FAA-2017-1036-0005_attachment_1
FAA-2017-1036-0005_attachment_1
78
Civil versions: N, N1, N2, N3
Military versions: F, Fi, Fs, K, K2
Revision 0 2017-06-13
Revision 1 2017-06-30
Revision 2 2017-11-14
Revision 3 2018-03-02
Summary:
Compliance:
Airbus Helicopters renders compliance with this ALERT SERVICE BULLETIN mandatory.
1.A. EFFECTIVITY
Not applicable.
1.C. REASON
Revision 0:
Following the EC225 accident off Norway in April 2016, and Airbus Helicopters subsequently working closely
with the Norwegian Accident Investigation Board and other authorities, a cracked outer race in a second
stage planet gear was identified as the cause of the helicopter’s mechanical failure.
During the investigation into the 2016 EC225 accident, one of two types of planet gear was identified as
being susceptible to developing cracking because of higher roller contact pressures generated in the Main
Gearbox. As part of the protective measures developed and approved with EASA to ensure safe operation of
the EC225/AS332 L2 fleet, this type of planet gear has been permanently removed from service.
In pursuit of its commitment to ensuring total safety across all its products, Airbus Helicopters has reviewed
its entire range of helicopters in regard to this particular issue.
As a result, Airbus Helicopters has decided to implement precautionary measures on the Dauphin family
(AS365/AS565/EC155/SA366) to improve the reliability of the Dauphin Main Gearbox.
This additional safety measure is made as a precaution notwithstanding that as of today, the Dauphin fleet
has logged around 6.5 million flight hours, with no accident or serious incident related to the Main Gearbox
planet gears.
Three types of planet gears from three different suppliers, each with different characteristics, are currently in
service across the Dauphin fleet. Among those, two types have been identified as having characteristics
comparable to the planet gear removed from service on the EC225/AS332 L2 fleet.
After verification, it appears that a large proportion of the in-service fleet is not equipped with the types which
are to be removed from service.
Airbus Helicopters stresses that this retrofit is a precautionary measure, which is entirely unrelated to any
accident involving a Dauphin helicopter, and is intended to enhance the safety of the helicopters concerned.
Following the detection of an inconsistency which led to incorrect planet gear identification, Airbus
Helicopters has decided to revise this ALERT SERVICE BULLETIN, in order to update the Appendices
(paragraph 4.) and paragraph 1.E.2. to enable the identification of the planet gear type.
In addition, detailed information is provided on the check which can be carried out by the pilot (paragraph
1.G.).
Airbus Helicopters makes compliance with Revision 1 of this ALERT SERVICE BULLETIN mandatory.
Revision 1 affects compliance with Revision 0 of this ALERT SERVICE BULLETIN.
Revision 2:
Airbus Helicopters makes compliance with Revision 2 of this ALERT SERVICE BULLETIN mandatory.
Revision 2 affects compliance with Revision 1 of this ALERT SERVICE BULLETIN only for helicopters for
which planet gears were replaced through compliance with an Airbus Helicopters Technical Agreement or
Service Bulletin No. AS365-63.00.21 revision 0.
Revision 3:
- To modify the time limit for the periodic check of the magnetic plugs from “after each last flight of the day
without exceeding 10 flight hours” to “at intervals not exceeding 10 flight hours”.
- To modify the length (L) and surface (S) criteria of the particles collected, in order to harmonize these
criteria with other helicopters from the Airbus Helicopters range.
Airbus Helicopters renders compliance with Revision 3 of this ALERT SERVICE BULLETIN mandatory.
1.E. COMPLIANCE
- For all helicopters, regardless of whether Revision 0 of this ALERT SERVICE BULLETIN has been
complied with or not:
. Check the Log Card (FM) of the MGB to identify the type of the five installed planet gear assemblies.
.. If the Log Card indicates five planet gears of Type Z, leave as is.
.. If the Log Card (FM) of the MGB does not mention Type Z for the five planet gears,
. Check the Log Card (FM) of the MGB to identify the Serial Numbers (S/N) of the five installed
planet gear assemblies.
