/145
Mike Morters
105/117/135/145
Chris Carter
105/117/135/145
John Sharski
120
Ed Spalding
120/332/365
Brent Butterworth Avionics/Autopilot
Jim Creighton
155/365
John Wintermote 365 USCG
Dieter Schmidt
Avionics/Electrical
Manfred Wimmer 105/117/135/145
Ronald Caulkins HUMS Specialist
Eric Crossin
225 Specialist
Regional Representatives
Steve Smith
425/821-6797
Scott Dodge
207/698-5051
Jon Hubbell
317/336-7887
Dave Dunstan
530/626-0451
Ryan Olsen
949/305-8532
Bob Swanson
303/688-9618
Tom Brown
702/898-6307
Kelly Haller LUH
972/641-3402 Bill Biddlecome
928/632-0697
John Shauger
812/597-5528
Erich Crossin
972/641-3402
Chris Breaux
985/649-8004
Les Weatherhead LUH
817/453-7829
Eric Herbst
972/641-3734
Terry Kratovil
724/838-7438
Phil Rizan
770/687-2775
Cambren Davis
352/848-0009
EC145 Fleet as of February 2009
North America
98
Europe
79
Far East
Asia
12 (KHI)
5
Central America
6
South East Asia
5
Australia
5
South America
2
EC145 Fleet Leaders as of February 2009
S/N
Operator
Flight Hours
• S-9038
• S-9051
• S-9095
• S-9027
• S-9026
• S-9044
• S-9054
• S-9039
• S-9029
• S-9004
DRF (Germany)
~ 4,365
Pegaso (Mexico)
~ 3,850
Pegaso (Mexico)
~ 3,765
ADAC (Germany)
~ 3,650
Rega (Switzerland)
~ 3,500
Vanderbilt (USA)
~ 3,475
Vanderbilt (USA)
~ 3,155
Vanderbilt (USA)
~ 3,106
ADAC (Germany)
~ 3,100
Hessen Police (Germany)
~ 3,050
Total Fleet: 212 aircraft
~ 233,000
BK117 Fleet as of February 2009
North America
Europe
76
125
Far East
85
Middle East
29
Central America
7
Africa
5
Australasia
37
South America
13
BK117 Fleet Leaders as of February 2009
S/N
Operator
Flight Hours
• S-7023
• S-7038
• S-7201
• S-7207
• S-7133
• S-7215
• S-7027
• S-7078
• S-7051
• S-7112
Omniflight Helicopters Inc.
~ 16,111
Omniflight Helicopters Inc.
~ 15,867
Air Methods Corp. (ARCH)
~ 15,466
Air Methods Corp. (ARCH)
~ 15,067
Omniflight Helicopters Inc.
~ 14,195
Omniflight Helicopters Inc.
~ 14,110
Air Methods Corp.
~ 13,700
Omniflight Helicopters Inc.
~ 13,331
Air Methods Corp.
~ 13,200
Omniflight Helicopters Inc.
~ 12,673
Total Fleet: 385 aircraft
~ 2,322,000
Technical Issues
ATA 05 – Continuous Maintenance Program
• A continuous maintenance
program is planned for the
EC145.
• Draft version completed, final
validation scheduled 1st
quarter 2009.
• Planned introduction with
MSM Temporary Revision
010a.
ATA 21 – Brushless Cabin Pax Blower
• Improved brushless cabin pax blower B212M2054101 installed
from S-9231 and up.
• Distribution of Service Bulletin 21-004 planned shortly.
ATA 21 – Cockpit Ventilation Blower Motor TBO
• The TBO of blower motor
ES73175-7 has changed from
a fixed value of 1,000 hr, to a
variable value of 600 hr +
(remaining useable brush
length divided by wear per
flight hour).
• Same principle as used on
the EC135.
ATA 22 – DAFCS BK117 C1 Remote Vertical Gyros
• Current Aeronetics RVG-801E
remote vertical gyros (p/n 5208014-003) for BK117s with
DAFCS configuration II are
obsolete, and repaired units have
become very expensive.
• Two new modified vertical gyros
VG 208E from L-3 Avionics
Systems are currently under
evaluation.
• Certification flight tests with the
new gyros are currently
underway.
ATA 23 – Intercomm System Becker DVCS 6100
• Becker Avionics Service Letter SL-REU6100/2008-1 (refer to
EC145 Service Information MBB BK117 C-2-056) introduced
upgraded firmware version 1.40 which improves the operating
capabilities of the REU6100.
• This new firmware is not compatible with the configuration tool
CSW6100 up to software version 1.10!
• CSW6100 software version 1.20 or higher is mandatory.
ATA 24 – Starter/Generators
• Increased reports of failures on new type 23081-072 startergenerators.
• Investigations of affected units with Goodrich revealed that the
brush leads get hung up, which prevents sufficient contact of
the brushes to the commutator (brushes cannot travel freely in
the brush holders).
• Introduction of -072 type
scheduled for BK 117 C-1.
ATA 24 – Starter/Generators
Correct!
Incorrect!
ATA 25 – Retrofit of Hand Grips on Cockpit Frame
• Handgrips can now be installed on the cockpit frame to
facilitate entrance into the helicopter for the pilots.
• Retrofit with SB 25-004.
ATA 25 – EC145 Interior Paint Colors (Standard)
ATA 25 – Cockpit Interior Paint Colors (Std & NVG)
ATA 25 – Interior Paint Colors (NVG)
ATA 31 – NVG Standby Horizon
• Standby Horizon AI-803CY (NVG) and AI-804DC (non-NVG)
show a high failure rate due to defective internal lighting. NVG
version is on the US-ITAR list and has extremely long lead
times!
