ALERT SERVICE BULLETIN

EASB
EMERGENCY
ALERT SERVICE BULLETIN
SUBJECT: MAIN ROTOR DRIVE - Epicyclic module
Replacement of the epicyclic module second stage planet gears
For the attention of
HELICOPTER(S)
CONCERNED
NUMBER
AS332
AS532
EC225
EC725
63.00.83
63.00.38
63A030
63A029
Version(s)
Civil
L2
Military
A2, U2
LP
AP
Revision No.
Date of issue
Revision 0
2016-06-29
Summary:
For helicopters which are not subject to EASA Airworthiness Directive No. 2016-0104-E, this ALERT SERVICE
BULLETIN requests that you identify the P/Nos. of the epicyclic module second stage planet gears and replace the
module if its planet gears have the P/Nos. concerned.
Compliance:
Airbus Helicopters renders compliance with this ALERT SERVICE BULLETIN mandatory.
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EASB
1.
PLANNING INFORMATION
1.A. EFFECTIVITY
1.A.1. Helicopters/installed equipment or parts
AS332 L2 and EC225 LP version helicopters delivered before June 27, 2016 which are not subject to EASA
Airworthiness Directive No. 2016-0104-E.
AS532 A2 and U2 and EC725 AP version helicopters delivered before June 27, 2016.
1.A.2. Non-installed equipment or parts
Epicyclic modules, Part Number 332A32-3020-00, 332A32-3020-01, 332A32-3021-00, 332A32-3021-01,
332A32-5021-00, 332A32-5021-01, 332A32-5023-01 or 332A32-5023-02.
1.B. ASSOCIATED REQUIREMENTS
Not applicable.
1.C. REASON
Following the accident involving an EC225LP helicopter in Norway on April 29, 2016, investigations are
ongoing and still not finalized. The purpose of this ALERT SERVICE BULLETIN is to propose a
precautionary measure relating to the potential initial event "opening of the MGB fixed-ring gear due to
internal epicyclic module damage" described in SIN No. 3043-S-00, as a complement to the measures
introduced through ALERT SERVICE BULLETIN Nos. 05.01.07 (AS332), 05.00.82 (AS532),
05A049 (EC225) and 05A045 (EC725).
As a precautionary measure, it was decided to maintain only one of the two types of epicyclic module second
stage planet gears in service. This decision is based on the following observations on the planet gear type
maintained in service:
- The detailed design of the planet gear bearing has an increased damage tolerance.
- Modeling and calculation reveal a lower load level on the external race of the planet gear bearing.
- In-service experience shows enhanced reliability.
This ALERT SERVICE BULLETIN therefore requests that you identify the P/Nos. of the epicyclic module
second stage planet gears and replace the module if its planet gears have the P/Nos. concerned.
1.D. DESCRIPTION
Compliance with this ALERT SERVICE BULLETIN consists in:
- identifying the second stage planet gears fitted on the epicyclic module,
- replacing the epicyclic modules equipped with at least one second stage planet gear assembly with
P/N 332A32-3335-02, 332A32-3335-03, 332A32-3335-05 or 332A32-3335-07.
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EASB
1.E. COMPLIANCE
1.E.1. Compliance at H/C manufacturer level
Not applicable.
1.E.2. Compliance in service
The work on the helicopter is to be performed by the operator.
Helicopters/installed equipment or parts:
- Upon receipt, check the Log Card (FM) of the epicyclic module to identify the Part
Numbers (332A32-3335-xx) of the eight second stage planet gear assemblies installed.
If the Log Card (FM) specifies the Part Numbers of the bare second stage planet gears (332A32-3070-2X),
refer to Appendices 4.A. to 4.D. to identify the Part Number (332A32-3335-xx) of the second stage planet
gear assembly, using the Serial Number:
. for helicopters equipped with an epicyclic module with at least one second stage planet gear assembly
with P/N 332A32-3335-02, 332A32-3335-03, 332A32-3335-05 or 332A32-3335-07:
- remove the epicyclic module to replace the second stage planet gear assemblies as per paragraph 3.
within 15 flying hours following receipt of this ALERT SERVICE BULLETIN.
. for helicopters equipped with an epicyclic module with eight second stage planet gear assemblies with
P/N 332A32-3335-00, 332A32-3335-04 and/or 332A32-3335-06:
- flights are authorized.
