Eurocopter

EC135
Technical Briefing
Heli-Expo 2009
February 2009

EC135 The Team!

Team Contacts
Manager Technical Support
James JB Kincaid
Phone: 972-641-5068
Fax:
972-641-3710
Mobile: 214-701-5094
James.kincaid@eurocopterusa.com

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

Michael.morters@eurocopterusa.com

Chris.carter@eurocopterusa.com

Product Manager
EC135/EC145/BK117/BO105
Dave Vogel
Phone: 972-641-3573
Fax:
972-641-3710
Mobile: 817-201-1196
Dave.vogel@eurocopterusa.com

Customer Support Improvements

Office Hours
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
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

Monthly newsletter to inform of technical tips, service improvements, publication updates, spare
parts topics, etc. Distributed by email and posted on AEs 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

Overview

Fleet Statistics
Documentation
Technical Follow-Up
Corrosion

EC135/635 Fleet Statistics (as of 12/31/08)

EC135/EC635 Total

HC delivered:

741

HC in service:

719

Operators:

219

Countries:

46

FH in 2008:
FH accumulated:

254,110
1,299,570

EC135/635 Fleet Statistics (as of 12/31/08)

Aircraft S/N

Operator

Country

Flight Hours

4067

Northumbria Police Authority

United Kingdom

11081

4079

Thames Valley Police Authority

United Kingdom

9249

4040

West Mercia Constabulary

United Kingdom

8564

4064

Metro Aviation, Inc.

United States

8610

4107

Royal Cayman Islands Police

Cayman Islands

8285

4063

North Wales Police Auth. A.S.U.

United Kingdom

8028

4215

Merseyside Police Authority

United Kingdom

7828

4018

Metro Aviation, Inc.

United States

7700

4209

Thames Valley Police Authority

United Kingdom

7502

4013

Metro Aviation, Inc.

United States

7220

EC135/635 Fleet Statistics (as of 12/31/08)

EC135/EC635 Helicopters in Service
By mission

Miscellaneous
8%

By region

Executive/VIP
16%
Military
5%
Offshore
5%

Rescue
48%

Police
18%

South
America
4%

Central
America
2%

Pacific Area
1%
Africa
0%

North America
29%
Europe
53%
Far East
9% Middle East
2%

EC135/635 Fleet Statistics (as of 12/31/08)

EC135/EC635 Helicopters in Service

North America

190

Europe

Far East

370

64

Middle East

14

Central America

11
Africa

2
Australia

4
South America

23

Overview

Fleet Statistics
Documentation
Technical Follow-Up
Corrosion

EC135 Documentation
SI EC135-35 Rev.1

Titles Service Information and Alert

Service Information have been changed

Titles Information Notice and Safety

Information Notice are used now

These documents are harmonized

(EC/ECD)

The new documents may be effective for

several helicopter models at the same time

The index shows a list of all documents

that are effective for the EC135

EC135 Documentation
EMERGENCY Alert Service Bulletin
An Alert Service Bulletin is marked
with the word Emergency, if the
period of time in which the tasks to
be performed must take place is
within 50 FH / 7 days

This document is harmonized (EC/

ECD)

Case by case decision for transition

period up to 110 FH / 1 month

Used first time for

ASB EC135-53A-022
Ring Frame Aft

EC135 Documentation
MSM Rev. 9, Printed Version - Errors and Corrections

Revision 009 of the Master Servicing Manual (MSM) of the

EC135 has several shortcomings due to various reasons

Information Notice Nr. 2021-I-00 published, 4th of December

2008

These short comings basically are related to two points:

MSM Revision 9
Corrections

Format

Content

EC135 Documentation
Format

The documentation Manuals had been migrated

to another content management system (IT- System)
The MSM becomes inactive on the INDOC CD-ROM
Possibility to have links to the Aircraft Maintenance Manual from the
MSM
One side effect is, that no revision bars can be produced at the
moment of adjustment

EC135 Documentation
Content
es
c
n
re by rs
e
f f e d ba
i
D rk n
a
m visio
re

Paper Version
Rev. 09

Paper Version
Temp. Rev. 10a

MSM Rev. next steps

Co
co rrec
im nten ted
p le t
m of M
en
te SM
d

CD ROM
Rev. 10

CD- ROM
Rev. 09
coming soon

EC135 Documentation
05-13-00: Time Limits Overhauls Inspections
Fire Protection System: The part number of the affected fire extinguishing bottle remains 33000025-1 as it was before Revision 009

05-23-00: 12-Month Inspection

Section: General Information: The references for (3) and (6) remain 0525-00 and 05-12-00 as they were before Revision 009
6-1 Landing Gear (1): Inspect Grounding Straps iaw. 32-10-00, 6-1 (10)
reference for high landing gear to be incorporated: 32-16-00, 6-1
(11)

