ASB No. AS365-63.00.

22
Civil version(s): N3
Military version(s): K2

ALERT SERVICE BULLETIN

PROTECTIVE MEASURE

MAIN ROTOR DRIVE - Indicating

Replacement of electrical magnetic plug of Main Gearbox (MGB) pump intake
with non-electrical magnetic plug
Corresponds to modification 0763C96

For the attention of

Revision No. Date of issue

Revision 0 2018-07-11

Summary:

As a complement to the protective measure put in place by ALERT SERVICE BULLETIN No. 05.00.78, Airbus
Helicopters introduces modification 0763C96 through this ALERT SERVICE BULLETIN to improve the process and
performance in collecting metal particles in the MGB. This modification replaces the electrical magnetic plug of the
MGB pump intake with a non-electrical magnetic plug.

Compliance:

Compliance with this ALERT SERVICE BULLETIN is mandatory.

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1. PLANNING INFORMATION

1.A. EFFECTIVITY

1.A.1. Helicopters/installed equipment or parts

Helicopters version K2 which have not embodied modification 0763C96 (Replacement of electrical magnetic
plug of MGB pump intake by non-electrical magnetic plug).

Helicopters version N3 which meet all of the following criterias:

- have not embodied modification 0763C96,
- have embodied modification OP63B92 (Electric magnetic plugs on MGB).

NOTE 1

Helicopters version N3 which have not embodied

modification OP63B92 are not concerned by this ALERT
SERVICE BULLETIN because they are equipped with a non-
electrical magnetic plug at the MGB pump intake.

NOTE 2

Refer to the Individual Inspection Log Book (RIC AMS)

and/or Aircraft Log Book to identify the actual modification
status of the helicopter.

1.A.2. Non-installed equipment or parts

Main Gearboxes (MGB) equipped with electrical magnetic manufacturer part number (MP/N): 1B7807
(704A34543017) at the MGB pump intake, that have not embodied modification 0763C96 and whose part
number is listed as follows:
- 365A32-6001-01,
- 365A32-6001-02,
- 365A32-6001-04,
- 365A32-6001-05,
- 365A32-6004-04.

NOTE 3

Refer to the Equipment Log Card (FM) to identify the actual

modification status of the MGB.

Electrical magnetic plug MP/N: 1B7807 (704A34543017).

1.B. ASSOCIATED REQUIREMENTS

Not applicable.

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1.C. REASON

Following the H225 accident off Norway in April 2016, Airbus Helicopters has conducted a series of analysis
to ensure safe operation of the MGB. These investigations expanded to include the MGB of the Dauphin
family and subsequently led to the issuance of ALERT SERVICE BULLETIN No. 05.00.78.

As a complement to the protective measure put in place by ALERT SERVICE BULLETIN No. 05.00.78,
Airbus Helicopters introduces modification 0763C96 through this ALERT SERVICE BULLETIN to improve
the process and performance in collecting metal particles in the MGB. This modification replaces the
electrical magnetic plug of the MGB pump intake with a non-electrical magnetic plug. This non-electrical
magnetic plug is installed on the MGB pump intake in earlier versions of the Dauphin helicopters.

The replacement of this electrical magnetic plug with a non-electrical magnetic plug will ease the periodic
visual inspection for engineers, and changes neither the activation logic nor the recording of the metal
particles detection of the remaining electrical magnetic plugs on the MGB.

PRE MOD POST MOD

Non-electrical Connector to
magnetic plug be discarded
Electrical magnetic plug

Unused wires
to be capped
and stowed.

Airbus Helicopters makes compliance with Revision 0 of this ALERT SERVICE BULLETIN mandatory.

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1.D. DESCRIPTION

This ALERT SERVICE BULLETIN consists of:

- replacing the electrical magnetic plug of the MGB pump intake with a non-electrical magnetic plug,
- modifying the wiring of the electrical particle detection system of the MGB, including disconnection and
stowage of unused wires.

NOTE 4

To replace the electrical magnetic plug, the MGB must be

drained. On completion of the modification, the MGB will be
filled again. A ground run-up is required to complete the
filling task.

1.E. COMPLIANCE

1.E.1. Compliance at H/C manufacturer level

Helicopters/installed equipment or parts:

Airbus Helicopters makes it mandatory to apply the instructions of paragraph 3. except paragraphs 3.B.6.
and 3.D. of this ALERT SERVICE BULLETIN before the delivery of the helicopter.

