# 0 Sikorsky A United Tech n ologies Company 

### Sikorsky Ai rcr aft Corporation 6900 Maln Street P .O.**Bo~** 9729 Stratford , Co n necticut 06615·9129 (203) 386·4000 

# moHrnTI**~~rnmorn~ ~**  I

# ~ I I

TH IS ALERT SERVICE BULLETIN I S THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION AND IS PROTECTED UNDER THE COPYRIGHT LAWS OF T HE UN ITED STATES AND OTHER COUNTRIES. TH IS AL ERT SERVICE BUL LETI N IS DISTRIBU TED ONLY TO OWNERS/OPERATORS OF COMMERCIALLY-CERTIFIED S IK

ORSKY HELICOPTERS AND SIKORSKY-AUTHORIZED LOGISTIC AN D SERVICE CENTERS FOR THE PURPOSE OF FOSTERING T HE SAFE AND EFFICI ENT OPERATION OF SUCH HELICOPTERS AND UNDER THE EXPRESS CONDITION TH AT T HE CONTENTS OF T HI S ALERT SERV ICE BULLETI N ARE NOT TO BE DISCLOSED, REPRODUCED. OR DI STRIBUTED , IN WHOLE OR IN PART, TO AN Y TH I RD PARTY , OR ADAPTED AS A DER IVATIVE WORK, WITHOUT THE EXPR E SS DOCUMENTED CONSENT OF S IK ORSKY AIRCRAFT CORPORATION. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL AND/OR CR I M I NAL PENAL TIES. LIMITED DISTRIBUTION • S I KORSKY AIRCRAFT CORPORATION 1999 ALL R IGHTS RESERVED No
. 92-63-014A Subject: ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One-Time Replacement of Mounting Studs

1. PLANNING INFORMATION A. Effectivity S-92A Model Main Gearboxes which contain a 92351-15110-042 , -043, -044 main housing assembly which have not been reworked. Main housing assemblies reworked will be identified by part marking TS-062-01 in the same location as part number. Component MGB Oil Filter Assembly B
. Purpose This Alert Service Bulletin (ASB) provides instruction to remove MGB filter bowl assembly mounting titanium studs and replace them with steel mounting studs
. Background Undetected damage to an oil filter stud can lead to fa ilure of the stud
. Enhanced procedures are being added to the maintenance manual to help identify potentially damaged studs. To further enhance reliability of this connection, the titanium studs are being replaced with steel. C. Description Helicopter is prepared for maintenance. Central cover is removed , if required. MGB oil filter assembly is removed. Titanium filter bowl assembly mounting studs are removed
. Steel mounting studs are installed. MGB oil filter assembly is reinstalled. Main transmission is January 28/09 Page 1 of 10 63-24-02 Revision A - March 20/09

# I**ffi[~rnu ~~mw~rn~**  

# mrnmrrauJm No. 92-63-014A ROTOR DRIVES • Main Module Asse mbly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs
1. PLANNING INFORMATION (Continued)



## D.

E. serviced. Reinstall central cover, if removed. A ground test procedure is performed. Helicopter is returned to service. Compliance Compliance is essential. One-time replacement outlined herein Is to be accomplished before next flight. Approval The change effected by this document is classified as Ma jor, and is FAA approved in accordance with the applicable requirements of Federal Aviation Regulations FAR 29. This constitutes EASA approval under the terms of the current interim procedures for working with the European Community on airworthiness certification and continued airworthiness. The repair data provided in this document is automatically approved by ED Decision 2004/04/CF, as amended by ED Decision 2007/001/C. Reference to the ED Decisions mentioned above shall be made in the release documents issued by the EASA 145 approved organization, releasing the relevant EU registered helicopter or component to service. F. Personnel Qualifications Personnel required to perform this task must have experience with metal working or machining. If personnel with suitable qualifications are not available, contact Customer Service Engineering at 1-800-Winged-S or 1-203·4 16-4299 regarding training or information regarding contractors capable of perform i ng this work. As well , check EASA requirements for personnel certification/ qualifications. Demonstration video will be provided. G. Manpower (Estimated) Removal of Oil Filter Assembly Removal of Filter Bowl Mounting Assembly Studs Install Filter Bowl Mounting Assembly Studs Reinstallation of Oil Filter Assembly No
. of Men 1