. Look up these Serial Numbers (S/N) in Appendices 4.A. to 4.C. to identify the planet gear type.
.. If the type of at least one planet gear assembly cannot be identified from Appendices 4.A.
to 4.C., contact Airbus Helicopters at TechnicalSupport.Helicopters@airbus.com, or the approved
repair center which delivered the MGB, to obtain information on the installed planet gear
assemblies.
.. If the type of the five planet gears has been identified using Appendices 4.A. to 4.C., continue as
described below,
. For helicopters equipped with an MGB which includes at least one planet gear assembly of Type X:
.. Replace the planet gears assemblies as per paragraph 3.B.1.a or 3.B.1.b. within 50 flying hours
following the issue of this ALERT SERVICE BULLETIN Revision 0, without exceeding
June 30, 2019.
.. It is prohibited to install MGBs equipped with at least one planet gear assembly of Type X.
. For helicopters equipped with an MGB which includes at least one planet gear assembly of Type Y:
.. If the TSN (Time Since New) of each of the planet gears is less than or equal to 1250 flying hours,
replace the planet gears assemblies as per paragraph 3.B.1.a or 3.B.1.b. within 300 flying hours
following the issue of Revision 0 of this ALERT SERVICE BULLETIN, without exceeding 1300
flying hours for the TSN of each of the planet gears and, without exceeding June 30, 2019.
.. If the TSN of at least one planet gear is more than 1250 flying hours, replace the planet gears
assemblies as per paragraph 3.B.1.a or 3.B.1.b. within 50 flying hours following the issue of
Revision 0 of this ALERT SERVICE BULLETIN, without exceeding June 30, 2019.
. For helicopters equipped with a MGB which includes five planet gear assemblies of Type Z:
.. Leave as is.
2) Upon receipt of Revision 1, complete the Information Sheet in Appendix 4.E. and send it to
Airbus Helicopters at the following address: TechnicalSupport.Helicopters@airbus.com, unless it has
already been sent during compliance with Revision 0.
3) Helicopters equipped with a MGB which includes at least one planet gear assembly of Type X or Y will
be unfit for flight from July 01, 2019.
4) Upon receipt of Revision 3, comply with paragraph 3.B.2. (Check of MGB magnetic plugs) at intervals
not exceeding 10 flight hours.
. For helicopters for which planet gears were replaced through compliance with an Airbus Helicopters
Technical Agreement or Service Bulletin No. AS365-63.00.21 revision 0 or later:
.. if the MGB was drained following complete compliance with the Airbus Helicopters Technical
Agreement or Service Bulletin No. AS365-63.00.21 revision 0 or later, no additional measures are
required.
.. if the MGB was not drained following complete compliance with the Airbus Helicopters Technical
Agreement or Service Bulletin No. AS365-63.00.21 revision 0 or later, comply with paragraph 3.B.3
within 50 flying hours following the issue of Revision 2 of this ALERT SERVICE BULLETIN.
. For helicopters for which planet gears were replaced through removal and replacement of the MGB,
through this ALERT SERVICE BULLETIN:
.. no additional measures are required.
- For MGBs, regardless of whether Revision 0 of this ALERT SERVICE BULLETIN has been complied with
or not:
Before installation,
. Check the Log Card (FM) of the MGB to identify the type of the five installed planet gear assemblies.
.. If the Log Card indicates five planet gears of Type Z, the MGB can be installed.
.. If the Log Card (FM) of the MGB does not mention Type Z for the five planet gears,
. Check the Log Card (FM) of the MGB to identify the Serial Numbers (S/N) of the five installed
planet gear assemblies.
. Look up these Serial Numbers (S/N) in Appendices 4.A. to 4.C. to identify the planet gear type.
.. If the type of at least one planet gear assembly cannot be identified from Appendices 4.A.
to 4.C., contact Airbus Helicopters at TechnicalSupport.Helicopters@airbus.com, or the approved
repair center which delivered the MGB, to obtain information on the installed planet gear
assemblies.