Non-installed equipment or parts:

Airbus Helicopters makes it mandatory to apply the instructions of paragraph 3.B.6.a. of this ALERT
SERVICE BULLETIN before the delivery of the MGB mentioned in paragraph 1.A.2. of this ALERT SERVICE
BULLETIN.

1.E.2. Compliance in service

Helicopters/installed equipment or parts:

The work must be performed on helicopter by the Operator.

Airbus Helicopters makes compliance with this ALERT SERVICE BULLETIN mandatory.

Comply with paragraph 3. except paragraphs 3.B.6. and 3.D. of this ALERT SERVICE BULLETIN
within 110 FH as from receipt of this ALERT SERVICE BULLETIN published at the date mentioned in the
page footer and at the latest on June 30, 2019.

Non-installed equipment or parts:

The work must be performed on the MGB by the Operator.

Before installation on helicopter, modify the MGB as per paragraph 3.B.6.a. of this ALERT SERVICE
BULLETIN.

Building up spare stocks of non-electrical magnetic plug for compliance with this ALERT SERVICE
BULLETIN is left to the Operator’s initiative.

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1.F. APPROVAL

Approval of modifications:

The information or instructions relate to modification 0763C96, which was approved on June 22, 2018 by the
EASA for civil version helicopters subject to an Airworthiness Certificate.

The information or instructions relate to modification 0763C96, which was approved on June 18, 2018 by the
Airbus Helicopters Airworthiness Department for export military version.

Approval of this document:

The technical information contained in this ALERT SERVICE BULLETIN Revision 0 was approved
on July 11, 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 0 was approved
on July 11, 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 0 was approved
on July 11, 2018 by 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: - 1 Electrical Technician,

- 1 Mechanical Technician.

Specialist: - 1 Pilot.

The Estimated Man-hours are indicated for reference purposes only and based on a standard helicopter
configuration.

Estimated Man-hours: - 2 hours for Electrical Technician,

- 5 hours for Mechanical Technician,
- 0.5 hours for Pilot.

Estimated helicopter downtime is indicated for reference purposes only, based on a standard helicopter
configuration.

Helicopter downtime is estimated at one day.

1.H. WEIGHT AND BALANCE

Change in weight and moment is negligible.

1.I. POWER CONSUMPTION

Not applicable.

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1.J. SOFTWARE UPGRADES/UPDATES

Not applicable.

1.K. REFERENCES

The following documents are required for compliance with this ALERT SERVICE BULLETIN.

Maintenance Manual:

MET: 12.00.00.307: Drainage and filling MGB - Routine servicing

MET: 12.00.00.601: Checking a magnetic component - Routine servicing
MET: 24.00.00.300: General instructions - Electrical power system
MET: 60.00.00.300: General mechanical instructions - Rotors

Safety Information Notice:

SIN: 3069-S-63: Checking procedure for magnetic plug installation and locking - Main Rotor Drive

Standard Practices Manual:

MTC: 20.02.01.418: Protection of electrical wiring during maintenance operations - General

MTC: 20.02.06.402: Safetying with lockwire - Safetying and locking assemblies
MTC: 20.05.01.222: Application of PR 1771 B2 sealant - General sealing procedures
MTC: 20.07.01.201: Handling of helicopters in a hangar and in a prepared area - Handling
MTC: 20.07.02.201: Helicopter parked in a repair shop - Safety instructions
MTC: 20.07.03.401: Instructions applicable during maintenance operations on mechanical assemblies -
Technical instructions
MTC: 20.07.03.408: Appearance checks on an aircraft after an inspection or repair - Technical instructions
MTC: 20.08.05.101: Drafting and updating the log card (FM) - General rules applicable to aircraft
MTC: 20.08.05.102: Rules in force applicable for repair and maintenance of aircraft - General rules
applicable to aircraft
MTC: 20.09.02.901: Preservation and packing methods of airborne equipment - Preservation
MTC: 20.80.20.101: Contact insertion and extraction method and tools - Electrical power
MTC: 20.80.20.402: Installation and removal of cable ties - Electrical power
MTC: 20.80.20.404: Backshell tightening / safetying / lossening methods - Electrical power
MTC: 20.80.20.435: Quick-ty backshell assembly method - Electrical power
MTC: 20.80.20.441: Installation of electrical cable bundles and optical fibres - Electrical power
MTC: 20.80.20.603: Securing rules for electrical harnesses - Electrical power

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1.L. OTHER AFFECTED PUBLICATIONS

CAUTION

TO COMPLY WITH THIS ALERT SERVICE

BULLETIN, THE OPERATOR MUST ENSURE THAT
ALL THE MAINTENANCE DOCUMENTS REQUIRED
FOR THE MAINTENANCE OF THIS INSTALLATION
ARE AVAILABLE. OTHERWISE, IT IS THE
OPERATOR’S RESPONSIBILITY TO PROCURE THE
PUBLICATIONS VIA THE USUAL AIRBUS
HELICOPTERS CONTACT.