### 1 No
. of Hours 0.40 1.50 1.50 0.40 " Man-Hours 0.40 1.50 1.50 0.40
NOTE: • Estimate does not include time required to prepare helicopter or return it to flight status. January 28/09 Page 2 63-24-02 Revision A - March 20/09

# ffi[~rnu**~~rnvm;~ mmiTIT~uJm**  No
. 92-63-014A ROTOR DRIVES • Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs
1. PLANNING INFORMATION (Continued) H. Material One-quart container, or equivalent. I. Tooling NOTE: For tooling availability, contact Helicopter Support Inc. Refer to Material Information sectfon of this ASB. (1) Lockring Cutter, BT309 , or equivalent. (2) Lockring Drive Tool , S101D12 , M101D12N, or equfvalent. (3) Stud Install Wrench , R1105W, or equivalent. (4) Housing, Tapered Collet 1/4- 28 , CGS00-4 , or equivalent. J. Weight and Balance None. 

### K. Electrical Load Data Not affected. L. Software Load Data Not applicable. M. References (1) Maintenance Manual, SA S92A-A MM -OOO, Chapter/Section 54-40-01. (2) Maintenance Manual, SA S92A-AMM-OOO , Chapter/Section 63-20-00-610-001. (3) Maintenance Manual, SA S92A-AMM-OOO, Chapter/Section 63-24-02-900-002
. (4) Functional Check Flight Procedures Manual , SA S92A-FCP-OOO
. N. Publications Affected (1) Temporary Revision No
. 63-12 against Maintenance Manual , SA S92A-AMM-OOO, Chapters/Sections 63-24-02-900-002, will be issued to introduce a new nut (SS5086-04). January 28/09 Page 3 63-24-02 Revision A - March 20/09

# ffi[~mu**~~rn~m;~** 

# mm[ITauJm No. 92-63-014A ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTi me Replacement of Mounting Studs
1. PLANNING INFORMATION (Continued) 0. Attachment (1) None. 2 MATERIAL INFORMATION A. Basis for Mate rial Data Per helicopter
. B. Bill of Material New Part No. MS51990-105P SS5086-04 M83248 / 1-033 M83248/1-238 SLS11FJ101- 11SN12A 

# I (DMYN0-97393-

503) MS20002-4 3 3 

### 1

3

3 Key Word Lockring Nut Packing Packing Stud

Washe r Old Part No. MS51990-105P MS21043-4 M83248/1-033 M83248/1-238 SFJ101- 11TA12AE0301 (DMYN0-83324- 214) MS20002-4 I nstructions/ Disposition ( 1 ) (1) (1) 

### (1) (1)


### (1) (1) Parts and tooling are available at no cost. For parts and tooling availability and lead time requirements , contact your Customer Service Representative at Helicopter Support, Inc (HSI). Submit a purchase order referencing the ASB number and helicopter serial numbers upon which these will be used. This will allow HSI and the operator to track shipment

January 28/09 and receipt of parts. Orders will be accepted by letter, telephone, facsimile ( FAX), or HSI website: www.HS I US.com. For prompt shipment, reference address of each shipping destination
. Direct your order to: HELICOPTER SUPPORT INC. 124 Quarry Road P.O
. Box 11068 Trumbull , CT 06611 Attn : Customer Service Page 4 63-24-02 Revision A - March 20 /09

