**Page 1 of 9 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT**

**RECURRING INSPECTION**  

# 269D ALERT SERVICE BULLETIN

**WARNING: THIS DOCUMENT, OR AN EMBODIMENT OF IT IN A NY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETAR**  **Y, IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION AND/OR ITS SUBSIDIARIES, IS AN UNPUBLIS**  **HED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION**  **THAT IT IS NOT TO BE USED, DISCLOSED, REPRODUCED, I N WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DER**  **IVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN SIKORSKY AIRCRAFT CORPORATION AND**  **/OR ITS SUBSIDIARIES WITHOUT ITS WRITTEN CONSENT, A ND THAT NO RIGHT IS GRANTED TO DISCLOSE OR**  **SO USE ANY INFORMATION CONTAINED HEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICABLE LAW M**  **AY RESULT IN CIVIL AND CRIMINAL PENALTIES. EXPORT WARNING: THESE COMMODITIES, TECHNICAL DATA O**  **R SOFTWARE ARE SUBJECT TO THE EXPORT CONTROL OF EIT HER THE INTERNATIONAL TRAFFIC IN ARMS**  **REGULATIONS (ITAR) OR THE EXPORT ADMINISTRATION REG ULATIONS (EAR) AND CANNOT BE EXPORTED WITHOUT THE A**  **UTHORIZATION OF EITHER THE DEPARTMENT OF STATE OR THE DEPARTMENT OF COMMERCE PRIOR TO EXPORT**  **. EXPORT INCLUDES DISCLOSURE AND OR ACCESS TO COMMO DITIES, TECHNICAL DATA OR SOFTWARE BY**  **FOREIGN NATIONALS WHETHER LOCATED IN THE UNITED STA TES OR ABROAD. THIS REQUIREMENT APPLIES EQUALLY TO**  **FOREIGN NATIONAL EMPLOYEES OF U.S. COMPANIES AND THEIR FOREIGN SUBSIDIARIES.**  **DB-041.1 February 13/12**  **Revision 1** ! **February 24/12**

**SUBJECT: DRIVE TRAIN - Tail Rotor Drive Shaft Splin ed Fittings – Perform a One-Time Inspection and** 

**Implement a Recurring Inspection for Wear**

**Section 1. PLANNING INFORMATION A. Effectivity All Schweizer model 269D helicopters** 

**. B. Purpose To perform a one-time inspection of tail**  **rotor drive shaft splines for wear and to**

**implement a recurring visual inspection of the tail rotor drive shaft splines.**  **C. Description The tail rotor drive shaft splines a re cleaned, inspected and lubricated. Splined** 

**components that exceed wear limits are removed from service and returned to**  **Sikorsky Aircraft Corporation. Excessive spline wear in the forward and aft tail r**  **otor drive shaft splined fittings can lead to decoupling of the tail rotor drive shaf**  **t. A one-time inspection is required to check for excessive spline wear and to assure th**  **e drive shaft is properly lubricated. Follow-on 100 hour periodic inspections**  **of these components are required in accordance with HMI CSP-D-2 and CSP-D-9**  **Appendix B, Table B-2. The implementation of the recurring inspection shal**  **l be accomplished subsequent to the one-time inspection.**  **D. Compliance Compliance is essential. The one-time inspection outlined herein shall be** 

**accomplished within 100 flight hours or 60 days fro m the original release date of**  **this Alert Service Bulletin (ASB), whichever occurs first.**  **E. Approval Inspection Item.** Sikorsky Aircraft Corporation **6900 Main Street P.O. Box 9729 Stratford, Connecticut 06615-9129**  **(203) 386-4000**

### 269D ALERT **DB-041.1**



### SERVICE BULLETIN **February 13/12 Revision 1**  ! **February 24/12**

**Page 2 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT RECURRING**  **INSPECTION Section 1. PLANNING INFORMATION (Continued)**  **F. Manpower (Estimated)**

**Task No. of Men**  **No. of Hours Man-Hours**  ***** **Remove tail rotor drive shaft 2**  **.25 .50**  **Clean/inspect spline cavities 1**  **.50 .50**  **Lubricate spline cavities 1**  **.25 .25**  **Install tail rotor drive shaft 2**  **.30 .60**  **Total Man-Hours 1.85**  ***Estimate does not include time required to prepare helicopter or return it to flight status.** 
**G. Material None.**  **H. Tooling (1) Lubrication Tool (locally fabricated)**  **I. Weight and Balance Not affected.**  **J. Electrical Load Data Not affected.**  **K. Software Load Data Not applicable.**  **L. References (1) 269D Basic HMI CSP-D-2.**  **(2) 269D Configuration A Basic HMI CSP-D-9. M. Publications Affected**  **None. N. Attachment**  **None. DB-041.1**  

