TRANSMITTAL SHEET

SUBJECT: SERVICE BULL ETIN NO. 6 4B10- 3, ROTORS - Rotary Wing He ad - Ultr ason ic

Inspecti on of Horizontal Hinge Pin This page transmits Revision D, dated October 15/ 2007, to Service Bull etin No. 64B10-3, dated April 21/ 95. Please insert the attached pages, which are a com plete reissue of Service Bu lletin No. 64B10-3. Destroy the supe rseded pages s o that the c ontents will be as follows: Page No. Revision Date 1 through 14 D October 15/2007 The text changed by this revis ion is indi cated by a vertical l ine in the l eft-hand margin of the page. REVISI ON FEATURES: To designate the type of Service Bull etin on ti tle page hea ding, added

"(E)" fo r essential. Sect ion 1 . PLANNING I NFORMATI ON, Par agr aph A. NOTE del ete d "Co. " , paragraph C. removed "S" from "( S 45°/60° steel) ". Paragraph D., NOTE, reworded and changed "ASTM E-1444-93" t o "ASTM E-1444 (lates t revisi on)" and dele ted lastpart of sentence. D eleted paragraph G. Materials and renum bered rem aining paragraphs. Updated paragraph G. Special Equipment to read "Spec ial Tools" , updated lis t if tools. Updated paragraph J. , references to current m anual usage.

Sect ion 2 . ACCOMPLI SHMENT INSTRUCTIONS, CAUTION ch ange d " ASMT TC-1A LEVEL II" to " ASNT SNT-TC-1ALEVEL II, I SO 9712 LEVEL II"

. Paragraph A., NOTE, reworded and changed "ASTM E-1444-93" to "ASTM E-1444" and deleted l ast partof sentence. Paragr aph A., (3) added "Remove plugs and", and changed "(Fed Spec P- D-680, Type 2)" to "( MIL-PRF-680, Type II or I II)". Par agraph A., (4) reworded sent ence and added NOTE. Paragraph B., (2) c hanged "BR 0504-S45/S60)" to " (6455-40234-001)" and "(BNC-to-BNC)" to "( BNC-BNC )", (3) changed "( ESMT-K3-7043 )" to "( 6470-11175-001)". Par agraph B., (4) NOTE's SERVICE BULLETIN 6 4B10- 3Erickso n Air-C rane Inco rporated

Barbara F. Stiger Technical Publications Manager changed "CRT" to "A-scan". Paragraph B., (5) changed "( Ham ikleer 712-2, SAE 30 WT . Oil, o r equival ent)" to "( Sonotech Soundsafe , SAE 30 WT . Oil, or equival ent)" and corrected figure ref

erence. Paragraph B. , (9), (e) changed "CRT" to "screen" and changed NOTE, " StavelySonic-Model- 139-P" to "Sonic 1000S/1200S series"

. Paragraph B. (10), a dded "(Figure 5)" referenc e. Paragraph C. (1) , NOTE changed "Move" to " Rotate", CAUTION, added "PROBE SE LECTOR ". Paragraph C. (2) NOTE' s changed "CRT" to "LCD". Paragr aph C. (3), reworded and updated information. Paragraph C. (8) was change d to a "NOTE", replace d "suspici on" to "indicat ion", and moved below new paragraph (11) , remaining paragraphs wer e renumbered. Updated specificat ions in new paragr aphs C. (12), (13). Repl aced all of the Figures in this secti on with new illustrations and added Figure 7. Section 3. MA TERIAL IN FOR

MATION, U

pdated a ll of th e m aterials and specificati ons found in Section 3.October 19/79

Revision D - October 15/ 2007 1. PLANNING I NFORMATI ON A. Eff ectivity Model: S -64E S eries Com ponent: S1510-23099-1 Horizonta l Hinge Pin S1510-23099-001 Horizonta l Hinge Pin NOTE : Erickson Air- Crane expanded dash ( -) number ending of part number from one digit t o three digi ts, although the two part configurations are identical and interchangeable. B. Reason To detect possible circum ferential cracks in two specif ic areas of the shank diam eter of the horizontal hinge pin. C. Descrip tion The ultrasonic inspection (UT) m ethod is used to detect possible circum ferential cracks in two areas of the hori zontal hinge pin. The inspect ion is performed using the cont act method and angle beam ultrasonic techniques i n the bore of each hinge pin (Figure 1) . The angle beam inspecti on is performed using a dual 5 MHz - 1/ 4 inch (45°/60° st eel) cont act bore pr obe transducer assem

bly (Figure 2). The prob e is selectively switched to the aft transducer (45°) position use d for the smaller diameter inspec tion, or to the forward transduce r (60°) posi tion used for the lar ger diameter inspec tion. This ins pection may be done with the hinge pin instal led on the helic opter. 