# ill[~rnu**~~rn~m;~** 

# mcrmrrauJ m No. 92-63-014A ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs
2. MATERIAL INFORMATION (Continued) FAX: (203) 4 1 6 -429 1 Telephone : (203) 416· 4000 HSI website: www. HSIUS
.com C
. Consumable Mate rial

QTY AS REQ ' D AS REQ' D AS REQ ' D AS REQ'D AS REQ' D AS REQ ' D AS REQ ' D

AS REQ'D 

### WARNING 

# I OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAI NERS WHEN

.._ ____.. US I NG CONSUMABLES. WHEN APPLICABLE, WEAR NECESSARY

..., PROTECTIVE GEAR DURING HANDLING AND USE
. I F A CONSUMAB LE IS FLAMMABLE OR EXP LOSIVE , MAKE CERTAIN CONSUMABLE AND ITS VAPORS ARE KEPT AWAY FROM HEAT, SPARK, AND FLAME. MAKE C E RTAIN FI REFIGHTING EQU I PMENT IS READ I LY AVAILABLE PRIOR TO USE. FOR ADDITIONAL INFORMATION ON TOXICITY, FLASHPO I NT, AND FLAMMABILITY OF CHEMICALS , CONSULT YOUR MED ICAL PEOPLE , OR THE MANUFACTURER OF THE CONSUMABLE
. INSTRUCTIONS/ KEY WORD NOMENCLATURE DISPOSITION I SOPROPYL ALCOHOL COMMERC IAL GRADE OR (1) EQU IVALENT Q-TIP COMMERC IAL GRADE OR (1) EQUIVALENT LINT FREE C LOTH CCC-C-440 OR EQUIVALENT 

### (1) LUBRICATI NG O IL DOD- PRF-85743 

### (1) OR EQU IVALENT CLEAR EPOXY M I L-PRF-22750 (2) OR EQU IVALENT EPOXY P RIMER M I L-P-23377 , OR MIL-P-85582 , (3) OR EQU IVALENT SEALING COMPOUND AMS 3265 TYPE 2 (4) CHEM SEAL (CS) 5500CI CLASS B OR EQU IVALENT I NK A-A-208 (5) (1) Locally procure . (2) Manufactured by Chesapeake Bay Coatings , Website : http :// chesapeakebaycoatings .com / January 28/09 Page 5 63-24· 02 Revision A - March 20/09 

## I

# ffi[~rnu**~~rnv~~~** 

# mm[rrauJm No. 92-63-014A ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - Onenme Replacement of Mounting Studs
2
. MATERIAL INFORMATION (Continued) (3) Manufactured by T rans Chern Coatings-Industrial Finishes , Webs ite: http://www
.transchem.com/ (4) Manufactured by Flamemaster, Website: http://www.flamemaster.com/ (5) Manufactured by Specialty Adhesives lnc
. ,Webs ite: http://www.specialtyadhesives.com/ milspecs.htm 3. ACCOMPLISHMENT INSTRUCTIONS A
. Perform one-time removal of MGB filter bowl assembly mounting studs as follows : 

## WARNING 

# I TAKE ANY STEPS NECESSARY TO ENSURE THAT NO FOREIGN OBJECTS FALL I NTO THE GEARBOX DUR I NG THE REMOVAL AND REPLACEMENT OF STUDS AND LOCKRINGS. (1) Prepare helicopter for maintenance. (2) Turn off electrical and hydraulic power. (3) Remove central cover, if requ ired. Refer to Maintenance Manual , SA S92A-AMM-000 , Chapter/Section 54-40-01. (4) Remove MGB oil filter assembly, 92351-15802-101. (a) Remove nuts (MS2 1 043-4) and washers (MS20002-4) securing filter to main gearbox sump. Discard nuts. NOTE : Let oil drain i nto one-quart container when fi lter bowl is removed. (b) Pull filter bowl off MGB. (c) Remove packings (M83248/1-033 and M83248 / 1-238 ). (d) Inspect for any damage to packing. Any damage found , replace packings. (5) Carefully inspect the three studs where they attach to the MGB housing. Housing must be free from damage or corrosion in order to proceed with stud replacement. (6) Mask MGB filter bowl inside diameter to prevent foreign objects from entering housing. (7) Begin cutting lockrings , securing titanium studs (SFJ101 - 11TA12AE0301) (DMYN0-83324- 214). Typical three places. Janu ary 28/09 Page 6 63-24-02 Revision A - March 20 /09