… Pending information, do not install the MGB.
.. If the type of the five planet gears has been identified using Appendices 4.A. to 4.C., continue as
described below,
.. If the TSN of at least one planet gear is more than 1250 flying hours:
… Do not install the MGB.
… Refer to paragraph 2.D. for the material return conditions.
. Complete the Information Sheet in Appendix 4.E. and send it to Airbus Helicopters at the following
address: TechnicalSupport.Helicopters@airbus.com, unless it has already been sent during
compliance with the previous revisions.
Approval of modifications:
Not applicable.
The technical information contained in this ALERT SERVICE BULLETIN Revision 0 was approved
on June 13, 2017 under the authority of EASA Design Organization Approval No. 21J.700 for civil version
helicopters subject to an Airworthiness Certificate.
The technical information contained in this ALERT SERVICE BULLETIN Revision 0 was approved
on June 13, 2017 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 13, 2017 by the Airbus Helicopters Airworthiness Department for export military versions.
The technical information contained in this ALERT SERVICE BULLETIN Revision 1 was approved
on June 30, 2017 under the authority of EASA Design Organization Approval No. 21J.700 for civil version
helicopters subject to an Airworthiness Certificate.
The technical information contained in this ALERT SERVICE BULLETIN Revision 1 was approved
on June 30, 2017 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 1 was approved
on June 30, 2017 by the Airbus Helicopters Airworthiness Department for export military versions.
The technical information contained in this ALERT SERVICE BULLETIN Revision 2 was approved
on November 14, 2017 under the authority of EASA Design Organization Approval No. 21J.700 for civil
version helicopters subject to an Airworthiness Certificate.
The technical information contained in this ALERT SERVICE BULLETIN Revision 2 was approved
on November 14, 2017 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 2 was approved
on November 14, 2017 by the Airbus Helicopters Airworthiness Department for export military versions.
The technical information contained in this ALERT SERVICE BULLETIN Revision 3 was approved
on March 02, 2018 under the authority of EASA Design Organization Approval No. 21J.700 for civil version
helicopters subject to an Airworthiness Certificate.
The technical information contained in this ALERT SERVICE BULLETIN Revision 3 was approved
on March 02, 2018 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 3 was approved
on March 02, 2018 by the Airbus Helicopters Airworthiness Department for export military versions.
For compliance with this ALERT SERVICE BULLETIN, Airbus Helicopters recommends the following
personnel qualifications:
The time for the operations is given for information purposes, for a standard configuration.
The estimated helicopter downtime is approximately two days (excluding the time to analyze the particles
found at the magnetic plugs) for MGB replacement.
Not applicable.
Not applicable.
Not applicable.
1.K. REFERENCES
The documents required for compliance with this ALERT SERVICE BULLETIN are as follows:
Work Card: 05-53-00-201: Following operating incidents - Maintenance practices - Action to be taken after
discovery of magnetic particles on the MGB magnetic plug and/or in the MGB oil
filter
Work Card: 12-00-00-307: Routine servicing - Draining and Filling the MGB
Work Card: 12-00-00-601: Routine servicing - Inspection / Check - Examination of magnetic part
Work Card: 60-00-00-300: Rotors - Servicing - General mechanical instructions
Work Card: 63-20-00-401: Main Gearbox with single lubrication system - Removal - Installation
Work Card: 63-20-01-401: Main Gearbox with dual lubrication system - Removal - Installation
Work Card: 20-08-01-601: Periodical monitoring of lubricating oil checking elements - Monitoring of
lubricating oil contamination on mechanical assemblies equipped with magnetic
plugs
Service Bulletin No. AS365-63.00.21 revision 1 or later: Replacement of epicyclic reduction gear on MGB
Not applicable.
Not applicable.
NOTE 1
NOTE 2
Not applicable.
For any information, please contact your usual Key Logistics Manager from the Airbus Helicopters network.
For availability requests, please specify the maximum deadline for your need (Aircraft On Ground).
3.A. GENERAL
Read and comply with the general mechanical instructions as per MET Work Card 60-00-00-300.
