Airworthiness Directives; Eurocopter Deutschland GmbH Helicopters

[Federal Register Volume 79, Number 46 (Monday, March 10, 2014)]
[Rules and Regulations]
[Pages 13201-13204]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2014-04570]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2013-0554; Directorate Identifier 2012-SW-009-AD; 
Amendment 39-17774; AD 2014-05-01]
RIN 2120-AA64


Airworthiness Directives; Eurocopter Deutschland GmbH Helicopters

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are adopting a new airworthiness directive (AD) for 
Eurocopter Deutschland GmbH (Eurocopter) Model EC135P1, EC135P2, 
EC135P2+, EC135T1, EC135T2, and EC135T2+ helicopters. This AD requires 
analyzing the main gearbox (MGB) oil for indications of metal chips or 
pieces, reviewing the MGB log or equivalent record, and inspecting 
certain teeth in the MGB after two chip indications. This AD was 
prompted by a partial tooth rupture found in an MGB that was returned 
to the manufacturer for repairs. The actions of this AD are intended to 
detect wear in the MGB that could lead to a gear tooth rupture, failure 
of the MGB, loss of power to the main rotor, and subsequent loss of 
control of the helicopter.

DATES: This AD is effective April 14, 2014.
    The Director of the Federal Register approved the incorporation by 
reference of a certain document listed in this AD as of April 14, 2014.

ADDRESSES: For service information identified in this AD, contact 
American Eurocopter Corporation, 2701 N. Forum Drive, Grand Prairie, TX 
75052; telephone (972) 641-0000 or (800) 232-0323; fax (972) 641-3775; 
or at http://www.eurocopter.com/techpub. You may review the referenced 
service information at the FAA, Office of the Regional Counsel, 
Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas 
76137.

[[Page 13202]]

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov or in person at the Docket Operations Office 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this AD, the European Aviation Safety 
Agency (EASA) AD, any incorporated-by-reference service information, 
the economic evaluation, any comments received, and other information. 
The street address for the Docket Operations Office (phone: 800-647-
5527) is U.S. Department of Transportation, Docket Operations Office, 
M-30, West Building Ground Floor, Room W12-140, 1200 New Jersey Avenue 
SE., Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Rao Edupuganti, Aviation Safety 
Engineer, Regulations and Policy Group, Rotorcraft Directorate, FAA, 
2601 Meacham Blvd., Fort Worth, Texas 76137; telephone (817) 222-5110; 
email [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    On July 3, 2013, at 78 FR 40053, the Federal Register published our 
notice of proposed rulemaking (NPRM), which proposed to amend 14 CFR 
part 39 by adding an AD that would apply to Eurocopter Model EC135 P1, 
EC135 P2, EC135 P2+, EC135 T1, EC135 T2, and EC135 T2+ helicopters with 
an MGB, part number (P/N) 4649 010 003, 4649 010 005, 4649 010 006, 
4649 010 006X, 4649 010 008, 4649 010 008X, 4649 001 007, 4649 010 010, 
or 4649 010 013 installed. The NPRM proposed to require analyzing the 
MGB oil for indications of metal chips or pieces, reviewing the MGB log 
or equivalent record, and inspecting certain teeth in the MGB after two 
chip indications. The proposed requirements were intended to detect 
wear in the MGB that could lead to a gear tooth rupture, failure of the 
MGB, loss of power to the main rotor, and subsequent loss of control of 
the helicopter.
    The Required Actions section of the NPRM had a typographical error 
in some references to Eurocopter Alert Service Bulletin (ASB) EC135-
63A-012, Revision 5, dated September 6, 2011. That error has been 
corrected in this AD.
    The NPRM was prompted by AD No. 2009-0106R1, dated November 3, 
2011, issued by EASA, which is the Technical Agent for the Member 
States of the European Union. EASA advises that an MGB was returned to 
the manufacturer for repair after ``several chip indications.'' 
According to EASA, a partial tooth rupture was detected after 
disassembly of the gearbox and removal of a drive pinion. EASA states 
the tooth rupture was determined to have been caused by wear. EASA AD 
No. 2009-0106R1 includes requirements and timetables for oil sampling 
and analysis; checking the gearbox log card for chip indications; and 
corrective measures for chip indications. It also states that a 
prescribed modification to the MGB would be terminating action for the 
AD.

Comments

    We gave the public the opportunity to participate in developing 
this AD, but we received no comments on the NPRM (78 FR 40053, July 3, 
2013).

FAA's Determination

    These helicopters have been approved by the aviation authority of 
Germany and are approved for operation in the United States. Pursuant 
to our bilateral agreement with Germany, EASA, its technical 
representative, has notified us of the unsafe condition described in 
the EASA AD. We are issuing this AD because we evaluated all 
information provided by EASA and determined the unsafe condition exists 
and is likely to exist or develop on other helicopters of these same 
type designs and that air safety and the public interest require 
adopting the AD requirements as proposed except for correcting the 
references to Eurocopter Alert Service Bulletin EC135-63A-012, Revision 
5, dated September 6, 2011, in paragraphs (e)(2)(ii)(A), (e)(3), 
(e)(4)(i), and (e)(4)(ii). These corrections are consistent with the 
intent of the proposals in the NPRM (78 FR 40053, July 3, 2013) and 
will not increase the economic burden on any operator nor increase the 
scope of the AD.