# ill[~rnu**~~mv~rn~ mmrrrr~** **rn** No. 92-63-014A ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs
3. ACCOMPLISHMENT INSTRUCTIONS (Continued) (8) Using an indelible marker, mark housing to show location where lockring teeth were in contact with MGB housing. (9) Using hand drill and lockring cutter (BT309, or equivalent) , cut lockring by rotating drill at slow speed. CAUTION MUST BE USED WHEN DRILLING , AS TO PREVENT DAMAGE FROM DRILLING TOO DEEP. (a) Drill a little and stop, checking cutter depth ; just enough to cut lockring. 1 If unsuccessful , repeat drilling, maintaining a slow drill speed , until lockring is either cut through, or cut enough so that it can be collapsed. Remove lockring. 

# 1**~~ ~6g~**  CONTACT WITH HOUSING WHEN USING REMOVAL (10) Using stud tool, wind out stud (SFJ101-11TA12AE0301) (DMYN0-83324-214) by rotating counterclockwise. Typical three places. (11) Thoroughly clean out tapped hole using Isopropyl Alcohol (commercial grade , or equivalent) and Q-tip (commercial grade, or equivalent), and shop air. B. Perform visual inspection of MGB housing and tapped holes as follows : (1) Carefully, visually inspect tapped holes for signs of damage
. If any damage to threads is detected , stop work and contact a Sikorsky Field Service Representative, Customer Service Manager or Customer Service engineering at 1·800-WI NGED·S or 1-203-416-4299 for assistance. (2) Visually inspect housing lockring counterbore to determine suitability for installation of new lock ring
. (a) Make sure new location, at 90 degrees from original position , is available for lockring teeth
. Lockring can only be installed twice (including original installation) without reworking MGB housing. If rework of MGB housing is requ ired , contact Sikorsky (see step above). (b) If lockring counterbore is acceptable for installation of new lockring, proceed to section 

### C. C. Perform one-time installation of MGB filter bowl assembly mounting studs as follows: January 28/09 Page 7 63-24-02 Revision A - March 20/09

# ffi[~ITm**~~mwm~~** 

# mmrrrrauJm No. 92-63-014A ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One Time Replacement of Mounting Studs
3. ACCOMPLISHMENT INSTRUCTIONS (Continued) NOTE : Repeat this procedure to install all three studs. (1) Locate previous mark made on MGB housing. Teeth of new lockring (MS51990-105P) will be installed 90 degrees from that point. 

## 1 (2) Apply epoxy primer (MIL-P-85582 , or MIL-P-23377, or equivalent) onto threads of new stud. Install stud while epoxy primer is wet. (3) Thread new stud (SLS11FJ101-11SN12A) (DMYN0-97393-503) into MGB housing tapped hole , using stud tool kit, or equivalent (listed in Tooling section of this ASB). Stud external spline should be .010- .020-inch below mounting surface. Refer to Figure 1. NOTE: Make sure new lockring teeth are located 90 degrees from previous lockring position. (4) Install lockring by placing lockring over stud and onto MGB housing lockring counterbore so that lockring internal spline aligns with stud external spline. Set lockring into MGB housing lockring counterbore using lockring drive tool (S1 01 012 , M1 01D12N, or equivalent). (a) Clean and coat rock hard coating with clear epoxy (MIL-PRF-22750 , or equivalent). (b) Apply sealing compound (AMS 3265 , Type 2, or equivalent) to lockring (MS51990- 1 05P). Remove all squeeze-out in lockring counterbore using lint free cloth (CCC-C-440 , or equivalent). (5) Clean any residue using Isopropyl Alcohol (commercial grade, or equivalent) and lint free cloth (CCC-C-440 , or equivalent). (6) Remove masking from MGB filter bowl diameter. (7) Reinstall MGB oil filter assembly. (a) Using packing installation tool set (WE301 K, or equivalent) , install packings (M83248/1- 033 and M83248/1-238) on filter bowl. (b) Install filter bowl onto replacement mounting studs
. NOTE: Make sure new nuts (SS5086-04) are installed. (c) Install washers (MS20002-4) and replacement nuts (SS5086-04). January 28/09 Page 8 63-24-02 Revision A - March 20/09