# Service Bulletin

NO. 64B10-3 (E) SUBJECT: ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin

Page 1 of 14ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

October 19/79 Revision D - October 15/ 2007 Page 2 D. Com pliance The m anufacturer believes com pliance to be essential and recomm ends accom plishm ent of the work outlined her ein as follows: (1) On all horizont al hinge pins with 1100 flight hours ormore, within the next 20 flight hours or withi n 200 flight hours si nce last fluor escent magnetic part icle ins pection as specified in the below NOTE, ultrasonical ly inspectper Section 2. Accomplishment Instruction s. NOTE : Horizontal hinge pins are to be f luorescent m agnetic particle inspected per ASTM E-1444 (latestrevision) , using wet conti nuous method and consisting of one or more distinct magnetizi ng operations

. CAUTION : IN NO CASE S HALL THE F LIGH T HOUR LI MITATI ON OR

YEAR CALENDAR TIME BE EXCEEDED PRI OR TO ACCOMPLI SHINGTHE ULTRASO NIC INSPECTI ON. (2) At next 200 flight hours after init ial ultrasonic i nspection, orone year, whichever comes first, and every 200 flight hour s thereafter , or at one yearinterval s, whichever comes first, ultrasoni cally ins pect horiz ontal hinge pi ns per Secti on 2. Accomplishm ent Instruction s. E. Approval FAA Approval F. Manpower Preparatio n of

ultrasonic 2 0.3 0.6 inspecti on per horizont al hinge pin Instrum ent calibratio n 1 0.3 0.3 Ultrason ic inspectio n per 1 0.3 0.3 horizontal hinge pin ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 1. PLANNING I NFORMATI ON (Co nti nued)ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

Page 3 October 19/79 Revision D - October 15/ 2007 G. Special Tools Dual Transducer B ore Hinge Pin Reference Standard Sonic Portable Ultrasonic Flaw Detectors, 1000S/ 1200S series, orequivalent . May be purchased from Olym

pus NDT Inc., 48 Wo e r d

Avenue, W altham MA 02453. H. Electrical Load Data Not aff ected I. W eight and Balanc e Not aff ected J. References Maintenanc e Manual for Model S-64E HelicopterPublicati on Num ber EAC007 K. Other P ublication s Af fected None ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 1. PLANNING I NFORMATI ON (Co nti nued)ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

October 19/79 Revision D - October 15/ 2007 Page 4 WARNING : OBSERVE ALL CAUTIO NS AND WARNING S ON TH E

CONTAINERS W HEN USINGCONSUMABLES . WHEN APPLICABLE, W EAR PROTECTIVE G EAR DURING H ANDLING AND USE. IF A CO NSUMABLE IS F LAMMABLE O R EXPLOSI VE, MAKE CERTAI N CONSUMABLE AND I TS VAPORS ARE KEPT AWAY FROM HEAT, SPARK , OR FLAM E. MAKE CERTAI N HELICO PTER IS PRO PERLY GRO UNDED AND FIRE FIG HTING EQUIPM ENT IS READILY AVAI LABLE PRIOR TO USE. FOR ADDITIO NAL INFORM ATION O N TOXICI TY, FLASHP OINT, AND FLAMMABI LITY OF CH EMICALS, CONSULT TH E MANUFACTURER OF THE CONS UMABLES. CAUTION : ULTRASONIC I NSPECTIO N MUST BE PERFO RMED BY