### 269D ALERT

**February 13/12** 

### SERVICE BULLETIN **Revision 1** ! **February 24/12**

**Page 3 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT**

**RECURRING INSPECTION**  **Section 2. MATERIAL INFORMATION A. Basis for Material Data**  **Per helicopter. B. Bill of Material**  **None. C. Consumable Material** 

**Qty Nomenclature**  **Part No. Source**  **As Req’d Solvent**  **Stoddard Solvent, MIL-PRF-680, Type I, or equivalent**  **(Alternate) Varsol, MIL-PRF-680, Type II, or equivalent**  **(1)**

**As Req’d Grease**  **Syn-Tech NS-3913-G1, or equivalent (2)**  **As Req’d Polypropylene Plastic Sheet,** 

**0.125-inch thick Commercial grade or equivalent**  **(3) As Req’d**  **PVC Pipe, 0.75-inch diameter Commercial grade or equivalent**  **(3) As Req’d**  **PVC Adhesive Commercial grade or equivalent**  **(3)**

**(1) Stoddard solvent is available from www.sciencestuff.com** 

**. Varsol is available from**  **www.exxonmobilechemical.com**

**. (2) Syntech is available from**  **www.syn-techlube.com**

**. (3) Procure from local supply.**  **OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN USING CONSUMABLES. WHEN APPLICABLE, WEAR**  **NECESSARY PROTECTIVE GEAR DURING HANDLING AND USE. IF**  **A CONSUMABLE IS FLAMMABLE OR EXPLOSIVE, MAKE CERTAI N**  **CONSUMABLE AND ITS VAPORS ARE KEPT AWAY FROM HEAT, SPARK AND FLAME. MAKE CERTAIN FIREFIGHTING EQUIPMEN**  **T IS READILY AVAILABLE PRIOR TO USE. FOR ADDITIONAL**  **INFORMATION ON TOXICITY, FLASHPOINT AND FLAMMABILIT Y**  **OF CHEMICALS, CONSULT YOUR MEDICAL PEOPLE OR THE MANUFACTURER OF THE CONSUMABLE.** 

### 269D ALERT **DB-041.1**



### SERVICE BULLETIN **February 13/12 Revision 1**  ! **February 24/12**

**Page 4 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT RECURRING**  **INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. Prepare helicopter for inspection: (1) Turn off all helicopter electrical power.**  **(2) Remove tail rotor drive shaft from helicopter. Reference Applicable Basic HMI, Section 10.**  **(3) Using cleaning solvent, remove all grease from spline cavities of tail rotor dr ive shaft**  **forward and aft end fittings and main rotor transmi ssion pinion splined drive sleeve and**  **driven spline adapter of tail rotor transmission. Blow dry with clean, compressed air. B. Perform tail rotor drive shaft splined fitting i**  **nspection as follows: (1) Visually inspect internal splines of forward an**  **d aft drive shaft fittings for excessive wear, galling, spalling, chipping, distortion, corrosion,**  **heat discoloration or any defect that indicates inadequate spline engagement or lack of l**  **ubricant. (a) Measure internal splines of fittings for excess**  **ive wear. Reference Applicable Basic HMI, Section 10.**  **NOTE: The main transmission pinion drive spline sleeve a**  **nd the tail rotor transmission**

**driven spline have identical external spline dimens ions. The overall pin**  **dimension inspection applies to both. (2) Visually inspect external splines of drive slee**  **ve on main rotor transmission pinion and external splines of driven spline on tail rotor tra**  **nsmission input shaft for excessive wear, galling, spalling, chipping, distortion, corrosion,**  **heat discoloration, or any defect that indicates inadequate spline engagement or lack of l**  **ubricant. (a) Measure for excessive wear over two 0.1200 inch diameter gage pins placed 180°**  **apart in external splines. Reference Applicable Basic HMI, Section 10. (3) If tail rotor drive shaft is equipped with grea**  **se fittings, inspect grease fittings for security, presence of check balls inside fittings, and for proper operation**  **and seating of check balls. Replace any grease fittings that are loose, are missing check balls, or are suspect**  **ed of improper operation.**  **(4) If wear is found in splines of drive shaft fittings, splined drive sleeve or splined adapter**  **which meets serviceable limits, copy and fill out t he Customer Reply Form and mail to**  **address shown on form. NOTE:**  **Contact HSI for return and evaluation. (5) Remove from service any components that exceed**  **wear limits and send to Helicopter Support Inc. (HSI). Fill out Component Return Form**  **and place in shipping container and ship components to address shown on form.** **DB-041.1** 