. if Appendices 4.A. to 4.D. do not enable the Part Number of at least one second stage planet gear
assembly to be identified:
- contact Airbus Helicopters at the address [email protected] or the approved
repair station which delivered the epicyclic module to obtain information on the second stage planet gear
assemblies installed,
- pending information, flights are authorized within a limit of 15 flying hours.
Non-installed equipment or parts:
- Prior to installation, check the Log Card (FM) of the epicyclic module to identify the Part
Numbers (332A32-3335-xx) of the eight second stage planet gear assemblies installed.
If the Log Card (FM) specifies the Part Numbers of the bare second stage planet gears (332A32-3070-2X),
refer to Appendices 4.A. to 4.D. to identify the Part Number (332A32-3335-xx) of the second stage planet
gear assembly, using the Serial Number:
. epicyclic module equipped with at least one second stage planet gear assembly with
P/N 332A32-3335-02, 332A32-3335-03, 332A32-3335-05 or 332A32-3335-07:
- do not install the epicyclic module,
- refer to paragraph 2.D. for the material return conditions.
. epicyclic module equipped with eight second stage planet gear assemblies with P/N 332A32-3335-00,
332A32-3335-04 and/or 332A32-3335-06:
- no additional measures are required.
. if Appendices 4.A. to 4.D. provided do not enable the Part Number of at least one second stage planet
gear assembly to be identified:
- contact Airbus Helicopters at the address [email protected] or the approved
repair station which delivered the epicyclic module to obtain information on the second stage planet gear
assemblies installed,
- pending information, do not install the epicyclic module.
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EASB
1.F. APPROVAL
Approval of modifications:
Not applicable.
Approval of this document:
The technical information contained in this ALERT SERVICE BULLETIN Revision 0 was approved
on June 29, 2016 by the Airbus Helicopters Airworthiness Department for civil version helicopters which are
not subject to EASA Airworthiness Directive No. 2016-0104-E.
The technical information contained in this ALERT SERVICE BULLETIN Revision 0 was approved
on June 29, 2016 under the prerogatives of the recognition of design capability FRA21J-002-DGA for French
Government helicopters.
The technical information contained in this ALERT SERVICE BULLETIN Revision 0 was approved
on June 29, 2016 by the Airbus Helicopters Airworthiness Department for export military versions.
1.G. MANPOWER
For compliance with this ALERT SERVICE BULLETIN, Airbus Helicopters recommends the following
personnel qualifications:
Qualification: - 2 Mechanical Engineering Technicians,
- 1 Pilot.
The time for the operations is indicated for reference, for a standard configuration.
Time for the operations: - approximately 40 hours (per Technician),
- approximately 2 hours for the Pilot.
The estimated helicopter downtime is 1 week.
1.H. WEIGHT AND BALANCE
Not applicable.
1.I.
POWER CONSUMPTION
Not applicable.
1.J. SOFTWARE UPGRADES/UPDATES
Not applicable.
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EASB
1.K. REFERENCES
The documents required for compliance with this ALERT SERVICE BULLETIN are as follows.
AS332 and AS532 helicopters - Aircraft Maintenance Manual (MMA):
MMA: 60-00-00-611: Rotor Standard Practices - General Standard Maintenance Instructions
MMA: 63-00-00-611: Main Transmission Power System - General Standard Maintenance Instructions
MMA: 63-22-00-021: Epicyclic Reduction Gear - Removal
MMA: 63-22-00-421: Epicyclic Reduction Gear - Installation
EC225 and EC725 helicopters - Aircraft Maintenance Manual (MMA):
MMA: 60-00-00-611: Rotor Standard Practices - General Standard Maintenance Instructions
MMA: 63-00-00-611: Main Transmission Power System - General Standard Maintenance Instructions
MMA: 63-22-00-062: Epicyclic Reduction Gear - Removal-Installation
1.L. OTHER AFFECTED PUBLICATIONS
Not applicable.
1.M. PART INTERCHANGEABILITY OR MIXABILITY
Not applicable.
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EASB
2.
EQUIPMENT OR PARTS INFORMATION
2.A. EQUIPMENT OR PARTS: PRICE - AVAILABILITY - PROCUREMENT
For any information concerning the modification kits and/or components or assistance, contact the Sales and
Customer Relations Department.