Publications to be updated:

This modification will be integrated into the following manuals:

- Flight Crew Data (FCD),

- Maintenance Manual (MET),
- Description and Operational Manual (MDF),
- Index of Modifications (SIM).

These documents will be circulated at a later date as per subscription.

Revisions of Illustrated Parts Catalog (IPC) and Wiring Diagram Manual (MCS) will be updated upon the
customer’s order.

1.M. PART INTERCHANGEABILITY OR MIXABILITY

Interchangeability:

PRE MOD electrical magnetic plug and POST MOD non-electrical magnetic plug are not interchangeable.

PRE MOD and POST MOD MGBs are not interchangeable.

Mixability:

Not applicable.

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2. EQUIPMENT OR PARTS INFORMATION

2.A. EQUIPMENT OR PARTS: PRICE - AVAILABILITY - PROCUREMENT

For any information concerning price of modification kits and/or components or for assistance, contact the
Airbus Helicopters Network Sales and Customer Relations Department.

Delivery deadlines will be indicated by Sales and Customer Relations Department on Operator’s request.

Order the required quantity from the Airbus Helicopters Network Sales and Customer Relations Department:

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 helicopter 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.

2.C. EQUIPMENT OR PARTS REQUIRED PER HELICOPTER/COMPONENT

Kits to be ordered for one helicopter or one assembly:

Order as required:

New Old
Key Word Qty Item
P/N P/N  Instruction

Magnetic Plug 1 365A32-7701-00 1 1B7807 Store

(704A34543017)
Body, Magnetic plug ref. For reference only 1a For ref only
Magnetic part ref. For reference only 1b For ref only
O’ring (Viton) 1 PS701-6006-126 2
Cap 4 E0737B0816 3

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Equipment or parts to be ordered separately:

As per Work Cards mentioned in this ALERT SERVICE BULLETIN, and as required the list below:

New Old
Key Word Qty Item
P/N P/N  Instruction

Lockwire 0.5 m EN3628-0,8 4

Clamp 1 E0043-4A0P 5

Consumables to be ordered separately:

As per Work Cards mentioned in this ALERT SERVICE BULLETIN and, as required, the list below:

Product
Key Word Qty CM Item
P/N

Oil 0.1 L NATO-O-155 CM 123 6

Oil, Can 1-4 gal 0.1 L JETOIL2 CM 103 7
Lubricating Oil, Air 0.1 L DEF STAN 91-100-L CM 181 8
Grease, G-361 0.1 L DCSEA361 CM 149 9
Sealant 0.1 kg ECS2339-60 CM 6068 10

NOTE 3

Procurement of oil (6), (7), or (8) is dependent on the type of

oil used for the MGB, according to helicopter version.

The consumables can be ordered separately from the company KLX AEROSPACE SOLUTIONS.
Website : https://www.klxaerospace.com/klxaero/
Telephone: +1.305.925.2600
AOG: +1.305.471.8888

Special tools:

As per Work Cards mentioned in this ALERT SERVICE BULLETIN.

2.D. EQUIPMENT OR PARTS TO BE RETURNED

Not applicable.

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3. ACCOMPLISHMENT INSTRUCTIONS

3.A. GENERAL

- Read and comply with general safety instructions on electrical power as per Work
Card 24.00.00.300 (MET).
- Read and comply with general mechanical instructions on rotors as per Work Card 60.00.00.300 (MET).
- Read and comply with instructions on protection of electrical wiring during maintenance operations as per
Work Card 20.02.01.418 (MTC).
- Read and comply with instructions on handling of helicopters in a hangar and in a prepared area as per
Work Card 20.07.01.201 (MTC).
- Read and comply with instructions on helicopters parked in a repair shop as per Work
Card 20.07.02.201 (MTC).
- Read and comply with instructions applicable during maintenance operations on mechanical assemblies as
per Work Card 20.07.03.401 (MTC).
- Read and comply with rules in force applicable for repair and maintenance of aircraft as per Work
Card 20.08.05.102 (MTC).
- Read and comply with instructions on contact insertion and extraction method and tools as per Work
Card 20.80.20.101 (MTC).
- Read and comply with instructions on backshell tightening, safetying and lossening methods as per Work
Card 20.80.20.404 (MTC).
- Read and comply with instructions on quick-ty backshell assembly method as per Work
Card 20.80.20.435 (MTC).
- Read and comply with instructions on installation of electrical cable bundles as per Work
Card 20.80.20.441 (MTC).
- Read and comply with instructions on securing rules for electrical harnesses as per Work
Card 20.80.20.603 (MTC).