PROPERLY TRAI NED PERSONNEL H AVING SP ECIFIC ULTRASONIC I NSPECTIO N TRAININGEQUIVALENT TO ASNT SNT-TC- 1ALEVEL II, I SO 97 12 LEVEL II OR SPECI FIC TRAININGCONDUCTED BY THE TYP E CERTIFICATE H OLDER. A. On all horizont al hinge pins with 1100 flight hours ormore, within the next 20 flight hour s or within 2 00 f

light hou rs since last f

luorescent m agnetic p article inspe ction, u ltrasonically inspect as follows: NOTE : Horizontal hinge pins are to be f luorescent m agnetic particle inspected per ASTM E-1444 using the wet c ontinuous method and consisti ng of one or more distinct magnetizing operati ons. (1) Position main rotor hea d to gain acce ss to the threaded end of the hori zontal hinge pin (Figure 1 ). (2) Disconnect pit ch control r od assembly (6410-21007-013) from the spindle horn t o gain access to the hinge pin bore per Maintenance Manual. (3) Rem ove plugs and cle an hinge pin bore and exposed surface of corr osion prevent ive compound using a clean cloth, damp with solvent ( MIL-PRF-680, Type II or I II). ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONSERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

Page 5 October 19/79 Revision D - October 15/ 2007 Figure 1. Ins pection Areas Horizont al Hinge Pin C 4 1 4 6

. I R

. 6 4 B 1 0
- 3 D

(4) Using a light, c heck that the interna l surface of the hinge pi n to be inspect ed is clean and free from any f

oreign material orevidence of corros ion, which would preventgood surface contact of

transducer assem

bly. NOTE : If corrosion i s found, remove and replace hinge pin. (5) Com

ply with paragr aphs B. through E. B. Calibrateultrasonic instrum ent fo r inspectio n of hinge p in as f

ollows : (1) Turn on ultras onic instrument and allow to warm up as required by instrument m anual. (2) Connect dual tr ansducer bore probe assembly (6455-40234-001) to instrument using interconnecting c able (BN C-BN C) as req uired. (F igure 2) (3) Insert the dual transducer bore pr obe assembly completely into the Hinge Pi n Standard (6470-11175-001). ( Figures 3 and 4) CAUTION : MAKE SURE S WITCH IS NOT M OVED DURINGTEST. (4) Place dual transducer bore probe selector switch in the 45 ° mode position. NOTE : The 45° mode position is used to i nspect the 2.125 i nch diameter area. See

Figure 5 for a typ ical A-scan presentation. NOTE : The 60° mode position is used to i nspect the 2.250 i nch diameter area. See

Figure 6 for a typ ical A-scan presentation. ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONSERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

October 19/79 Revision D - October 15/ 2007 Page 6 ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONS (Cont inue d) (5) Fill syring e with co uplant ( Sonotech Soundsafe , SAE 30 WT . Oil, or equival ent) and thread syr inge into coupl ant port. Depre ss plunger and r otate probe 360° to apply couplant to calibratio n area. (F igure 1) (6) Adjust instrum ent to obtain a response from reference notch as probe is rotated at a rate not to exceed 10° pe r second. (7) Maxim ize (peak) response from reference notch. (8) Adjus t instrum ent sensitiv ity contro l (gain) until a respon se of 80 perce nt fu ll scale height (FSH) from notch is obtained. (9) The following minim um instrum ent requir ements should be maintained: (a) Frequency - selected to m atch transducer assem bly - 5 MHz. NOTE : If equipment has broadband capabil ity, stay within 2 to 10 MHz range; if frequency select ion is not compatible, the next highestfrequency to the transducer assem

bly should be used.

C4147.IR.64B10-3D Figure 2. Dual Transducer Probe Assembly ( 6455-40243-001)ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

Page 7 October 19/79 Revision D - October 15/ 2007 ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONS (Cont inue d)

(b) Instrum ent Reje ct of S uppress ion Co ntrol - adju sted to ob tain desired calibration response with minimum

amplification and desir ed baseline noise. (c) Dam

ping- minimum

. (d) Gain/S ensitivity - a djusted to obtain d esired calib ration resp onse w ith m inim um am plification and desired baseline noise. (e) Screen Range an d Delay - selected to position calibration response and indicati ons in centerof screen with enough range to indicate full metal coverage. NOTE : When using the Sonic 1000S/1200S series, the 1 to 3 inch range is

suggested. (f) Transducer Mode Selection - pulse echo posi tion (si ngle). (g) Pulse Repetition F requenc y (PR F) - m axim

um . (10) Rotate probe 90° i n area of reference not ch (not to exc eed 10° per second) to verify detectability

of ref erence no tch at calib ration lev el. (Figu re 5) NOTE : This shall be the scanning rate used f or inspection. C. Ultrason ically insp ect hingepin as f ollows : (1) Insert the dual transducer bore pr obe assembly completely into the bor e of the hinge pin. NOTE : Rotate blade up ordown, as required, t o gain access to bore with pr obe, and

hold blade in this positi on.ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

