Sb as 532530037 en Rev 2

SERVICE BULLETIN AS532

53.00.37 Page 1/26This document is available on the Internet: www.eurocopter.com/techpub 2008.07.08

EUROCOPTER DIRECTION TECHNIQUE SUPPORT 13725 MARIGNANE CEDEX FRANCE MILITARY VERSION(S): AC,AL,SC,UC,UL,A2,U2

SERVICE BULLETIN

No. 53.00.37

SUBJECT: FUSELAGE

Reinforcement of ferry tank inserts on 1,500 kg floors

Corresponds to MOD 0726279

LIST OF REVISIONS REVISION No. 2 APPROVED

No. 0: On August 23, 2004 On June 17, 2008 No. 1: On August 29, 2005


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1. PLANNING INFORMATION

1.A. EFFECTIVITY

1.A.1. Helicopters Helicopters pre-MOD 0726279, equipped with floor panels listed in Paragraph 1.A.2.

NOTE

Refer to Individual Inspection Log Book (RIC) (RIC AMS) to identify the actual modification status of the aircraft.

1.A.2. Components affected (Figure 2) Cabin floors, aircraft version MK1 P/N 332A21-1613-00, 332A21-1616-03, 332A21-1630-0201, 332A21-1614-03, 332A21-1617-01, 332A21-1618-03, 332A21-1619-00 and 332A21-1618-02. Cabin floors, aircraft version MK2, P/N 332A21-1613-01, 332A21-1616-04, 332A21-1630-0501, 332A21-1614-04, 332A21-1617-02, 332A21-1618-05, 332A21-1619-01 and 332A21-1618-04.

1.B. ASSOCIATED REQUIREMENTS Not applicable.

1.C. REASON This Service Bulletin, for the MK1 aircraft version, was intended to reinforce the ferry tank inserts further to an incident, in order to increase the tear-off strength margins in case of a crash. Revision 1 was intended to: - integrate the MK2 aircraft version (A2 and U2) in this Service Bulletin, - modify some paragraphs for the aircraft version MK1 (see 1.D. Description), - change Detail I into Detail B for floor P/N 332A21-1617-01 (version MK1). Revision 1 supersedes initial compliance with this Service Bulletin on aircraft version MK1. Revision 2 of this Service Bulletin is intended to: - allow trimming and drilling of upper reinforcements as required, - change P/Ns of attachment rivets. Revision 2 of this Service Bulletin does not supersede compliance with the prior revision. Compliance with this Service Bulletin allows the airworthiness limitations defined in Alert Service Bulletin No. 01.00.33 to be cancelled.


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1.D. DESCRIPTION The modification consists of installing reinforcement plates, bonded and riveted on the upper and lower faces of the cargo floor, at ferry tank insert attachment points. Revision 2 consists of: - trimming and drilling the upper reinforcements as required, - changing P/Ns of attachment rivets (it. 4) in all kits.

1.E. COMPLIANCE EUROCOPTER recommends compliance with this Service Bulletin.

1.E.1. At the works

1.E.1.a. On aircraft

For aircraft pre-MOD 0726279, comply with paragraph 2.B. of this Service Bulletin before delivery.

1.E.1.b. On spares

Not applicable.

1.E.2. Retrofit action on the operator's site

1.E.2.a. On aircraft: By the operator

- For aircraft MK1 version for which Revision 0 of this Service Bulletin was complied with: Comply with paragraph 2.B.1.e. at the time of next scheduled intervention, as of reception of Revision 2. - For aircraft MK1 and MK2 version for which Revision 1 of this Service Bulletin was complied with: Not applicable. - For aircraft MK1 version for which this Service Bulletin was not complied with: At the time of next scheduled maintenance as from receipt of Revision 0, comply with paragraph 2.B. - For aircraft MK2 version for which this Service Bulletin was not complied with: At the time of next scheduled maintenance as from receipt of Revision 1, comply with paragraph 2.B.