# ill**~rnu ~~mwm~~**  

# mmrrrrauJm No. 92-63-014A ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - OneTime Replacement of Mounting Studs
3. ACCOMPLISHMENT INSTRUCTIONS (Continued)

# ~~

# ~ USE CAUTION DURING FILTER I NSTALLATION TO AVOID DAMAGING MOUNTING STUDS. SEAT FILTER INTO BORE EITHER BY HAND (PREFERRED) OR BY GRADUAL TIGHTENING OF INSTALLATION NUTS. DO NOT DRAW FILTER INTO PLACE USING ONLY ONE OR TWO NUTS AS THIS MAY CAUSE COCKING OF THE FILTER , PINCHING OF THE PACKINGS , OR DAMAGE TO STUDS
. (d) Draw filter into place by even, gradual tightening of all three nuts. Torque nuts to 100 inch-pounds. (e) Mark MGB housing, TS-062-01, in area of part number and serial number identification with ink or impression stamp (A-A-208, or equivalent). but not to be construed as part of the component part number. (f) Service main transmission. Refer to Maintenance Manual, SA S92A-AMM -OOO, Chapter/ Section 63-20-00-610-001. (g) Examine components for security. Make sure area is clean and free of foreign objects. (h) Reinstall central cove r, if removed. Refer to Maintenance Manual, SA S92A-AMM-OOO, Chapter/Section 54-40-01. (i) Do ground test procedures. Refer to Functional Check Flight Procedures Manual, SA S92A-FCP-OOO. (8) Return helicopter to service. D. Record of Compliance (1) Make an appropriate logbook entry to show compliance with this ASB 92-63-014A. 

## 1 (2) Upon compliance with this Alert Service Bulletin , complete attached ALERT SERVICE BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation.

January 28/09 Page 9 63-24-02 Revision A - March 20/09STUD

# ffi[~rnu**~~mvm;~** 

# mrnrriTauJrn No. 92-63-014A

LOCKRING I NSTALLATION NOTES 1. WITH APPLICABLE WRENCH , INSTALL STUD TO

DEPTH SHOWN. NOTE: LOCATION OF FLANGE IS IMPORTANT SO THAT LOCKR I NG DRIVE TOOL WILL NOT CONTACT STUD EXTERNAL SPLINE. ANY I MPACT OR PRESSURE ON THIS SURFACE MAY REMOVAL CAUSE DAMAGE TO THREADS IN PARENT MATERIAL , TOOL RESULTING IN A LOOSE FIT. 2. APPLY SEALING COMPOUND {AMS3265 , TYPE 2 , OR EQUIVALENT)

AND WITH APPLICABLE DRIVE TOOL, I NSTALL LOCKRING TO DEPTH SHOWN.