NOTE 1
- Refer to the procedure described in paragraph 2.D. for the material return conditions.
- Install an MGB which is airworthy, as per MET Work Card 63-20-00-401 or 63-20-01-401.
NOTE 2
Or,
NOTE 3
Check that there are no particles on the two magnetic plugs at the lower part of the MGB, as per MET Work
Card 12-00-00-601.
Check the cumulative surface area of the particles Resume flights under close monitoring as per
collected since last MGB overhaul (or since new if MET Work Card 05-53-00-201***
no overhaul has been performed since) If, during close monitoring, further particles are
collected, contact Airbus Helicopters.
(support.technical-dyncomp.ah@airbus.com
and
TechnicalSupport.Helicopters@airbus.com)
before resuming flights.
Is the
NO Cumulative YES
area of collected
particle
Examine the particles with ≥3mm²
the largest surface area (S) ?
NO Presence YES
of 16NCD13 or 18NC16
particles******?
Analyze all the particles collected until - Take a 1 liter sample of oil and return it to Airbus
now, as per MTC Work Helicopters.
Card 20-08-01-601**. - Remove the MGB for depot-level inspection.
****** Refer to Appendix - Install an airworthy MGB.
Resume flights if the criteria defined in 4.D. for the detailed - Report this event to Airbus Helicopters using the
Work Card 20-08-01-601** are not checmical composition of follow-up sheet defined in MTC Work
reached. 16NCD13 and 18NC16 Card 20.08.01.601 (**):
materials. support.technical-dyncomp.ah@airbus.com and
TechnicalSupport.Helicopters@airbus.com
Record compliance with this ALERT SERVICE BULLETIN, with its revision number, on the Log Card (FM) of
the MGB.
Not applicable.
4.A. APPENDIX: List of ‘Serial numbers’ (S/N) for planet gears of Type X (1/14)
8 65 116 162 212 260 309 358 402 444 493 543 590 649 737
16 68 117 163 216 261 310 359 404 445 495 545 591 652 739
17 69 118 166 217 262 311 360 405 446 498 546 593 654 740
18 70 119 168 218 263 313 361 406 447 500 547 596 655 742
19 71 120 169 219 264 314 362 407 448 501 548 597 657 744
20 72 121 170 221 265 315 363 408 449 502 549 598 658 745
21 73 122 171 222 266 316 364 409 450 503 550 599 660 746
22 74 123 172 223 267 318 365 410 451 504 551 600 661 747
23 78 124 173 224 269 319 366 411 452 505 553 603 662 748
24 79 125 174 225 270 320 367 412 453 506 554 604 664 749
25 80 126 175 227 271 322 368 413 455 507 555 606 665 750
26 81 127 176 228 273 324 369 414 456 509 556 608 669 751
27 82 128 177 229 274 325 370 415 457 510 557 609 670 752
28 83 129 178 230 275 326 371 416 458 511 558 610 671 753
29 84 130 180 231 276 327 372 417 460 512 559 611 672 755
30 86 131 182 234 277 329 373 418 461 514 560 612 673 757
31 91 132 183 235 278 330 374 419 462 515 561 613 674 758
34 92 133 184 236 279 331 375 420 463 516 563 615 677 759
35 93 135 187 238 280 333 376 421 465 517 564 616 679 760
36 94 136 188 239 285 335 377 422 467 519 565 619 684 761
37 95 137 189 240 286 336 378 423 468 520 566 621 685 762
38 96 139 190 241 287 337 379 424 469 521 567 622 686 763