1.E.2.b. On spares

By Operator, before installation on aircraft, comply with paragraph 2.B.1.d. and 2.B.1.e.


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1.F. APPROVAL The technical information contained in this Service Bulletin No. 53.00.37 Revision 2 was approved on June 17, 2008 under the authority of The Department of Airworthiness of EUROCOPTER.

1.G. MANPOWER Qualification: 1 fitter and 1 mechanic. Time: 100 hours approximately.

1.H. WEIGHT AND BALANCE - For clients not having complied with Revision 0: Carry out aircraft weighing on completion of the works as per MET Work Card 08.00.00.603 for aircraft version MK1 and as per MMA Task 08-30-00-221 for aircraft version MK2. Mention the results in the " Weight & Balance " sheet (Flight Manual - PMV). - For clients having complied with Revision 0 and 1: Not applicable.

1.I. EFFECT ON ELECTRICAL LOADS Not applicable.

1.J. SOFTWARE MODIFICATION EMBODIMENT STATE Not applicable.

1.K. REFERENCES Standard Practices Manual (MTC), Work Cards: 20.02.05.401, 20.06.01.101, 20.07.02.204, 20.06.01.407 and 20.04.05.101. Flight Manual (PMV), Supplement 10-51. For aircraft version MK1: - Refer to Maintenance Manual (MET), Work Cards: 08.00.00.603, 28.92.00.601, 28.10.00.902,

25.25.00.201 and 53.20.10.401. For aircraft version MK2: - Refer to Maintenance Manual Aircraft (MMA), Tasks: 08-30-00-221, 25-23-01-051,28-10-00-622,

28-13-01-211 and 53-44-01-061.

1.L. OTHER DOCUMENTS CONCERNED Illustrated Parts Catalog (IPC).


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1.M. INTERCHANGEABILITY AND MIXABILITY OF PARTS

1.M.1. Interchangeability Not interchangeable with pre-mod floor.

1.M.2. Mixability Prohibited.


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2. ACCOMPLISHMENT INSTRUCTIONS

2.A. GENERAL Disconnect all electrical power supplies. Earth aircraft. Comply with instructions concerning fuel tank safety as per Work card 20.07.02.204 (MTC).

2.B. OPERATIONAL PROCEDURE

2.B.1. Aircraft version MK1

2.B.1.a. Preliminary steps

Implement suitable access means. As required remove ferry tank inserts as per MET Work Card 28.92.00.601. Remove trooper seats as per MET Work Card 25.25.00.201. Store fuel tanks on aircraft as per MET Work Card 28.10.00.902.

2.B.1.b. Reinforcement of ferry tank inserts on floors as per Figures below

- Figure 1: Reinforcement installation guidelines as per details. - Figure 2: P/Ns for floors according to inserts. - Figure 3: Detail of reinforcement installation. - Figure 4: Reinforcement for inserts at details A and C. - Figure 5: Reinforcement for inserts at details B and E. - Figure 6: Reinforcement for inserts at details F and G. - Figure 7: Reinforcement for insert at detail D. - Figure 9: Reinforcement for inserts at details J and H. - Figure 10: Reinforcement for inserts at details K and L

2.B.1.c. Preparation of upper and lower reinforcements for ferry tank inserts

Mark location of ferry tank insert attachment points (Figures 1 and 2). Remove cabin floors as per MET Work Card 53.20.10.401.

NOTE 1

For reinforcements located at details C, H, J, K and L, the existing freight ring reinforcement plate must be removed and replaced by upper reinforcements at each detail. For reinforcement A, freight ring reinforcement plate must be riveted with rivets (4).


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2.B.1.d. Installation of reinforcements on floor (Figures 2, 3, 4, 5, 6, 7, 9 and 10)

NOTE 2

Upper reinforcements (1) must be routed or drilled to match the rivet positions and the position of attachment bolt cups on floor.