### 269D ALERT

**February 13/12** 

### SERVICE BULLETIN **Revision 1** ! **February 24/12**

**Page 5 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT**

**RECURRING INSPECTION**  **Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)**

**(6) Service drive shaft fittings as follows: (a) Service drive shafts that are not equipped with**  **grease fittings as follows: 1. Fabricate and assemble Lubrication Tool (Figure**  **1 Sheet 1 and Sheet 2). 2. Apply grease (Syn-Tech NS-3913-G1 grease or equivalent) to drive shaft**  **fittings (Figure 1, Sheet 2). 3. Adjust grease volume in fittings by inserting tool until legs of Lubrication**  **Tool plates bottom against safety wire flanges on exteri**  **or of splined fittings (Figure 1, Sheet 2).**  **4. Rotate tool a minimum of 180°. Verify grease cov erage and depth as required**  **in HMI. Reference Applicable Basic HMI, Section 10. (b) Service drive shafts equipped with grease fittings with grease (Syn-Tech NS-391**  **3- G1 grease or equivalent). Grease aft fitting first**  **and avoid aft preloading by alternately greasing fittings at both ends. Referen**  **ce Applicable Basic HMI, Section 10.**  **(7) Install tail rotor drive shaft in helicopter. R eference Applicable Basic HMI, Section 10.**  **B. Implement recurring tail rotor drive shaft inspection as follows: (1) Review and comply with Applicable Basic HMI App**  **endix B, Table B-2. C. Record of compliance:**  **(1) Make helicopter logbook entries to show complia nce with this ASB as follows:**  **(a) Make helicopter level logbook entry on form SA7 343-15.**  **(b) When ASB modifies a component that can be remov ed from this helicopter:**  **1. Make component log card entries on forms SA7343- 22 & SA7343-21 as**  **applicable. (2) Upon compliance with this ASB, complete attache**  **d ALERT SERVICE BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation.** 

### 269D ALERT **DB-041.1**



### SERVICE BULLETIN **February 13/12 Revision 1**  ! **February 24/12**

**Page 6 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT RECURRING**  **INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)** 

**LUBRICATION TOOL – FABRICATION OF DETAIL PARTS**

**FIGURE 1 (SHEET 1 OF 2) SA**  C1B-022_4 FABRICATE TWO PLATES SLOT DETAIL OF -5 PLATE SLOT DETAIL OF -3 PLATE

FABRICATE TWO PLATES SLOT DETAIL OF -5 PLATE SLOT DETAIL OF -3 PLATE LUBRICATION TOOL DETAILS FOR FORWARD SPLINED FITTING

LUBRICATION TOOL DETAILS FOR AFT SPLINED FITTING 1.19

1.85

0.06 0.13 0.13 0.06

0.74 2.88 1.50 0.88

2.50 0.22

0.37 1.25

0.66 0.13 0.06 1.25

1.70 1.70

0.06 1.25

2.38 0.81
0.68 0.19 (TYP)

0.53 (TYP)

1.32 2.38 0.86

1.19

NOTES
1. SUGGESTED MATERIAL IS 1/8 INCH THICK POLYPROPYLENE PLASTIC SHEET AND 3/4 INCH PVC PIPE. ANY SUITABLE MATERIAL MAY BE USED. 2. FABRICATE - 1 PVC PIPE HANDLE AS SHOWN IN SHEET 2 WITH SLOTS 90 APART. SLOT WIDTHS ARE TO MATCH MATERIAL THICKNESS. 3. ASSEMBLE PARTS AS SHOWN IN SHEET 2 AND BOND ASSEMBLY TOGETHER USING APPROPRIATE ADHESIVE FOR PVC PIPE.**DB-041.1** 

### 269D ALERT

**February 13/12** 

### SERVICE BULLETIN **Revision 1** ! **February 24/12**

**Page 7 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT**

**RECURRING INSPECTION**  **Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)**

**SA** C1B-022_5 ASSEMBLY OF LUBRICATION TOOL

LUBRICATION TOOL (REF) SAFETY WIRE FLANGE (REF) 0.13 (TYP.) 0.06

(TYP.)