October 19/79 Revision D - October 15/ 2007 Page 8 Figure 3. Trans ducer Assembly in Hor izontal Hinge Pin C4148.IR.64B10-3D ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONS (Cont inue d)

CAUTION : MAKE SURE P ROBE SELECTO R SWITCH IS NOT M OVED

DURING TEST. (2) Place probe selector switch in the 45° mode position. NOTE : The 45° mode position is used to i nspect the 2.125 i nch diameter area. See

Figure 5 for ty

pical LC D prese ntation. NOTE : The 60° mode position is used to i nspect the 2.250 i nch diameter area. See

Figure 6 for ty

pical LC D prese ntation. (3) Fill syring e with co uplant ( Sonotech Soundsafe , SAE 30 WT . Oil, or equival ent) and thread syr inge into coupl ant port. Depre ss plunger and r otate probe 360° to apply couplant to calibratio n area (Fi gure 1). (4) Rotate probe 360° t o scan inspect ion area ata rate notto exceed 10° persecond. (5) A hinge pin having ultrasonic i ndications equal to or gr eater than 60 percent full scale height is suspect.ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

Page 9 October 19/79 Revision D - October 15/ 2007

Figure 4. Configur ation of Ultr asonic Hinge Pin Standard C4149.IR.64B10-3D ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONS (Cont inue d) (6) If hinge pin is sus pect, recalibrate instrument on Hinge Pin Standar d per paragr aph B., and recheck pi n per paragr aph C. (7) If rechecked pin ha s ultras onic indica tions equal to or great er than 60 per cent full scal e height, using afelt marking pen, identify at threaded end of pin the l ocations of ultrasonic responses that exceed specified inspection c riteria. (8) Rem ove suspect hi nge pin from service prior t o further flight i f pin has ultras onic indicati on equal to or gr eater than the 60 perce nt full scale height. ContactErickson Air-Crane, ProductSupport Department. Advise them of the suspect pin and forward suspect pin for furthe r analysi s.ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

October 19/79 Revision D - October 15/ 2007 Page 10 TYPICAL A-SCAN PRESENT

A TION 80% FSH RESPONSE FROM 0.012 INCH NOTCH C4229.IRSB64B10-3 80% CALIBRA

TION RESPONSE

60% REJECTION LEVEL ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONS (Cont inue d) (9) Replace suspect pin w ith a pin that m eets the requirements of this Service Bu lletin. (10) Place probe se lector s witch in the 60° mode position and calibra te ultr asonic instrument per paragr aph B., steps (3) through (10). (Fi gure 6) (11) W ith probe se lector s witch in 60° mode position, ultrasonical ly inspectthe 2.250 inch diam eter area pe r steps (3) through (9 ) of th is paragra ph. NOTE: If a crack-l ike indica tion appear s between clock angles of 7:00 to 11:00, as

viewed from threaded end of pin (Figure 7), i t may be caused by echoes from the locking flat . To verify indicat ion, remove spacer and scr ews and attempt to dampen signal by applying coupl ant to the area and rubbi ng with finger. If indicat ion moves up and down am plitude- wise, it is considered non-relevant and hinge pin i s acceptabl e.

Figure 5. Ultr asonic Response From Fabr icated Notch in 2.125 I nch Diameter

Area With Tr ansducer at 45° Mode PositionERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

Page 11 October 19/79 Revision D - October 15/ 2007 Figure 6. Ultr asonic Response From Fabr icated Notch in 2.250 I nch Diameter Ar ea

With Transduc er at 60° M ode Position TYPICAL

A-SCAN PRESENT

A TION 80% FSH RESPONSE FROM 0.010 INCH NOTCH C4230.IRSB64B10-3 80% CALIBRA

TION RESPONSE

60% REJECTION LEVEL ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONS (Cont inue d) (12) If existing hi nge pin is found sati sfactory, reappl y corrosion pr eventive compound (MIL-PRF-16173, Grade I) , to pin bore ar ea prior t o reassembly. (13) Seal pin, as i t extends through spindle e ar, with seal ing compound (AMS-S-8802, Type 2, Cla ss B-1/2 ). Rein stall plugs