05-24-00: Periodical Inspection

Tail Rotor: The references for (1) remain the same as before Revision
009, i.e. (64-22-00, 6-1, 64-22-00. 6-2, 64-22-00, 6-3). The effectivity [1]
will be deleted

EC135 Documentation
05-24-00: Periodical Inspection cont.
6-1 Electrical Power (5): Perform functional test of blocking diode
reference to be corrected: 24-60-00, 5-1
6-1 Landing Gear (1): Inspect landing gear iaw. 32-10-00, 6-1
reference for high landing gear to be incorporated: 32-16-00, 6-1
6-1 Fuselage (5): Inspection of upper decks reference to be
corrected: 53-50-00, 6-2

05-25-00: Supplementary Inspections according to Operating Time

Fuselage: Step (4) inspection of the stator blades every 50 FH is
deleted. (ASB EC135-53A-001 Rev.5 remains effective)
Tail rotor: Step (1) title changed in remove, disassemble and inspect
tail rotor [1]. Interval: 800 fh / 3 years. References: (64-22-00, 4-1),
(64-22-00-, 4-3), (64-22-00, 6-1), (64-22-00, 6-2), (64-22-00, 6-4) up
to and including (64-22-00, 6-23)

EC135 Documentation
05-25-00: Supplementary Inspections according to Operating Time
6-1 Navigation (8): Compensate compass system every 12 months
unless otherwise specified by local and/or international regulations
6-1 Tail Rotor (1): Remove laminated tension-torsion bars and check
that no laminate is broken reference 64-22-00, 6-3 to be deleted
6-1 Flight Controls (2): Inspect control rods for cracks every 12
months Task to be shifted to 12 Months Inspection (05-23-00, 6-1)
and reference 67-10-00, 4-2 to be deleted (removal of control rods not
requested)
6-1 Engine Indicating System (1): Check of electronic engine
overspeed fuel shut-off system every 4.000 Fh to be deleted, as
the check is run through at every FADEC selftest

EC135 Documentation
05-25-00: Supplementary Inspections according to Operating Time
6-1 Engine Indicating System (2): Check electronic engine overspeed
fuel shut-off system every 1.000 Fh to be deleted as cross engine
inhibition overspeed test is accomplished in accordance with MSM 0562-00, 6-3 E.(2) or F.(2) every ground run or test flight (400/800 Fh)
already
6-1 Engine Indicating System (3): Check emergency engine control
every 800 Fh (applicable for T2 only) Check is applicable for all
engines and has to be done in accordance with AMM 76-12-00, 5-2
(not TM Maintenance Manual), task will be shifted to Periodical
Inspection (05-24-00, 6-1)
6-1 Optional Equipment (22): Inspect fixed part of the cargo hook
reference to CMM to be deleted
6-1 Optional Equipment (23) & (24): Inspect cargo hook & Inspect
cargo hook beam reference to AMM to be deleted

Overview

Fleet Statistics
Documentation
Technical Follow-Up
Corrosion

ATA Chapter: 21 New Air Cond and Basic Vent System

Performance Improvement
~ 60% over electric AirCon
System

Performance of current
electrical AirCon system
= 5.2 kw

Mechanical driven compressor

Two evaporators / dual zone system
Sufficient cooling even in extreme climatic conditions
Increased airflow
Modern, effective and light weight components
Efficient water drainage

ATA Chapter: 21 New Air Cond and Basic Vent System

Cabin Evaporator

Cockpit Evaporator

ATA Chapter: 21 New Air Cond and Basic Vent System

Cold air showers for forward cabin area

ATA Chapter: 21 New Air Cond and Basic Vent System

ATA Chapter: 21 New Air Cond and Basic Vent System

ATA Chapter: 24 Starter Generator 073

Issue:

Increased failures of starter generators equipped with long life brushes (.073)
Status:

Several starter generators have been investigated by Goodrich

Failures are caused by so called brush hang up
Goodrich has taken already corrective measures to instruct all licensed repair
and overhaul centers

In all cases incorrectly routed brush leads caused the hang-up problem.
However, a brush positioned tightly in the brush box will enhance the problem.
Most of the failures occur as a result of a brush inspection procedure where the
bushes were pulled out and were reinstalled after measuring the remaining
brush length. Samples of hung up brushes showed signs of BHU conditions on
the brush leads.

H. Haehn explained the consequences of a BHU case in terms of brush sparking

and its impact on collector commutation film destruction and total brush
malfunction.