39 97 141 192 242 289 338 380 425 470 522 568 624 688 764
40 98 142 193 243 290 339 382 426 471 523 569 627 689 765
41 99 143 194 244 291 342 383 427 472 524 570 629 692 766
42 100 144 195 245 292 343 384 428 473 526 571 631 694 767
43 101 146 196 246 293 344 386 429 474 527 572 634 696 768
44 102 147 197 247 294 345 387 430 476 528 573 635 710 769
47 103 148 199 248 295 346 388 431 477 529 575 636 711 771
54 104 149 200 250 296 347 390 432 479 530 576 637 714 772
55 105 151 201 251 297 348 391 433 480 532 577 639 715 773
56 106 152 202 252 298 349 392 434 481 533 578 640 716 775
57 108 153 203 253 299 350 393 435 484 534 579 641 718 776
58 109 154 204 254 302 351 394 436 486 535 581 642 719 777
60 110 155 206 255 303 352 396 438 487 538 582 643 728 778
61 111 156 207 256 304 354 397 439 488 539 584 644 729 779
62 113 157 208 257 305 355 398 440 489 540 585 645 731 780
63 114 159 209 258 307 356 399 441 490 541 588 646 733 781
64 115 161 210 259 308 357 400 442 491 542 589 647 735 782
783 825 872 924 972 1023 1070 1114 1237 1304 1422 1470 2077 2355 2864
784 826 873 925 973 1025 1071 1115 1239 1321 1423 1471 2087 2356 2865
785 827 874 926 974 1026 1072 1116 1240 1322 1424 1472 2099 2357 2866
786 828 875 928 975 1027 1073 1122 1241 1323 1425 1473 2107 2358 2867
787 829 876 930 976 1030 1074 1123 1242 1324 1428 1474 2111 2365 2868
788 830 877 931 977 1031 1075 1126 1245 1325 1429 1475 2112 2401 2871
789 831 878 933 978 1034 1077 1128 1246 1326 1430 1476 2150 2483 2872
790 832 879 934 979 1035 1078 1129 1248 1327 1431 1477 2158 2484 2874
791 833 880 935 980 1036 1079 1135 1250 1329 1433 1478 2169 2489 2875
792 835 882 936 981 1037 1080 1136 1252 1330 1435 1479 2181 2493 2876
793 837 886 937 982 1038 1081 1137 1254 1331 1438 1480 2196 2494 2877
794 838 888 938 984 1039 1082 1140 1257 1332 1439 1481 2200 2499 2891
795 839 890 941 985 1040 1083 1142 1258 1333 1440 1483 2206 2502 2892
797 840 892 942 986 1042 1084 1147 1259 1335 1442 1484 2218 2505 2896
798 841 894 943 987 1043 1085 1152 1260 1342 1443 1485 2219 2526 2981
800 842 895 944 988 1044 1086 1155 1261 1357 1445 1486 2236 2546 2985
801 843 896 945 989 1045 1087 1165 1262 1359 1446 1543 2283 2558 3013
802 844 897 946 990 1046 1088 1166 1263 1360 1447 1613 2287 2564 3032
803 845 898 947 991 1047 1089 1171 1264 1369 1448 1642 2288 2616 3033
804 846 899 949 992 1048 1090 1173 1266 1373 1449 1644 2312 2630 3034
805 847 900 950 993 1049 1092 1175 1267 1375 1450 1645 2319 2634 3035
806 848 901 951 995 1050 1094 1177 1267 1381 1451 1674 2320 2638 3037
807 849 902 952 997 1051 1095 1178 1269 1382 1452 1675 2325 2639 3039
808 850 903 953 998 1052 1096 1181 1270 1384 1453 1682 2326 2641 3041
809 851 904 955 999 1054 1097 1184 1272 1399 1454 1698 2327 2655 3044
810 852 905 956 1000 1055 1098 1185 1273 1401 1455 1699 2330 2660 3064
811 855 906 957 1002 1057 1100 1186 1274 1404 1456 1784 2331 2662 3081
812 856 907 958 1005 1058 1101 1188 1275 1405 1457 1789 2332 2666 3087
813 858 908 959 1006 1059 1102 1194 1277 1406 1458 1793 2333 2667 3089