Order as required from:
Airbus Helicopters
Etablissement de Marignane
Direction Ventes et Relations Client
13725 MARIGNANE CEDEX
FRANCE
NOTE 1
On the purchase order, please specify the mode of
transport, the destination and the Serial Numbers of the
helicopters to be modified.
NOTE 2
For ALERT SERVICE BULLETINS, order by:
Telex: HELICOP 410 969F
Fax: +33 (0)4.42.85.99.96
2.B. LOGISTIC INFORMATION
Not applicable.
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EASB
2.C. EQUIPMENT OR PARTS REQUIRED PER HELICOPTER/COMPONENT
Kits to be ordered for one helicopter or one assembly:
Designation
Qty
New P/N
For AS332 and AS532 helicopters
332A32-3020-00
Epicyclic module
1
or
332A32-3020-01
Epicyclic module
1
332A32-3021-00
or
332A32-3021-01
For EC225 and EC725 helicopters
332A32-5021-00
or
332A32-5021-01
Epicyclic module
1
or
332A32-5023-01
or
332A32-5023-02
Former
P/N
→
Item
Instruction
/
332A32-3020-00
or
332A32-3020-01
Not HUMS-capable
/
332A32-3021-00
or
332A32-3021-01
HUMS-capable
/
332A32-5021-00
or
332A32-5021-01
or
332A32-5023-01
or
332A32-5023-02
/
Consumables to be ordered separately:
As per the Tasks specified in this ALERT SERVICE BULLETIN.
The consumables can be ordered separately from the INTERTURBINE AVIATION LOGISTICS company:
Website:
http://www.interturbine.com
Telephone:
+49.41.91.809.300
AOG:
+49.41.91.809.444
2.D. EQUIPMENT OR PARTS TO BE RETURNED
The retrofit of the planet gear of the epicyclic module is a depot level intervention that can only be performed
by Airbus Helicopters or Airbus Helicopters approved repair centers.
A customized schedule is currently being drawn up for each operator concerned. The retrofit will be carried
out according to this schedule.
Further practical information will be proactively provided to each customer, including the indication of a focal
point of contact at Airbus Helicopters for each retrofit. Airbus Helicopters will provide the retrofit means as
well as the transport free of charge and will require the immediate return of the core unit for standard
exchange by the Airbus Helicopters carrier. More detailed information concerning the logistics organization
will be provided by the usual logistic point of contact along with a check list concerning the organization.
As soon as an epicyclic module is declared by the customer to be concerned by this ALERT SERVICE
BULLETIN, the log card must be sent to [email protected] for confirmation.
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EASB
3.
ACCOMPLISHMENT INSTRUCTIONS
3.A. GENERAL
- Read and comply with the general standard maintenance instructions applicable to rotors as per MMA
Task 60-00-00-611.
- Read and comply with the general standard maintenance instructions applicable to the main rotor drive as
per MMA Task 63-00-00-611.
3.B. WORK STEPS
- Remove the epicyclic module as per:
. MMA Task 63-22-00-021 for AS332 and AS532 helicopters,
. Sub-task 63-22-00-032-001 (PRE MOD 0753023) of MMA Task 63-22-00-062 for EC225 and EC725
helicopters,
. Sub-task 63-22-00-032-002 (POST MOD 0753023) of MMA Task 63-22-00-062 for EC225 and EC725
helicopters.
- Refer to the procedure described in paragraph 2.D. for the material return conditions.
- Install an epicyclic module as per:
. MMA Task 63-22-00-421 for AS332 and AS532 helicopters,
. Sub-task 63-22-00-432-001 (PRE MOD 0753023) of MMA Task 63-22-00-062 for EC225 and EC725
helicopters,
. Sub-task 63-22-00-432-002 (POST MOD 0753023) of MMA Task 63-22-00-062 for EC225 and EC725
helicopters.
3.C. COMPLIANCE CONFIRMATION
Compliance with this document:
Record compliance with this document, with the revision number, on the Log Card (FM) of the epicyclic
module.
3.D. OPERATING AND MAINTENANCE INSTRUCTIONS
Not applicable.
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EASB
4.