Differences Between This AD and the EASA AD

    The EASA AD applies to military EC635 helicopters. This AD does not 
apply to EC635 helicopters because they are not type certificated in 
the United States.

Related Service Information

    Eurocopter issued ASB EC135-63A-012 on August 8, 2007, which was 
followed by five revisions, the most recent of which was issued 
September 6, 2011. The ASBs prescribe procedures to monitor and detect 
wear in time to prevent MGB tooth ruptures in main transmissions for 
EC135 and EC635 model helicopters. Revision 5 of the ASB prescribes 
procedures for taking and analyzing scheduled oil samples, identifying 
and addressing chip indications, and inspecting certain teeth in 
gearboxes.

Costs of Compliance

    We estimate that this AD affects 242 helicopters of U.S. Registry 
and that labor costs average $85 per work-hour. Based on these 
estimates, we expect the following costs:
    <bullet> Taking oil samples will take 1 work-hour. Assuming 2 
samples per aircraft per year, we estimate a total cost of $170. No 
parts are needed, so the total cost for the U.S. fleet is $41,140.
    <bullet> A laboratory analysis of 2 oil samples cost $200 per 
helicopter for labor and equipment, for a total fleet cost of $48,400.
    <bullet> Inspecting the oil filter element for a chip requires 
about a half-hour of labor for a cost per helicopter of about $43. No 
parts are needed.
    <bullet> Inspecting certain teeth in the gearbox, performing a 
ground run, and inspecting for leaking oil takes 8 work-hours for a 
labor cost of $680. Parts cost $196, for a total cost per helicopter of 
$876.
    <bullet> If the oil sample analysis indicates metal chips, 
recording the results on the aircraft log card takes a half-hour for a 
labor cost of about $43 per helicopter.
    <bullet> The cost of examining the log card for any previously 
recorded chip indications is minimal.
    <bullet> Inspecting the chip detector for deposits requires about 5 
minutes of labor for a labor cost of about $7.
    <bullet> Replacing the MGB with an airworthy MGB requires 8 work-
hours for a labor cost of $680. Parts cost $145,000 for total cost per 
helicopter of $145,680.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority of the FAA Administrator. Subtitle VII: Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701: ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on helicopters identified in this 
rulemaking action.

[[Page 13203]]

Regulatory Findings

    This AD will not have federalism implications under Executive Order 
13132. This AD will not have a substantial direct effect on the States, 
on the relationship between the national government and the States, or 
on the distribution of power and responsibilities among the various 
levels of government.
    For the reasons discussed above, I certify that this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866;
    (2) Is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979);
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction; and
    (4) Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared an economic evaluation of the estimated costs to comply 
with this AD and placed it in the AD docket.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

    Authority:  49 U.S.C. 106(g), 40113, 44701.


Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive (AD):

2014-05-01 Eurocopter Deutschland GmbH (Eurocopter): Amendment 39-
17774; Docket No. FAA-2013-0554; Directorate Identifier 2012-SW-009-
AD.

(a) Applicability

    This AD applies to Model EC135P1, EC135P2, EC135P2+, EC135T1, 
EC135T2, and EC135T2+ helicopters with a main gearbox (MGB), part 
number (P/N) 4649 010 003, 4649 010 005, 4649 010 006, 4649 010 
006X, 4649 010 008, 4649 010 008X, 4649 001 007, 4649 010 010, or 
4649 010 013 installed, certificated in any category.

(b) Unsafe Condition

    This AD defines the unsafe condition as a tooth rupture in the 
MGB. This condition could result in failure of the MGB, loss of 
power to the main rotor, and subsequent loss of control of the 
helicopter.

(c) Effective Date

    This AD becomes effective April 14, 2014.

(d) Compliance

    You are responsible for performing each action required by this 
AD within the specified compliance time unless it has already been 
accomplished prior to that time.