3.B. WORK STEPS

3.B.1. Preliminary steps

- Park the helicopter in a maintenance hangar.

CAUTION

BEFORE WORKING ON ELECTRICAL CIRCUITS,

READ WORK CARD 24.00.00.300 (MET).

CAUTION

BEFORE WORKING ON MECHANICAL SYSTEM,

READ WORK CARD 60.00.00.300 (MET).

CAUTION

WHEN WORKING ON MGB, BE CAREFUL NOT TO

SCRATCH OR DAMAGE THE MGB, OR DAMAGE
ANY ADJACENT SYSTEMS.

- Disconnect all electrical power supply sources.

- Install appropriate access means.
- Drain MGB (a) as per Work Card 12.00.00.307 (MET) (Figure 1).
- Remove equipment to get access to work zone, as necessary.

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3.B.2. Procedure

3.B.2.a. Replacement electrical magnetic plug of MGB pump intake with non-electrical magnetic plug (Figure 1)

3.B.2.a.1. Removal of electrical magnetic plug (Figure 1, DETAIL A, PRE MOD)

- Disconnect connector (b) from electrical magnetic plug "81E" (c) as shown in the photograph below:

- Push and turn by a quarter turn to remove electrical magnetic plug "81E" (c) from electrical magnetic
plug body (d).
- Cut and remove lockwire from the electrical magnetic plug body (d) as shown in photograph below.

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- Loosen and remove the electrical magnetic plug body (d).
- Remove and discard O’ring (e).
- Store the electrical magnetic plug “81E” (c) and the electrical magnetic plug body (d) as per
Work Card 20.09.02.901 (MTC).
- Clean area.

3.B.2.a.2. Installation of non-electrical magnetic plug (Figure 1)

- Remove magnetic part (1b) from magnetic plug body (1a) of magnetic plug (1)
(DETAIL A, POST MOD).
- Lubricate O’ring (2) with oil (6), (7) or (8):
. make sure that the oil (6), (7) or (8) is the same type of oil to be filled in the MGB (a).

- Install the lubricated O’ring (2) onto the magnetic plug body (1a).
- Lubricate screw thread of the magnetic plug body (1a) with grease (9).
- Install and torque-tighten the magnetic plug body (1a) on the MGB (a).
- Safety the magnetic plug body (1a) on the MGB (a) with lockwire (4) as per Work
Card 20.02.06.402 (MTC) (DETAIL B).
- Apply a bead of sealant (10) along the mating surfaces between the magnetic plug body (1a) and the
MGB (a) as per Work Card 20.05.01.222 (MTC) (DETAIL A, POST MOD).

CAUTION

MAKE SURE THAT MAGNETIC PART (1b) IS

CORRECTLY LOCKED AS PER SAFETY
INFORMATION NOTICE NO. 3069-S-63 (SIN).
- Install the magnetic part (1b) on the magnetic plug body (1a).

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3.B.2.b. Modification of wiring of electrical particle detection system of the MGB (Figure 2 or Figure 3)

- Disconnect connector (f) from electrical magnetic plug "79E" (g) as shown in photograph below.
- Remove label "79E-P1" (h) from wire harness connected to the connector (f).

f
h
5

CAUTION

DO NOT REMOVE WIRES THAT HAVE BEEN

DISCONNECTED. DO NOT CUT THESE WIRES.

- Modify the wiring of the electrical particle detection system of the MGB from PRE MOD to POST MOD
using caps (3) as shown in Figure 2 or Figure 3:
. for helicopters version N3, refer to Figure 2,
. for helicopters version K2, refer to Figure 3,
. stow disconnected and unused wires along existing wire routing,
. discard connector (b) as shown in the photograph above.