. (14) Connect pitch control rod ass embly to acceptable hor izontal hi nge pin per the Maintenance Manual. (15) Repeat cali bration and i nspection r equirements per para graphs B. and C., for each of the remaining five horizontal hinge pins. D. At next 200 flight hours after init ial inspe ction, or one ye ar, whichever c omes f irst, and every 200 flight hour s thereafter , or at one yearinterval s, whichever comes first, ultrasoni cally ins pect horiz ontal hinge pi ns per paragr aphs A., B., and C.ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

October 19/79 Revision D - October 15/ 2007 Page 12 ROTOR S - Ro tary Win g Head - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 2. ACCOMPLI SHMENT I NSTRUCTIONS (Cont inue d)

C4150.IR.64B10-3D

Figure 7. Clock Angles Wher e Ultrasonic Response M ay Be in Error
E. Record of Com

pliance (1) Make an appropriate m aintenance record entry to show: (a) Com

pliance w ith ultrason ic inspectio n (b) Incorporat ion of Section 2. ACCOMPLISHMENTINSTRUCT IONS into the maintenance program.ERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

Page 13 October 19/79 Revision D - October 15/ 2007 ROTOR - Rotary WingHead - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 3. MATERIAL I NFORMATI ON
A. Basis f

or Material Data Not applicabl e B. B ill of Material When ord ering parts , refe rence this S ervice B ulletin. P arts required for th is inspectio n are listed below:

New Part No. Qty Descrip tion Old P art No. Instruction s/ Dispo sition
6455-40234-001 1 Dual Transducer B ore BP 0504-S45/S60 (1) (2) 6470-11175-001 1 Hinge Pin Reference Standard ESMT-K3-7043 (1) BNC-BNC 1 Cable Assem bly None (1) 6470-11177-301 1 Hinge Pin Reference Standard None (1) (3) Sonic 1000S+ 1 Ultrason ic Flaw Dectector with Battery, Charg er & Accessories None (3)

(1) May be obtaine d from Erickson Air- Crane Product SupportDepartment. (2) Where equipment and cable i nterconnect ion are not c ompatible, the cable i nstrument termination end should be modif ied to be compatible. (3) Optional: Can be pur chased as a ki t which include s: (1) 6470-11178-307 Transit Case (1) Sonic 1000S+ Ultrason ic FlawDetecto r with B attery, C harger, & Accessories (2) 6455-40234-001 Bore Probe (1) 6470-11175-001 Reference S tandard (1) Tube Sonotech Soundsafe Couplant (6) 10CC Luer-L ock Couplant SyringesERI CKSON AI R-CRANE SERVICE BULLETIN NO . 64B10 -3

October 19/79 Revision D - October 15/ 2007 Page 14 ROTOR - Rotary WingHead - U ltrason ic Insp ection o f Horiz ontal Hin ge Pin 3. MATERIAL I NFORMATI ON (Co nti nued) C. Consum able Material WARNING : OBSERVER ALL CAUTIO NS AND WARNING S ON TH E

CONTAINERS W HEN USINGCONSUMABLES . WHEN AP PLICABLE, WEAR PROTECTI VE GEAR DURINGHANDLINGAND USE. IF A CONSUMABLE I S FLAMMABLE O R EXPLOSI VE, MAKE CERTAI N CONSUMABLE AND I TS VAPORS ARE KEPT AWAY FROM HEAT, SPARK, O R FLAME. MAKE CERTAI N HELICO PTER IS PRO PERLY GROUNDED AND F IRE FIG HTINGEQUIPM ENT IS READILY AVAILABLE PRIO R TO USE. FO R ADDITIO NAL INFORM ATION O N TOXICI TY, FLASHP OINT, AND FLAMMABI LITY OF CH EMICALS, CONSULT TH E MANUFACTURER OF THE CONS UMABLE. As Required Ultrasonic couplant Sonotech Soundsafe or Ultrasonic couplant SAE-30 WT . Oil As Required Solvent MIL-PRF- 680, Type II o r III As Required Corrosion Prevent ive Compound MIL-PRF-16173, Grade I As Required Sealing Compound AMS-S-8802. Type 2, Class B-1/2, As Required 10CC Luer-L ock Couplant Syringes