NOTE 3

Before bonding lower reinforcements check mounting plane between reinforcements and lower skin. Fill gaps underneath lower reinforcements with adhesive (6) to restore a correct mounting plane.

Prepare surfaces to be bonded as per MTC Work Card 20.06.01.101 (paint stripping). According to floor, see paragraph 3.C.1. and Figure 1, bond reinforcements (1 and 2) on upper and lower skins by means of adhesive (6) as per MTC Work Card 20.06.01.407. Allow parts to dry. Counter-drill upper reinforcements (1) to 3.3 mm diameter as per Figures 3, 4, 5, 6, 7, 9 and 10. Fit rivets (4) as per MTC Work Card 20.02.05.401. Bond lower reinforcements (3) with adhesive (6) as per MTC Work Card 20.06.01.407 and Figures 2, 3, 4, 5, 6, 7, 9 and 10. Allow parts to dry. On lower reinforcements (3), mark and drill to 4.1 mm, countersink to 100. Fit rivets (5) as per MTC Work Card 20.02.05.401 and as per Figure 3.

NOTE 4

Rivet crushing: 2 mm maximum.

Figure 3 - Detail A.

Carry out paint touch-up (alodine, primer and black anti-skid paint) as per MTC Work Card 20.04.05.101. Re identify floors as per paragraph 2.C.

2.B.1.e. For operators having complied with Revision 0 of this Service Bulletin

Replace reinforcement of Detail I by reinforcement of Detail B as per procedure in paragraph 2.B.1.d.

2.B.1.f. Final steps

Install cabin floors as per MET Work Card 53.20.10.401. Carry out depreservation of fuel tanks as per MET Work Card 28.10.00.902. Install trooper seats as per MET Work Card 25.25.00.201. Install ferry tank inserts as per MET Work Card 28.90.00.601.


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2.B.2. Aircraft version MK2

2.B.2.a. Preliminary steps

Implement suitable access means. As required remove ferry tank inserts as per MMA Task 28-13-01-211. Remove trooper seats as per MMA Task 25-23-01-051. Store fuel tanks on aircraft as per MMA Task 28-10-00-622.

2.B.2.b. Reinforcement of ferry tank inserts on floors as per Figures below

- Figure 1: Reinforcement installation guidelines as per details. - Figure 2: P/Ns for floors according to inserts. - Figure 3: Detail of reinforcement installation. - Figure 4: Reinforcement for inserts at details A and C. - Figure 5: Reinforcement for inserts at details B and E. - Figure 6: Reinforcement for inserts at details F and G. - Figure 7: Reinforcement for insert at detail D. - Figure 8: Reinforcement for insert at detail I. - Figure 9: Reinforcement for inserts at details J and H. - Figure 10: Reinforcement for inserts at details K and L.

2.B.2.c. Preparation of upper and lower reinforcements for ferry tank inserts

Mark location of ferry tank insert attachment points (Figures 1 and 2). Remove cabin floors as per MMA Task 53-44-01-061.

NOTE 5

For reinforcements located at details C, H, J, K and L, the existing freight ring reinforcement plate must be removed and replaced by upper reinforcements at each detail. For reinforcement A, freight ring reinforcement plate must be riveted with rivets (4).

2.B.2.d. Installation of reinforcements on floor (Figures 2, 3, 4, 5, 6, 7, 8, 9 and 10)

NOTE 6

Upper reinforcements (1) must be routed or drilled to match the rivet positions and the position of attachment bolt cups on floor.

NOTE 7

Before bonding lower reinforcements check mounting plane between reinforcements and lower skin. Fill gaps underneath lower reinforcements with adhesive (6) to restore a correct mounting plane.