(e) Required Actions

    (1) Within 100 hours time-in-service (TIS), and thereafter at 
intervals not to exceed 100 hours or 12 months, whichever occurs 
first, take an oil sample in accordance with the Accomplishment 
Instructions, Part 1, of Eurocopter Alert Service Bulletin EC135-
63A-012, Revision 5, dated September 6, 2011 (ASB EC135-63A-012).
    (2) Within 25 hours TIS after taking the oil sample in paragraph 
(e)(1) of this AD, analyze the oil sample in accordance with the 
Accomplishment Instructions, Part 2.A. through Part 2.C. of ASB 
EC135-63A-012, except that you are not required to contact 
Eurocopter.
    (i) If the analysis indicates Stage II as specified by the 
Accomplishment Instructions, Part 2.B., of ASB EC135-63A-012, within 
25 hours TIS, remove and inspect the oil filter element for a chip, 
defined as any solid piece of metal but not metallic fuzz or fine 
particles.
    (A) If there are no chips, clean the oil filter element and chip 
detector, inspect the drive stage toothing, perform a ground run, 
and inspect for leaking oil in accordance with the Accomplishment 
Instructions, Part 4.A through 4.G, of ASB EC135-63A-012. Change the 
oil.
    (B) If there is a chip, replace the MGB with an airworthy MGB 
before further flight.
    (ii) If the analysis indicates Stage III as specified by the 
Accomplishment Instructions, Part 2.B., of ASB EC135-63A-012 and if 
the water content is between 0.1 and 0.5 percent, within 10 hours 
TIS, remove and inspect the oil filter element for a chip.
    (A) If there are no chips, clean the oil filter element and chip 
detector, inspect the drive stage toothing, perform a ground run, 
and inspect for leaking oil in accordance with the Accomplishment 
Instructions, Part 4.A through 4.G, of ASB EC135-63A-012. Change the 
oil.
    (B) If there is a chip, replace the MGB with an airworthy MGB 
before further flight.
    (3) Before the MGB has accumulated 300 hours TIS, determine 
whether two or more chip indications have occurred. If two or more 
chip indications have occurred, inspect the drive stage toothing, 
perform a ground run, and inspect for leaking oil in accordance with 
the Accomplishment Instructions, Part 4.A through 4.G, of ASB EC135-
63A-012.
    (4) Any time there is a chip indication, remove and inspect the 
chip detector for deposits (fine particles or metallic fuzz) or 
chips, and remove and inspect the oil filter element for a chip.
    (i) If there are no chips and a minimal amount of particles or 
metallic fuzz, corresponding to Figure 5, Stage A of ASB EC135-63A-
012, clean the chip detector and the oil filter element and enter 
the chip indication on the MGB log card before further flight.
    (ii) If there are no chips and some particles or metallic fuzz, 
corresponding to Figure 5, Stage B of ASB EC135-63A-012, clean the 
chip detector and the oil filter element and enter the chip 
indication on the MGB log card before further flight, and within 10 
hours TIS inspect the drive stage toothing, perform a ground run, 
and inspect for leaking oil in accordance with the Accomplishment 
Instructions, Part 4.A through 4.G, of ASB EC135-63A-012. Perform a 
ground run for 15 minutes at the flight-idle power setting, and then 
re-inspect the chip detector for a chip, particles, and metallic 
fuzz.
    (iii) If there is a chip, replace the MGB with an airworthy MGB.

(f) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Safety Management Group, FAA, may approve AMOCs 
for this AD. Send your proposal to: Rao Edupuganti, Aviation Safety 
Engineer, Regulations and Policy Group, Rotorcraft Directorate, FAA, 
2601 Meacham Blvd., Fort Worth, Texas 76137; telephone (817) 222-
5110; email [email protected].
    (2) For operations conducted under a 14 CFR part 119 operating 
certificate or under 14 CFR part 91, subpart K, we suggest that you 
notify your principal inspector, or lacking a principal inspector, 
the manager of the local flight standards district office or 
certificate holding district office, before operating any aircraft 
complying with this AD through an AMOC.

(g) Additional Information

    The subject of this AD is addressed in the European Aviation 
Safety Agency (EASA) AD No. 2009-0106R1, dated November 3, 2011. You 
may view the EASA AD on the Internet at http://www.regulations.gov 
in Docket No. FAA-2013-0554.

(h) Subject

    Joint Aircraft Service Component (JASC) Code: 6320, Main Rotor 
Gearbox.

(i) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Eurocopter Alert Service Bulletin EC135-63A-012, Revision 5, 
dated September 6, 2011.
    (ii) Reserved.
    (3) For Eurocopter service information identified in this AD, 
contact American Eurocopter Corporation, 2701 N. Forum Drive, Grand 
Prairie, TX 75052; telephone (972) 641-0000 or (800) 232-0323; fax 
(972) 641-3775; or at http://www.eurocopter.com/techpub.
    (4) You may view this service information at FAA, Office of the 
Regional Counsel, Southwest Region, 2601 Meacham Blvd., Room 663, 
Fort Worth, Texas 76137. For information on the availability of this 
material at the FAA, call (817) 222-5110.

[[Page 13204]]

    (5) You may view this service information that is incorporated 
by reference at the National Archives and Records Administration 
(NARA). For information on the availability of this material at 
NARA, call (202) 741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued in Fort Worth, Texas, on February 24, 2014.
Bruce E. Cain,
Acting Directorate Manager, Rotorcraft Directorate, Aircraft 
Certification Service.
[FR Doc. 2014-04570 Filed 3-7-14; 8:45 am]
BILLING CODE 4910-13-P

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