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

# 269 ALERT SERVICE BULLETIN

WARNING: THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF SIK ORSKY AIRCRAFT CORPORATION AND/OR ITS SUBSIDIARIES, IS AN UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, REPRODUCED, IN WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FO R MANUFACTURE FOR ANYONE OTHER THAN SIKORSKY AIRCRAFT CORPORATION AND/OR ITS SUBSIDIARIES WITHOUT ITS WRITTEN CONSENT, AND THAT NO RIGHT IS GRANT ED TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED HEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL AND CR IMINAL PENALTIES. EXPORT WARNING: THESE COMMODITIES, TECHNICAL DATA OR SOFTWARE ARE SUBJECT TO THE EXPORT CONTROL OF EITHER THE INTERNATIONAL TRA FFIC IN ARMS REGULATIONS (ITAR) OR THE EXPORT ADMINISTRATION REGULATIONS (EAR) AND CANNOT BE EXPORTED WITHOUT THE AUTHORIZATION OF EITHER TH E DEPARTMENT OF STATE OR THE DEPARTMENT OF COMMERCE PRIOR TO EXPORT. EXPORT INCLUDES DISCLOSURE AND OR ACCESS TO COMMODITIES, TECHNICAL DATA OR SOFTWARE BY FOREIGN NATIONALS WHETHER LOCATED IN THE UNITED STATES OR ABROAD. THIS REQUIREMENT APPLIES EQUALLY TO FOREIGN NATIONAL EMPLOYEE S OF U.S. COMPANIES AND THEIR FOREIGN SUBSIDIARIES. B-299.1 February 13/12 Revision 1 ▪ February 24/12

SUBJECT: DRIVE TRAIN - Tail Rotor Drive Shaft Spli ned Fittings – Perform a One-Time Inspection and Implement a Recurring Inspection for Wear

Section 1. PLANNING INFORMATION A. Effectivity All Schweizer model 269A, A-1, TH-55A, 269B, and 269C 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 spli nes are 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 rotor drive shaft splined fittings can lead to decoupling of the tail rotor dr ive shaft. A one-time in spection is required to check for excessive spline wear and to assure the drive shaft is properly lubricated. Follow-on 100 hour periodic inspections of these components are required in accordance with HMI CSP-C- 2 and CSP-C-10 Appendix B, Table B-2. The implementation of the recurring inspection shall be accomplished subsequent to the one-time inspection. D. Compliance Compliance is essential. T he one-time inspection outlined herein shall be accomplished within 100 flight hours or 60 days from 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

### 269 ALERT B-299.1 

### 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 prepa re 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) 269A, A-1, TH55A, 269B, and 269C Basic HMI CSP-C-2. (2) 269C (1809 & Subs.) Basic HMI CSP-C-10. M. Publications Affected None. N. Attachment None.B-299.1 

### 269 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 CERTAIN CONSUMABLE AND ITS VAPORS ARE KEPT AWAY FROM HEAT, SPARK AND FLAME. MAKE CERTAIN FIREFIGHTING EQUIPMENT IS READILY AVAILABLE PRIOR TO USE. FOR ADDITIONAL INFORMATION ON TOXICITY, FLASHPOINT AND FLAMMABILITY OF CHEMICALS, CONSULT YOUR MEDICAL PEOPLE OR THE MANUFACTURER OF THE CONSUMABLE.

### 269 ALERT B-299.1 

### 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 helicopte r. Reference Applicable Basic HMI, Section 10. (3) Using cleaning solvent, remove all grease fr om spline cavities of tail rotor drive shaft forward and aft end fittings and main rotor transmission pinion splined drive sleeve and driven spline adapter of tail rotor transmission. Blow dry with clean, compressed air. B. Perform tail rotor drive shaft sp lined fitting inspection as follows: (1) Visually inspect internal sp lines of forward and aft drive s haft fittings for excessive wear, galling, spalling, chipping, distortion, corros ion, heat discoloration or any defect that indicates inadequate spline engagement or lack of lubricant. (a) Measure internal splines of fittings fo r excessive wear. Reference Applicable Basic HMI, Section 10. NOTE: The main transmission pinion drive spline sleeve and the tail rotor transmission driven spline have identical external spline dimensions. The overall pin dimension inspection applies to both. (2) Visually inspect external splines of dr ive sleeve on main rotor transmission pinion and external splines of driven spline on tail rotor transmission input shaft for excessive wear, galling, spalling, chipping, distortion, corros ion, heat discoloration, or any defect that indicates inadequate spline engagement or lack of lubricant. (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 fo r proper operation and seating of check balls. Replace any grease fittings that are loose, are missing check balls, or are suspected 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 f ill out the 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.B-299.1 

### 269 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 equi pped 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 in serting tool until legs of Lubrication Tool plates bottom against safety wire flanges on exterior of splined fittings (Figure 1, Sheet 2). 4. Rotate tool a minimum of 180°. Veri fy grease coverage and depth as required in HMI. Reference Applicable Basic HMI, Section 10. (b) Service drive shafts equipped with grea se fittings with grease (Syn-Tech NS-3913- G1 grease or equivalent). Grease aft fitting first and avoid aft preloading by alternately greasing fittings at both ends. Reference Applicable Basic HMI, Section 10. (7) Install tail rotor drive shaft in helicopter . Reference Applicable Basic HMI, Section 10. B. Implement recurring tail rotor dr ive shaft inspection as follows: (1) Review and comply with Applicable Basic HMI Appendix B, Table B-2. C. Record of compliance: (1) Make helicopter logbook entries to sh ow compliance with this ASB as follows: (a) Make helicopter level logbook entry on form SA7343-15. (b) When ASB modifies a component that can be removed from this helicopter: 1. Make component log card entries on forms SA7343-22 & SA7343-21 as applicable. (2) Upon compliance with this ASB, comp lete attached ALERT SERVICE BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation.

### 269 ALERT B-299.1 

### 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 – FABRIC ATION 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.B-299.1 

### 269 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)

### 269 ALERT B-299.1 

### 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.comB-299.1 

### 269 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, Sikors ky requests 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 bottom of the page, so we may maintain proper records documenting the configuration of your aircraft. This information is useful when determining configuration and effectiv ity 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:

________________ 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. B-299.1 DRIVE TRAIN – Tail Rotor Drive Shaft Splined Fittings – Perform a One-Time Inspection and Implement a Recurring Inspection for WearNo 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 FAX to 

# FACSIMILE NUMBER (860) 998-7565 Or scan and email to: EMAIL ADDRESS: GPSIKSASProductSafet@utc.com or fold and return ENTIRE form to Sikorsky Airc raft Corporation