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Prepare surfaces to be bonded as per MTC Work Card 20.06.01.101 (paint stripping). According to floor, see paragraph 3.C.1. and Figure 1, bond reinforcements (1 and 2) on upper and lower skins by means of adhesive (6) as per MTC Work Card 20.06.01.407. Allow parts to dry. Counter-drill upper reinforcements (1) to 3.3 mm diameter as per Figures 3 to 10. Fit rivets (4) as per MTC Work Card 20.02.05.401. Bond lower reinforcements (3) with adhesive (6) as per MTC Work Card 20.06.01.407 and Figures 2 to 10. Allow parts to dry. On lower reinforcements (3), mark and drill to 4.1 mm, countersink to 100. Fit rivets (5) as per MTC Work Card 20.02.05.401 and as per Figure 3.

NOTE 8

Rivet crushing: 2 mm maximum.

Figure 3 - Detail A.

Carry out paint touch-up (alodine, primer and black anti-skid paint) as per MTC Work Card 20.04.05.101. Re identify floors as per paragraph 2.C.

2.B.2.e. Final steps

Install cabin floors as per MMA Task 53-44-01-061. Carry out fuel tank depreservation as per MMA Task 28-10-00-622. Install trooper seats as per MMA Task 25-23-01-051. Install ferry tank inserts as per MMA Task 28-13-01-211.

2.B.3. Functional tests Not applicable.

2.B.4. Spares

2.B.4a. Retrofitting of spare part stocks

Retrofit floor stocks mentioned in paragraph 1.A.2., as per paragraph 2.B.

2.B.4.b. Replacement of spare part stocks

At customer's initiative.


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2.C. IDENTIFICATION Record compliance with this Service Bulletin Revision 2 and embodiment of MOD 0726279 in the aircraft documents. Identify modified floors by marking MOD No. next to floor P/N, with indelible ink.

Key Word Former P/N New P/N Remark

Floor 01 332A21-1613-00 (MK1) and 332A21-1613-01 (MK2)

Floor 02 332A21-1616-03 (MK1) and 332A21-1616-04 (MK2)

Floor 03 332A21-1630-0201 (MK1) and 332A21-1630-0501 (MK2)

Floor 04 332A21-1614-03 (MK1) and 332A21-1614-04 (MK2)

Floor 05 332A21-1617-01 (MK1) and 332A21-1617-02 (MK2)

Floor 06 332A21-1618-03 (MK1) and 332A21-1618-05 (MK2)

Floor 07 332A21-1619-00 (MK1) and 332A21-1619-01 (MK2)

Floor 08 332A21-1618-02 (MK1) and 332A21-1618-04 (MK2)

2.D. OPERATING AND MAINTENANCE INSTRUCTIONS

2.D.1. Operating instruction(s) Refer to Flight Manual (PMV), Supplement 10-51.

2.D.2. Maintenance instruction(s) Not applicable.


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Figure 1


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FLOORS 532 1,500 kg, metallic FRAMESITEMS KEY WORD MK1 MK2

01 Floor, transversal, front 332A21-1613-00 332A21-1613-01 X3245 X3855 02 Floor, longitudinal, RH 332A21-1616-03 332A21-1616-04 X3855 X5295

03 Floor, 6th tank, w/ cargo

swing capability 332A21-1630-0201 332A21-1630-0501 X3855 X5295

04 Floor, longitudinal, LH 332A21-1614-03 332A21-1614-04 X3855 X5295 05 Floor, transversal, rear 332A21-1617-01 332A21-1617-02 X5295 X5905 06 Floor, half-moon, RH 332A21-1618-03 332A21-1618-05 X5905 X6815 07 Floor 5th tank 332A21-1619-00 332A21-1619-01 X5905 X6815 08 Floor, half-moon, LH 332A21-1618-02 332A21-1618-04 X5905 X6815

Figure 2


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Figure 3


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Figure 4


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Figure 5


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Figure 6


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Figure 7


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Figure 8


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Figure 9


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Figure 10


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3. MATERIAL INFORMATION

3.A. MATERIAL: COST AVAILABILITY

3.A.1. Cost For any information concerning kits or components, contact the EUROCOPTER Networks Customer Support Sales Department.