-3
-1 -5

2.00 0.50

FOR AFT SPLINED FITTING SHOWN

SPLINE FITTING (REF)

GREASE (REF)

### 269D ALERT **DB-041.1**



### SERVICE BULLETIN **February 13/12 Revision 1**  ! **February 24/12**

**Page 8 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT RECURRING**  **INSPECTION LUBRICATION TOOL – ASSEMBLY AND USE** 

**FIGURE 1 (SHEET 2 OF 2)** 

# COMPONENT RETURN FORM **Customer Name: ____________________________________ _ Helicopter Model: ______________**  **Customer Address: _________________________________ __ Helicopter**  

### S **erial N o**  **: ___________ ___________________________________ Component Time**  **: ______________**

**___________________________________**

**___________________________________**

**___________________________________ Ship To: Helicopter Support Inc.**  **124 Quarry Rd. PO Box 11068**  **Trumbull, Connecticut, 06611 USA Attn: Customer Service**  **Fax: (203) 416-4291 Telephone: (203) 416-4000 HSI Website:**  **www.HSIUS.com**



# COMPONENT RETURN FORM **Customer Name: ____________________________________ _ Helicopter Model: ______________**  **Customer Address: _________________________________ __ Helicopter**  

### S **erial N o**  **: ___________ ___________________________________ Component Time**  **: ______________**

**___________________________________**

**___________________________________**

**___________________________________ Ship To: Helicopter Support Inc.**  **124 Quarry Rd. PO Box 11068**  **Trumbull, Connecticut, 06611 USA Attn: Customer Service**  **Fax: (203) 416-4291 Telephone: (203) 416-4000 HSI Website:**  **www.HSIUS.com DB-041.1**  

### 269D ALERT

**February 13/12** 

### SERVICE BULLETIN **Revision 1** ! **February 24/12**

**Page 9 DRIVE TRAIN**  **ONE-TIME INSPECTION**  **IMPLEMENT**

**RECURRING INSPECTION**  

# CUSTOMER REPLY FORM **Customer Name: ____________________________________ _ Helicopter Model: ______________**  **Customer Address: _________________________________ __ Helicopter**  

### S **erial N o**  **: ___________**

**___________________________________**

**___________________________________**

**___________________________________**

**___________________________________ COMPONENT:**  **Drive Shaft FWD Splined Fitting: Wear: _________________ Total Time: ___________** 
**_________ Drive Shaft AFT Splined Fitting:**  **Wear: _________________ Total Time: ___________**
**_________ Main Trans. Pinion Drive Splined Sleeve:**  **Dimensions: ______________ Total Time: ________**
**____________ Tail Gearbox Driven Spline Adapter:**  **Dimensions: ______________ Total Time: ________**
**____________**

**Mail To: Helicopter Support Inc. 124 Quarry Rd.**  **PO Box 11068 Trumbull, Connecticut, 06611 USA**  **Attn: Customer Service Fax: (203) 416-4291 Telephone: (203) 416-4000**  **HSI Website: www.HSIUS.com** 

### (Fold over and tape closed)

SIKORSKY AIRCRAFT CORPORATION 

# FACSIMILE NUMBER (860) 998-7565
EMAIL ADDRESS: GPSIKSASProductSafet@utc.com

ATTENTION: SAS PRODUCT SAFETY MANAGER

SIKORSKY AEROSPACE SERVICES

(Fold Up to Arrows) 

# IMPORTANT NOTICE
Upon COMPLIANCE with the attached ASB, Sikorsky req uests your cooperation in completing and

returning this ENTIRE PAGE by MAIL, FAX, or scan & EMAIL. If you have internet access, you may go to www.sikorsky.com to record your compliance. 

### Please fill in the requested information at the bot tom of the page, so we may maintain proper records documenting the configuration of you r aircraft. This information is useful when determining configuration and effectivity of i ssues affecting fielded aircraft. This request is in keeping with our policy to assur e that our customers receive the latest information applicable for the maintenance of your aircraft. Thank you. ALERT SERVICE BULLETIN:

________________ Compliance Record Card TITLE: ___________________________________________ ________________________

_________________________________________________ __________________

_________________________________________________ __________________ OWNER/OPERATOR: __________________________________ ___________________ SUBMITTED BY: ___________________________ DATE: ____________________ FOLLOWING SERIAL NUMBERS ARE NOT AFFECTED BY THIS ASB ASB HAS BEEN COMPLIED WITH ON THE FOLLOWING SERIAL NUMBERS

___________ ___________ ___________ ________ ___ ___________ ___________

___________ ___________ ___________ ________ ___ ___________ ___________ **ASB No. DB-041.1 DRIVE TRAIN – Tail Rotor Drive Shaft Splined Fittin**  **gs – Perform a One-Time Inspection and Implement a Recurring Inspection for**  **Wear**No Postage Necessary


### BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT NO. 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. MAILSTOP: S328A ATTENTION: SAS PRODUCT SAFETY MANAGER SIKORSKY AEROSPACE SERVICES



## Please complete the form on the reverse side and FA X to 

# FACSIMILE NUMBER (860) 998-7565

Or scan and email to: EMAIL ADDRESS: GPSIKSASProductSafet@utc.com or fold and return ENTIRE form to Sikorsky Aircraft Corporation