ATA Chapter: 26 Fire Extinguisher System

Issue:

Inadvertent discharge of the fire extinguisher bottle

Status:

Incidents can be classified in two categories

1. Inadvertent discharge during pre flight procedure
- Caused by overlapping of test switch positions when test switch is moved rapidly
from the Off to the EXT/WARN position
- Procedure in the flight manual will be changed:
First from OFF to EXT (Cautions EXT & FIRE EXT must come on) and only
thereafter to EXT WARN (Cautions EXT/WARN, FIRE EXT & FIRE E TEST must
come on)

2. Inadvertent discharge due to defective fire detectors

- First batch of defective sensors have been sent to the manufacturer in CW 22 for
investigation.
- Failures were caused by ingress of moisture due to defective sealant

ATA Chapter: 31 CDS Current Situation

CDS failure
reason

EPROM

Monitor

Low MTBF in service

Obsolete part
Last order placed to secure

Low MTBF in service

High failure rate at supplier

repair process until a new

part is selected/ certified

Verification after complete

test bench
repair process

Critical TAT

ATA Chapter: 31 CDS Future Scenarios

HC Avionic Upgrade MTOW Upgrade
+ AEO Performance Upgrade, AP
Further Optionals and Performance
Upgrade
MTBF Improvements

Hardware
Improvement

New CDS
EC certified
or STC

HC retrofit from
CDS into CPDS
version

ase
e
r
c
in
e
c
n
ma
r
o
f
r
Pe
t
n
e
an
m
r
e
P

ATA Chapter: 32 Medium Height Landing Gear

Status November 2008:

Design finished
Prototype tested for certification in November 2008
Height increase + 3.9 in

Width increase + 4.5 in

ATA Chapter: 33 Fixed Landing Light

Issue:

Failure of fixed landing light attachment

Status:

New designed attachment has been successfully tested in summer 2008

Retrofit SB to be issued

ATA Chapter: 53 Tail Boom

Issue:

Introduction of 10.000 hrs SLL for tail boom (all tail booms affected)
Status:

Certification in progress to go back to on condition (tail boom tube)

Tail Boom Tube

ATA Chapter: 53 Tail Boom

Issue:

Fatigue testing of forward frame showed tendency to crack

Status:

Service Life Limit ~ 7000 flight hours will be introduced for forward frame
Two high time frames (>7000 hrs and >8000 hrs) have been removed already
for laboratory investigation

Both high time frames without any signs of cracking

In field replacement possible by trained technicians and field deployable
alignment tool in conjunction with SB EC135-53-021 soon to be released

New reinforced aluminum ring frame (on condition component) in serial

production beginning with A/C S/N 0870

ATA Chapter: 53 Tail Boom

Fwd frame X5730

Rear frame X9227

ATA Chapter: 53 Tail Boom

Ne
w

ld
O

gn
i
s
e
d

de

sig
n

ATA Chapter: 53 Tail Boom

Ne
w

de
sig
n

ATA Chapter: 53 Tail Boom

Issue:

Aft ring frame cracks detected on 6 helicopters

worldwide
Status:

Introduction of visual pre-flight check with ASB

EC135-53A-022.

Cracks start in extension of the horizontal

stabilizer line (verified by lab assessment of
cracked ring frame).

Replacement of countersunk rivets by

protruding rivets. (starting from A/C S/N 0830)

Retrofit solution (reinforcement doubler) to be

introduced through SB.

ATA Chapter: 53 Tail Boom

Installation of rear frame with universal head rivets

View 3D of the Reinforcement in its Position

ATA Chapter: 62 Main Rotor Mast

Issue:

Failures if main rotor mast strain gauge debonds

Status:

Cold Bonding Process to be introduced (Improved reliability & easier repair)

Completion date for cold bonding: 30th April 2009

ATA Chapter: 62 Main Rotor Mast

Status:

Bottom and Top of main rotor mast will be closed by design change to
counteract excessive accumulation of moisture

Solution to seal bottom of rotor mast available; design still to be frozen

Target for design freeze end of February 2009
Paint coating on the inner side of rotor mast will be deleted
Upper ventilation for rotor mast will be deleted

ATA Chapter: 62 Main Rotor Blade Dampers

Issue:

Life limit of blade dampers at 6 years

(starting from cure date)
Status:

Life limit of blade damper will be raised

to 8 years (Temp. Rev. 10a)

Cure
date

ATA Chapter: 63 Main Transmission

Input Drive Deterioration

Inspection IAW ASB 63-012 Rev 3

Remember to turn in your reports
to the FAX # or Email at the top of
the inspection form on p. 27

ATA Chapter: 63 Main Transmission

Input Drive Deterioration

ATA Chapter: 63 Main Transmission

Input Drive Deterioration Launched Actions (1/2):

Superfinishing (chemically activated polishing) of gears is no longer

considered as a solution, because the benefit will be too marginal since the
current quality of gear surfaces is already very high.