- Install the label "79E-P1" (h) on wire harness as close as possible to the connector (f) using clamp (5) as
per Work Card 20.80.20.402 (MTC) and as shown in the photograph above.
- Connect the connector (d) to the electrical magnetic plug "79E" (g).

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3.B.3. Tests

- Fill the MGB (a) as per Work Card 12.00.00.307 (MET) (Figure 1).
- Perform functional test of the electrical particle detection installation as per paragraph G.1. of
Work Card 12.00.00.601 (MET).

NOTE 1

The purpose of this test is to make sure that the particle

detection system continues to function with the remaining
electrical particle detectors on the MGB, after the wiring has
been modified.

3.B.4. Final steps

- Install equipment previously removed as per paragraph 3.B.1.

- Clean and restore work zones and helicopter as per Work Card 20.07.03.408 (MTC).
- Remove access means.
- Connect all electrical power supplies.
- Set the helicopter to flight condition.

3.B.5. Ground run-up / flight test

Perform ground run-up after filling of the MGB as required in the Work Card (MET) mentioned in this ALERT
SERVICE BULLETIN.

3.B.6. Work steps for non-installed equipment or parts

3.B.6.a. Stock retrofitting

- Replace the electrical magnetic plug MP/N: 1B7807 (704A34543017) of the MGB pump intake, on the
MGB listed in paragraph 1.A.2., as per paragraph 3.B.2.a. of this ALERT SERVICE BULLETIN.
- When equipping the MGB with its wire harnesses, modify wiring as per paragraph 3.B.2.b. of this
ALERT SERVICE BULLETIN.

3.B.6.b. Stock building-up

Building up spare stocks of the non-electrical magnetic plug is incumbent on the Operator.

3.C. COMPLIANCE CONFIRMATION

Compliance with this document:

Record full compliance with this ALERT SERVICE BULLETIN No. 63.00.22 revision 0 in the helicopter
documents.

Record full compliance with this ALERT SERVICE BULLETIN No. 63.00.22 revision 0 in the Equipment Log
Card (FM).

Tracking of modifications in the documentation:

Record full compliance with modification 0763C96 in the helicopter documents.

Fill in the Equipment Log Card (FM) of the MGB as listed in paragraph 1.A.2.; mention modification 0763C96
and ALERT SERVICE BULLETIN No. 63.00.22 and record installation of non-electrical magnetic plug
P/N: 365A32-7701-00 as per Work Card 20.08.05.101 (MTC).

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3.D. OPERATING AND MAINTENANCE INSTRUCTIONS

Operating instructions:

Refer to Flight Manual (PMV) in effect.

Maintenance instructions:

Scheduled

NOTE 2

The inspection interval of the non-electrical magnetic plug is

defined in ALERT SERVICE BULLETIN No. 05.00.78.

Unscheduled

Removal of non-electrical magnetic plug (Figure 1):

- Push and turn by a quarter turn to remove magnetic part (1b) from magnetic plug body (1a)
(DETAIL A, POST MOD).
- Cut and remove lockwire (4) from the magnetic plug body (1a) (DETAIL B).
- Loosen and remove the magnetic plug body (1a) (DETAIL A, POST MOD).
- Remove and discard O’ring (2).

Installation of non-electrical magnetic plug:

Install the non-electrical magnetic plug as per paragraph 3.B.2.a.2. of this ALERT SERVICE BULLETIN.

The Maintenance Manual (MET) will incorporate these instructions during a next revision. Further to
incorporation of these instructions in the Maintenance Manual (MET), refer to this manual.

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PRE MOD

e d

A
POST MOD

B CM 181 CM 103

2
CM 123
1a CM 149
2.54-3.04
222-265 1
a

1b

B
1a

Return to paragraph 3.B.1.

Return to paragraph 3.B.2.a.1.
Return to paragraph 3.B.2.a.2.
Return to paragraph 3.B.3.
Return to paragraph 3.D.
Figure 1

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Helicopters version N3

PRE MOD

POST MOD

Unless otherwise stated:

Cable gauge: DR22

Cable routing: 1BA

Existing wires to be modified

XXXXXX Existing wires

Existing Nomex sheath

Return to paragraph 3.B.2.b.
Figure 2

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Helicopters version K2

PRE MOD POST MOD

Unless otherwise stated:

Cable gauge: DR22

Cable routing: 1BA

Existing wires to be modified

XXXXXX Existing wires

Existing Nomex sheath

Return to paragraph 3.B.2.b.

Figure 3

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