3.B. INFORMATION CONCERNING INDUSTRIAL SUPPORT Not applicable.

3.C. MATERIAL REQUIRED FOR EACH AIRCRAFT, ENGINE/COMPONENTS

3.C.1. Kits to be ordered Operators of AS332 MK1 helicopters having complied with Revision 0 must order kit 332A08-0842-0576 in order to comply with Revision 2.

New P/N Qty Item Key Word Former P/N Packaging item 332A08-0842-0172 Insert kit for floor tank P/N 332A21-1613-00 and 332A21-1613-01 including:

332A08-0841-2401 1 1 Plate, upper, detail C 100 332A08-0842-2801 2 1 Plate, upper, detail B 101 332A08-0841-5401 1 2 Plate, lower, detail C 102 332A08-0841-5701 2 2 Plate, lower, detail B 103 332A08-0841-5501 1 2 Plate, lower, detail A 104 332A08-0841-8401 1 3 Plate, lower, riveted, detail C 105 332A08-0841-8201 2 3 Plate, lower, riveted, detail B 106 332A08-0841-8501 1 3 Plate, lower, riveted, detail A 107 ASNA0077A402 52 4 Rivet, blind 108 ASNA2051DXJ4009 4 5 Rivet, 100 csk head 109 332A08-0842-0272 Insert kit for floor tank P/N 332A21-1616-03 and 332A21-1616-04 including: 332A08-0841-2601 1 1 Plate, upper, detail D 100 332A08-0841-5701 1 2 Plate, lower, detail D 101 332A08-0841-8201 1 3 Plate, lower, riveted, detail D 102 ASNA0077A402 12 4 Rivet, blind 103 ASNA2051DXJ4009 1 5 Rivet, 100 csk head 104


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3.C.1. Kits to be ordered (cont'd)

New P/N Qty Item Key Word Former P/N Packagingitem 332A08-0842-0372 Insert kit for floor tank P/N 332A21-1630-0201 and 332A21-1630-0501 including: 332A08-0841-3101 1 1 Plate, upper, detail E 100 332A08-0841-3201 1 1 Plate, upper, detail F 101 332A08-0841-6201 1 2 Plate, lower, detail E 102 332A08-0841-6301 1 2 Plate, lower, detail F 103 332A08-0841-8601 1 3 Plate, lower, riveted, detail E 104 332A08-0841-8701 1 3 Plate, lower, riveted, detail F 105 ASNA0077A402 25 4 Rivet, blind 106 ASNA2051DXJ4009 2 5 Rivet, 100 csk head 107 332A08-0842-0472 Insert kit for floor tank P/N 332A21-1614-03 and 332A21-1614-04 including: 332A08-0841-3301 1 1 Plate, upper, detail G 100 332A08-0841-5701 1 2 Plate, lower, detail G 101 332A08-0841-8201 1 3 Plate, lower, riveted, detail G 102 ASNA0077A402 13 4 Rivet, blind 103 ASNA2051DXJ4009 1 5 Rivet, 100 csk head 104 332A08-0842-0572 Insert kit for tank floors (MK2) P/N 332A21-1617-02 including: 332A08-0842-2801 1 1 Plate, upper, detail B 100 332A08-0841-2301 1 1 Plate, upper, detail H 101 332A08-0842-3401 1 1 Plate, upper, detail I 102 332A08-0841-2201 1 1 Plate, upper, detail J 103 332A08-0841-5701 2 2 Plate, lower, details B and I 104 332A08-0841-5301 1 2 Plate, lower, detail H 105 332A08-0841-5201 1 2 Plate, lower, detail J 106 332A08-0841-8201 3 3 Plate, lower, riveted, details B, I and J 107 332A08-0841-8301 1 3 Plate, lower, riveted, detail H 108 ASNA0077A402 55 4 Rivet, blind 109 ASNA2051DXJ4009 4 5 Rivet, 100 csk head 110 332A08-0842-0576 Insert kit for tank floors (MK1) P/N 332A21-1617-01 including: 332A08-0842-2801 2 1 Plate, upper, detail B 100 332A08-0841-2301 1 1 Plate, upper, detail H 101 332A08-0841-2201 1 1 Plate, upper, detail J 102 332A08-0841-5701 2 2 Plate, lower, details B 103 332A08-0841-5301 1 2 Plate, lower, detail H 104 332A08-0841-5201 1 2 Plate, lower, detail J 105 332A08-0841-8201 3 3 Plate, lower, riveted, details B and J 106 332A08-0841-8301 1 3 Plate, lower, riveted, detail H 107 ASNA0077A402 55 4 Rivet, blind 108 ASNA2051DXJ4009 4 5 Rivet, 100 csk head 109