First test runs have confirmed the suspected failure modes (shift of load
pattern towards toe). Actual loads are definitely not the root cause of the
gear deterioration!
THE FAILURE MODE WAS REPRODUCED !

Investigation on main transmission oil pressure and oil distribution on the test
bench was undertaken in September 2008. Results to be evaluated by ZFL
(still on-going).

ATA Chapter: 63 Main Transmission

Input Drive Deterioration Launched Actions (2/2):

Investigation on the stiffness of the gearbox casings and symmetrical

alignment of all axis is being undertaken, together with load pattern test.

New gear (only bevel gear pinion will be changed, not the wheel) with
different load pattern (AEO load pattern) has successfully completed initial
test runs.

New pinion gears have a changed topography in order to shift load pattern
more towards heel of the gear tooth.

Certification process for gearbox with new bevel gear scheduled to start in
April 2009.

Availability of first serial units (new P/N main XMSN) expected approx.
August 2009.

ALL ACTIONS ARE ON TARGET, WITHIN THE SCHEDULED TIMEFRAME

AND SO FAR WITH POSITIVE RESULTS!

ATA Chapter: 63 Main Transmission

Issue:

MBG P/N 4649 010 010 (T2+/P2+) TBO verification program

*
**
**

* To be done by manufacturer or specially trained personnel; costs to be borne by

Eurocopter; XMSN remains on aircraft.
** To be done by manufacturer or specially trained personnel; costs to be borne by
by Eurocopter; XMSN to be removed from A/C and XMSN to be shipped to manufacturer

TBO verification program TBO verification program for 010 main XMSN to
be performed for each step on 3 to 5 XMNS only!

ATA Chapter: 63 Main Transmission

Issue:

Surface corrosion of collector shaft

Status:

Collector gear will be protected by means of applying a special resin coating

Coating process already identified; still to be tested

ATA Chapter: 63 Main Transmission

Issue:

Improved oil filler neck

Status:

New type of filler neck to enter serial production 1st April 2009
P/N of new oil filler neck 4649 208 040

Main Transmission Oil Filler Neck

The filler neck was tested by high pressure cleaner up to 60 bar and at 60C
for 2 min durations.

ATA Chapter: 63 Z- ARIS

Over the last 12 months, MTBF went up to over 4,400 FH !

Primary Bellows

!
d
e
s
o
Secondary
l
c
Bellows
e
u
s
Spring
Is
Mass
Jacket

Pendulum
Rod

ATA Chapter: 64 Tail Rotor Blade

Issue:

Life limit of tail rotor blade at 8,000 hrs

Status:

Life limit of tail rotor blade will be raised to

12,000 hrs

Chapter 04 revision currently at EASA for

release

Foreseen to be published with Temp. Rev. 10a

Benefit:

Reduced DMCs

ATA Chapter: 64 Tail Rotor

Issue:

Tear-down inspection at 1200hrs/3 years

Status:

DESC 0002 fleet evaluation shows positive results

Measurements from 2 aircrafts still needed to confirm the positive behavior of
all components

Results expected by April 2009

According to schedule interval for tear down inspection will be increased to
1600 hrs/3 years
Benefit:

Reduced DMCs

ATA Chapter: 71 Barrier Filter

Inlet Barrier Filter

ATA Chapter: 71 Barrier Filter

RH Filter

Bypass doors

LH Filter

ATA Chapter: 71 Barrier Filter

RH Bypass door

LH Bypass door

LH Filter
RH Filter

ATA Chapter: 71 Barrier Filter

ATA Chapter: 80 20VE Switch Panel

Issue:

Engine over-torque incidents due to unintended disengagement of training mode

Status:

Modification of 20VE switch panel

currently in design

Separate switches to select the engine

into training idle

Main engine switch not to be used

anymore (remains in FLIGHT position)
Benefit:

Unintended disengagement of training

mode will not cause single engine torque
exceedances anymore

Overview

Fleet Statistics
Documentation
Technical Follow-Up
Corrosion

Corrosion Offshore Kit

Corrosion protection by an additional coat of PU paint

Corrosion Offshore Kit

Corrosion protection by an additional coat of PU paint

Corrosion Protection Hydraulic MR Actuator

Electric connectors on MR actuator to be replaced with composite
connectors

All new serial production actuators will be affected (exact introduction

date TBA)

All MR actuators which are shipped for any repair will also receive
composite connectors

Offshore Kit Oil Cooler Protection

From March 2008, oil coolers are receiving an additional PU top
coating in order to improve resistance against corrosion

Offshore Kit Oil Cooler Fan Inlet Screen

From March 2008, the oil cooler
blower inlet screens get an
additional PU top coating and an
improved assembly procedure is
used to avoid contact corrosion
between steel screen and
aluminum ring

EUROCOPTER
LEVERAGING OUR STRENGTHS