814 859 909 960 1010 1060 1104 1212 1278 1407 1459 1894 2335 2687 3090
815 860 910 961 1011 1061 1105 1215 1279 1409 1460 2017 2336 2701 3091
816 861 912 962 1012 1062 1106 1221 1282 1410 1461 2024 2337 2704 3092
817 864 913 963 1013 1063 1107 1222 1283 1411 1462 2030 2339 2731 3093
818 866 917 965 1014 1064 1108 1225 1284 1412 1463 2032 2341 2748 3094
819 867 918 966 1016 1065 1109 1226 1284 1413 1464 2038 2343 2749 3095
821 868 919 968 1018 1066 1110 1229 1285 1415 1465 2042 2344 2774 3096
822 869 920 969 1019 1067 1111 1231 1286 1417 1466 2044 2349 2785 3097
823 870 922 970 1021 1068 1112 1232 1289 1418 1467 2064 2350 2825 3098
824 871 923 971 1022 1069 1113 1235 1301 1421 1469 2076 2351 2827 3099
3101 3210 3288 3328 3372 3417 3460 3504 3545 3587
3103 3213 3289 3329 3373 3418 3461 3505 3546 3588
3112 3214 3290 3331 3374 3419 3462 3506 3547 3590
3113 3215 3291 3332 3375 3420 3463 3507 3549 3591
3116 3216 3292 3333 3376 3421 3464 3508 3550 3594
3117 3222 3293 3334 3377 3422 3465 3509 3551 3595
3122 3225 3294 3335 3378 3423 3466 3510 3552 3596
3127 3226 3295 3336 3379 3424 3467 3511 3553 3597
3133 3227 3296 3337 3380 3425 3468 3512 3554 3598
3136 3228 3297 3338 3381 3426 3469 3513 3555 3599
3140 3247 3298 3339 3382 3427 3470 3514 3556 3600
3141 3249 3299 3340 3383 3428 3471 3515 3559 3601
3157 3254 3300 3341 3384 3429 3472 3516 3560 3602
3158 3258 3301 3343 3386 3430 3473 3517 3561 3604
3159 3261 3302 3344 3387 3431 3474 3518 3562 3620
3160 3263 3303 3345 3388 3432 3475 3519 3563 3621
3162 3264 3304 3346 3389 3433 3476 3520 3564 3622
3163 3265 3305 3348 3390 3434 3477 3521 3565 3623
3164 3266 3306 3349 3391 3435 3478 3522 3566 3625
3165 3267 3307 3350 3392 3436 3479 3523 3567 3626
3166 3268 3308 3351 3395 3437 3480 3525 3568 3627
3167 3269 3309 3352 3396 3438 3481 3526 3569 3628
3168 3270 3310 3354 3397 3439 3482 3527 3570 3629
3170 3272 3311 3355 3398 3441 3483 3528 3571 3630
3171 3273 3313 3356 3399 3442 3484 3529 3572 3631
3189 3274 3314 3357 3400 3443 3486 3530 3573 3632
3190 3275 3315 3358 3401 3444 3487 3531 3574 3633
3191 3276 3316 3359 3403 3445 3488 3532 3575 3700
3194 3277 3317 3360 3405 3446 3489 3533 3576 4401
3195 3278 3318 3361 3406 3447 3493 3534 3577
3196 3279 3319 3362 3407 3448 3494 3535 3578
3200 3280 3320 3363 3408 3450 3495 3536 3579
3201 3281 3321 3364 3409 3451 3496 3537 3580
3203 3282 3322 3365 3411 3452 3497 3539 3581
3204 3283 3323 3367 3412 3453 3498 3540 3582
3206 3284 3324 3368 3413 3455 3499 3541 3583
3207 3285 3325 3369 3414 3456 3501 3542 3584
3208 3286 3326 3370 3415 3457 3502 3543 3585
3209 3287 3327 3371 3416 3459 3503 3544 3586
(*): The iron content is not used as an identification criterion but as the element used to balance the
weight percentage values calculated. It must therefore be taken into account.
Other %
Material Si S V Cr Mn Ni Mo Cu Fe
designations weight
SAE 9315MILS
Min 0.15 0 0.8 0.3 3 0.2
7393 16NCD13
/ / (*)
Max 0.4 0.02 1.1 0.6 3.5 0.3
MILS 8690
Remarks:
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