REMOVAL NOTES 1. SECURE REMOVAL TOOL OR MILL IN CHUCK AND

LOWER OVER STUD BEFORE STARTING MOTOR. SET SPINDLE SPEED AT 300-700 RPM
. 2
. STUD: WITHOUT RAISING SPINDLE, START MOTOR. MILL

THROUGH LOCKRING , RAIS I NG TOOL EVERY FEW SECONDS TO ALLOW CHIPS TO CLEAR CUTTING TEETH
. BEST RESULTS WILL BE OBTAINED BY NOT MILLING COMPLETELY THROUGH LOCKRING. 3. STUD : APPLY REMOVAL TORQUE TO STUD. WHEN STUD THREAD FLANKS BEAR AGAINST LOWER SURFACE OF LOCKRING TO BE JACKED OUT, STUD REMOVAL MAY THUS BE COMPLETED. 4 . IF LOCKR ING HAS BEEN M I LLEDCOMPLETELY

THROUGH AND DOES NOT LIFT OUT WITH S TUD OR INSERT, PORTION REMAINING MAY BE COLLAPSED WITH A PUNCH AND REMOVED.

TD1819 

# .. GUIDE FOR REMOVAL AND I NSTALLATION OF MGB FILTER BOWL ASSEMBLY MOUNTING STUD AND LOCKRING FIGURE 1 January 28/09 Page 10 63-24-02 Revis ion A - March 20/09

### (Fold over and tape closed)

SIKORSKY AIRCRA FT CORPORATION 

# FACSIMILE NUMBER (860) 998-7565 ATTENTION: WCS PRODUCT SAFETY MANAGER WORLDWIDE CUSTOMER SERVICE 

# I I I I I I I I I I I I I IMPORTANT NOTICE Upon COMPLIANCE with the attached ASB, Sikorsky requests your cooperation in completing and returning by mail or FAX this ENTIRE PAGE. Please fill in the requested information at the bottom of the page, so we may maintain proper

records documenting the configuration of your aircraft. This information i s useful when determining configuration and effectivity of issues affecting fielded aircraft. This request is in keeping with our policy to assure that our customers receive the latest information applicable for the maintenance of your aircraft. Thank you. , ALERT SERVICE BULLETIN : No. 92-63-014A 

### Compliance Record Card TITLE:**_...JB:l.lO""-T.L.lO..uBI:l....LD.u:B::u.IVJL..E!;.JS~-...~:Mwa:11linL.l.....lloMw..oLUdJJJ!** J!.s:o.

e .....t.A:l..>:s,.;:,: se

COJ.mJ.IJhw.lyl'-=--**....LJMt.~.~:awin.L...J...:;Gu::;e.a.Ja rwh** **:u.ox~(M.ILI:G~B),J-L.ll lwlb.~.s::e** **'-' S~yl'-'=so.~.tteaJmu.__**  Fi lter Components - One-Time Replacement of Mounting Studs 

### OWNE WOPERATOR: . ____________________________________ _ SUBMITTED BY:.
____________ DATE
______ _ FOLLOWING SERIAL NUMBERS ARE NOT AFFECTED BY THIS ASB ASB HAS BEEN COMPLIED WITH ON THE FOLLOWING SERIAL NUMBERS

# , I I I I I 

# I I I

______________(Fold Up to Arrows)i
_______________ ...J SA 7673-2 Rev B

# O S

_

i

_ k

_ or

_

s___;

ky

::....___ A United T echnologies Company 

### BUSINESS REPLY MAIL FIRST- CLASS MAll.. PERMITNO. 432 BRIDGEPORT CT POSTAGE WILL BE PAID BY ADDRESSEE 

### SiKORSKY AIRCRAFT CORPORATION 

### P.O. BOX 9729 6900 

## MAIN STREET 

### STRATFORD, CONNECTICUT 06615-9129 

### U.S.A. MAlLSTOP: KlOOA 

### ATTENTION: WCS PRODUCT SAFETY MANAGER WORLDWIDE CUSTOMER SERV ICE



## Please completethe form on the reverse side and FAX to



# FACSIMILE NUMBER (860) 998-7565

or fold and return ENTIRE form to 

## Sikorsky Aircraft Corporation No Postage Necessary