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3.C.1. Kits to be ordered (cont'd)

New P/N Qty Item Key Word Former P/N Packagingitem 332A08-0842-0672 Insert kit for floor tank P/N 332A21-1618-03 and 332A21-1618-05 including: 332A08-0841-2001 1 1 Plate, upper, detail K 100 332A08-0841-5001 1 2 Plate, lower, detail K 101 332A08-0841-8001 1 3 Plate, lower, riveted, detail K 102 ASNA0077A402 12 4 Rivet, blind 103 ASNA2051DXJ4009 1 5 Rivet, 100 csk head 104 332A08-0842-0772 Insert kit for floor tank P/N 332A21-1619-00 and 332A21-1619-01 including: 332A08-0842-2801 2 1 Plate, upper, detail B 100 332A08-0841-5701 2 2 Plate, lower, detail B 101 332A08-0841-8201 2 3 Plate, lower, riveted, detail B 102 ASNA0077A402 26 4 Rivet, blind 103 ASNA2051DXJ4009 2 5 Rivet, 100 csk head 104 332A08-0842-0872 Insert kit for floor tank P/N 332A21-1618-02 and 332A21-1618-04 including: 332A08-0841-2101 1 1 Plate, upper, detail L 100 332A08-0841-5101 1 2 Plate, lower, detail L 101 332A08-0841-8101 1 3 Plate, lower, riveted, detail L 102 ASNA0077A402 13 4 Rivet, blind 103 ASNA2051DXJ4009 1 5 Rivet, 100 csk head 104

3.C.2. Materiel to be ordered separately Not applicable.

3.C.3. Ingredients to be ordered separately

New P/N Qty Item Key Word Former P/N Instructions Disposition

DHS172-172.20 1 6 Adhesive (1.6 L kit) MTC 20.06.01.407


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3.C.4. Material delivered by the customer Not applicable.

3.C.5. Tooling As per Work Cards and Tasks mentioned in this Service Bulletin.

3.D. MATERIAL REQUIRED FOR EACH SPARE PART

3.D.1. Kits to be ordered Order material defined in paragraphs 3.C.1. and 3.C.3. as required.

3.E. PARTS Not applicable.

3.F. TOOLING: COST AVAILABILITY For any information, contact the Customer Support Sales Department.


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3.G. PROCUREMENT CONDITIONS

3.G.1. Material Order the required quantity from EUROCOPTER Etablissement de Marignane Direction Ventes Service Client (C.R.) 13725 MARIGNANE CEDEX FRANCE

NOTE

On the purchase order, please specify the mode of transport, the destination and the serial numbers of the aircraft to be modified.

3.G.2. Ingredients The ingredients listed in this Service Bulletin and in the reference documents can be ordered from INTERTURBINE: Website: http://www.itlogistics.de Telephone: +49.41.91.809.300 AOG: +49.41.91.809.444.


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4. APPENDIX Not applicable.

Documents

Sb as 532530037 en Rev 2