APPENDIX
4.A. SECOND STAGE PLANET GEAR - P/N 332A32-3335-00
SECOND STAGE PLANET GEAR - P/N 332A32-3335-00
M3
M139
M349
M405
M540
M11
M140
M350
M408
M542
M22
M141
M351
M415
M543
M24
M143
M352
M416
M544
M28
M144
M353
M417
M546
M30
M146
M354
M419
M547
M39
M150
M355
M422
M548
M40
M306
M356
M423
M549
M41
M307
M357
M426
M550
M42
M308
M358
M429
M551
M43
M309
M359
M430
M552
M44
M310
M360
M432
M553
M45
M311
M361
M433
M554
M46
M312
M362
M435
M556
M47
M315
M363
M437
M557
M48
M316
M364
M438
M558
M51
M317
M365
M439
M52
M318
M366
M440
M53
M319
M367
M441
M54
M320
M368
M443
M56
M321
M369
M444
M57
M322
M370
M445
M72
M323
M371
M447
M88
M324
M372
M448
M107
M326
M373
M449
M108
M327
M374
M450
M116
M328
M375
M451
M117
M329
M376
M452
M119
M330
M377
M453
M120
M331
M378
M455
M121
M333
M379
M456
M122
M334
M380
M457
M123
M335
M381
M458
M124
M336
M382
M460
M125
M337
M383
M461
M127
M338
M384
M462
M129
M340
M385
M463
M130
M341
M386
M469
M131
M342
M387
M531
M132
M343
M388
M532
M133
M344
M389
M533
M134
M345
M390
M534
M135
M346
M392
M535
M136
M347
M394
M538
M138
M348
M400
M539
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4.B. SECOND STAGE PLANET GEAR - P/N 332A32-3335-04
SECOND STAGE PLANET GEAR - P/N 332A32-3335-04
M579
M702
M749
M815
M580
M703
M750
M816
M581
M705
M751
M582
M706
M752
M583
M707
M753
M584
M708
M754
M585
M709
M755
M586
M710
M756
M587
M711
M757
M588
M712
M758
M589
M713
M779
M590
M714
M780
M591
M715
M781
M592
M716
M782
M593
M717
M783
M594
M718
M784
M595
M719
M785
M596
M720
M786
M597
M722
M787
M598
M723
M788
M599
M724
M789
M600
M725
M790
M601
M726
M791
M602
M727
M792
M603
M728
M793
M604
M729
M794
M605
M730
M795
M606
M731
M796
M607
M732
M797
M608
M733
M798
M609
M734
M799
M610
M735
M800
M611
M736
M801
M612
M737
M802
M613
M738
M803
M614
M739
M804
M615
M740
M805
M616
M741
M806
M617
M742
M807
M618
M743
M808
M633
M744
M809
M636
M745
M810
M699
M746
M812
M700
M747
M813
M701
M748
M814
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4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
M759
M845
M902
M992
M1047
M760
M846
M903
M993
M1049
M761
M848
M904
M994
M1050
M762
M849
M905
M995
M1051
M763
M850
M906
M996
M1052
M764
M851
M907
M997
M1053
M765
M852
M908
M998
M1054
M766
M853
M909
M1002
M1055
M767
M854
M910
M1003
M1056
M769
M856
M911
M1004
M1057
M770
M857
M912
M1005
M1058
M772
M858
M913
M1007
M1059
M773
M863
M914
M1008
M1060
M774
M865
M915
M1009
M1061
M775
M869
M916
M1010
M1062
M776
M870
M958
M1011
M1063
M777
M873
M959
M1012
M1064
M778
M874
M960
M1013
M1065
M817
M875
M961
M1014
M1066
M818
M876
M962
M1015
M1067
M819
M877
M963
M1016
M1068
M821
M878
M964
M1017
M1069
M822
M879
M965
M1018
M1070
M823
M880
M966
M1019
M1071
M824
M881
M967
M1020
M1072
M825
M882
M968
M1021
M1073
M826
M883
M969
M1023
M1074
M827
M884
M970
M1024
M1075
M828
M885
M971
M1025
M1076
M829
M886
M972
M1027
M1077
M830
M887
M973
M1030
M1078
M831
M888
M974
M1031
M1079
M832
M889
M975
M1032
M1080
M833
M890
M977
M1034
M1081
M834
M891
M979
M1035
M1082
M835
M892
M980
M1036
M1083
M836
M893
M982
M1037
M1084
M837
M894
M983
M1038
M1085
M838
M895
M984
M1039
M1086
M839
M896
M985
M1041
M1087
M840
M897
M986
M1042
M1088
M841
M898
M988
M1043
M1089
M842
M899
M989
M1044
M1090
M843
M900
M990
M1045
M1091
M844
M901
M991
M1046
M1092
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M1093
M1094
M1095
M1096
M1097
M1098
M1099
M1100
M1101
M1102
M1103
M1104
M1105
M1107
M1108
M1109
M1110
M1111
M1112
M1113
M1114
M1115
M1116
M1117
M1118
M1119
M1120
M1121
M1122
M1123
M1124
M1125
M1126
M1127
M1128
M1129
M1130
M1131
M1132
M1133
M1134
M1135
M1136
M1137
M1138
M1139
M1140
M1141
M1142
M1143
M1144
M1145
M1146
M1147
M1148
M1200
M1201
M1202
M1203
M1204
M1205
M1206
M1207
M1209
M1210
M1211
M1212
M1213
M1214
M1215
M1216
M1217
M1218
M1219
M1220
M1221
M1222
M1224
M1225
M1226