• Solution by introducing an NVG Bezel (eye brow) that provides
external lighting with SB 33-008.
• Compatible for both versions.
ATA 31 – CVFDR Simplified 12-Month Inspection
• A simplified 12-month inspection has been approved for the
CVFDR.
• The special tools as listed in the AMM chapter 31-32-00, 5-8
are still required, but less workload involved.
• AMM to be revised with revision 10.
ATA 31 – 2nd OAT Indicator
• Due to recent changes in
certification regulations, ECD
is offering a 2nd OAT indicator
for redundancy.
• Available with Service Bulletin
90-120.
ATA 33 – 2nd Landing Light Cracks
• Frequent cracking of landing
light housing bracket reported
with subsequent loss of
landing light.
• Alert Service Information
MBB-BK117C-2-A042 issued.
• New design recently certified.
ATA 33 – 2nd Landing Light Cracks
ATA 34 – AHRS Compensation Box
• ECD now offers an AHRS compensation box
• Required for compensation of the magnetometers (test flight)
during the annual inspection.
• Easy installation at connectors J75007 (AHRS 1, white marked
cable) and J75107 (AHRS 2, yellow marked cable).
• Part number AHRS-ECD (ECD Material-# 1525413)
ATA 34 – Air Data Computer Functional Test
• Functional test introduced without necessity of ARINC 429
reader with AMM revision 009
ATA 52 – Sliding Cabin Door Back-Stops
• Middle guide rail might buckle if door operated too hard.
• New design installed from S-9231 and up.
• Retrofit with SB 52-003 Rev. 1.
ATA 53 – Tail Boom Retrofit
• Tail boom mods (series standard since S-9135) can now be
retro-fitted with SB 53-007.
ATA 62 – Main Rotor Blade Loop Inspection
• The 600 hour inspection interval (removal of fitting and
inspection of the loop for cracks) has changed to 1,800 hrs
TSN, then 1,200 hrs TSI (time since inspection), thereafter
every 600 hrs.
ATA 63 – Mast Moment Strain Gauge Bridge
• 16 known cases of strain gauge
bridge de-bonding so far.
• Special ‘approach and landing’
flight test program scheduled
using our prototype helicopter to
define possible alternative
measures (with inoperative mast
moment system).
ATA 65 – Service Life Limits IGB and TGB
• Revision 009 to the MSM
introduced new Service Life
Limits for the bevel gears.
• IGB raised to 4,200 hours.
• TGB raised to 4,600 hours.
• TBO set at 1,500 / 1,800 hours
(IGB / TGB); TBO extension
has high priority.
• The result of the SLL increase
reduces DOCs approximately
€5.59 (US$7.26) per hour.
ATA 65 – Service Life Limits IGB and TGB
• Two programs launched in February 2009 with ZFL:
ƒ Program 1 will introduce new oil (Transmax Z) starting May 2009
in all gearboxes repaired or overhauled at an approved repair
center.
- 5 of these replenished gearboxes will be chosen and monitored by
intermittent borescope inspections, then overhauled at the current
existing TBO limits (1,500 & 1,800 hours), and further monitored until
final goal of 2,100 & 2,300 hours (half TCI time) is achieved.
ƒ In parallel Program 2 has the goal to introduce new gearboxes with
improved gear load patterns and stiffer steel liners and should be
available around August 2010. We expect an even better TCI than
today’s values.
- Again, 5 of them will undergo another TBO verification program in order
to achieve the highest achievable TBO (3,200 or 4,000 hours??) limits.
ATA 67 – Alignment of Yaw-SEMA Clevis
• AMM does not describe the correct
alignment angle of the clevis.
• If not adjusted correctly (14°) the
SEMA may have contact with the
cowling.
ATA 67 – Pitch Links 117-31822
• A Service Evaluation using new technology spherical bearings
will begin this year.
• 4 different bearing types are to be evaluated.
• Tail rotor pitch links will be the first component to undergo
testing with the new bearings.
ATA 67 – YAW SEMA Control Rod Cracks
• 2 cases of cracked control rods reported.
• Non-critical, strength is still assured.
• Manufacturing process to be improved.
ATA 67 –YAW SEMA Spring Attachment
• Hole for spring attachment wears out.
• Part number is B673M4006201
ATA 67 – SPAS BK117
• SPAS sensor BHL4305-15-00 has been out of production for
some time..
• New sensor PDCR340-4509 recently certified, SB 80-160
distributed (1st qtr. 2009).
ATA 67 – SPAS Computer
• 50 % of all returned SPAS computers are found without failure!
• In future all SPAS computers will be labeled with an instruction
to adjust the potentiometer screws in accordance with the
procedure in the maintenance manual chapter 710-4.
• This is to be done whenever a computer or sensor is replaced
using tool 117-93431L96.0X
ATA 71 – Firewall Cracks
• Increased reports of cracked firewall on fairly new helicopters
ATA 71 – Engine Mounts
• The new design uses flanged bushings with a
tight fit and floating bushings with a slip fit.
• Series introduction with S-9151.
• SB 71-009 (for C-2) & 60-124 (for C-1)
scheduled 1st quarter 2009.
ATA 77 – Triple RPM Indicator
• New versions certified in 2008.
• Available 1st quarter 2009.
• Now 2 suppliers:
ƒ Diehl Aerospace: B771M40C1004
ƒ Vibro-Meter: B771M40C1005
ATA 79 – Electrical Chip Detectors in IGB & TGB
• Electrical chip detectors (nonzapper) available for the
intermediate and tail rotor
gearbox of the BK117.
• Cancels 50 hr. supplementary
inspection requirements.
• Retrofit available with SB 90117.
Eurocopter
LEVERAGING OUR STRENGTHS