M1227
M1228
M1229
M1230
M1231
M1232
M1233
M1234
M1235
M1236
M1237
M1238
M1239
M1240
M1241
M1242
M1243
M1244
M1245
M1246
M1247
M1248
M1249
M1300
M1301
M1302
M1303
M1304
M1305
M1306
M1307
M1308
M1309
M1310
M1311
M1312
M1313
M1314
M1317
M1318
M1319
M1320
M1321
M1322
M1323
M1324
M1325
M1326
M1327
M1328
M1329
M1330
M1331
M1332
M1333
M1334
M1335
M1336
M1337
M1338
M1339
M1340
M1341
M1342
M1343
M1344
M1345
M1346
M1347
M1348
M1349
M1367
M1368
M1369
M1370
M1371
M1372
M1373
M1374
M1375
M1376
M1377
M1378
M1379
M1380
M1381
M1382
M1383
M1384
M1385
M1386
M1387
M1388
M1389
M1390
M1391
M1392
M1393
M1394
M1395
M1396
M1397
M1398
M1399
M1400
M1401
M1402
M1403
M1404
M1405
M1406
M1407
M1408
M1409
M1410
M1411
M1412
M1413
M1414
M1415
M1416
M1444
M1467
M1469
M1470
M1471
M1472
M1473
M1474
M1475
M1476
M1478
M1479
M1481
M1483
M1484
M1485
M1486
M1487
M1488
M1489
M1490
M1491
M1492
M1493
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4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
M1494
M1589
M1636
M1783
M1871
M1495
M1590
M1637
M1785
M1872
M1496
M1591
M1638
M1786
M1873
M1497
M1592
M1639
M1787
M1874
M1498
M1593
M1640
M1788
M1875
M1499
M1594
M1641
M1789
M1876
M1500
M1595
M1642
M1790
M1877
M1501
M1596
M1643
M1791
M1878
M1502
M1597
M1644
M1792
M1879
M1503
M1598
M1645
M1793
M1880
M1504
M1599
M1646
M1794
M1881
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EASB
4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
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This document is available on the internet: www.airbushelicopters.com/techpub
EASB
4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
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This document is available on the internet: www.airbushelicopters.com/techpub
EASB
4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
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EASB
4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
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2016-06-29
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EASB
4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
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2016-06-29
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EASB
4.C. SECOND STAGE PLANET GEAR - P/N 332A32-3335-06 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-06
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2016-06-29
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EASB
4.D. SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
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EASB
4.D. SECOND STAGE PLANET GEAR - P/N 332A32-3335-07 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
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EASB
4.D. SECOND STAGE PLANET GEAR - P/N 332A32-3335-07 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
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This document is available on the internet: www.airbushelicopters.com/techpub
EASB
4.D. SECOND STAGE PLANET GEAR - P/N 332A32-3335-07 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
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EASB
4.D. SECOND STAGE PLANET GEAR - P/N 332A32-3335-07 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
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2016-06-29
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EASB
4.D. SECOND STAGE PLANET GEAR - P/N 332A32-3335-07 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
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EASB
4.D. SECOND STAGE PLANET GEAR - P/N 332A32-3335-07 (continued)
SECOND STAGE PLANET GEAR - P/N 332A32-3335-07
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2016-06-29
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