Page 1 of 11 ATA 63-20-00 ONE-TIME INSPECTION 

# S-92 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INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF SIK ORSKY AIRCRAFT CORPORATION AND/OR ITS SUBSIDIARIES, IS AN UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, REPRODUCED, IN WHOLE OR IN PART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. ASB 92-63-034 Basic Issue ▪ March 08/12

SUBJECT: ROTOR DRIVES – Main Gear Box – Main Module Assembly – Perform One-Time Eddy Current Inspection of Main Module Assembly for Cracks

Section 1. PLANNING INFORMATION A. Effectivity All S-92A model helicopters with serial numbers 920006 through 920157 with: Upper housing assembly part numbers 92351-15110-041 through -046 all serial numbers. Upper housing assembly part number 92351-15310-041 with serial numbers A1713-00001 through -00144 excluding -00143 through -00142, -00140, -00138, - 00127, -00111, -00109, -00103 through -0010 2, -00095, -00083, -00073 through - 00072, -00062, -00051, -00032, -00023 through -00015, -00013 and -00010. All main module assemblies (including spares). B. Purpose To perform an eddy current inspection of the main module assembly for cracks. To notify all operators that upon compliance with the inspection described herein, the current daily visual inspection implemented by ASB 92-63-032 is waived. C. Description The main module assembly is insp ected for cracks using the eddy current method. If suspect indications are found, a follow- on fluorescent penetrant inspection (FPI) is performed. If a suspect indication is c onfirmed, the main module assembly is removed from service. If no suspect indications are found, or if suspect indications are not confirmed by FPI, the helicopter is returned to service. D. Compliance Compliance is essential. The inspection outlined herein shall be accomplished within 200 flight hours or 90 days from the issue date of this Alert Service Bulletin (ASB), whichever occurs first. Sikorsky Aircraft Corporation 6900 Main Street P.O. Box 9729 Stratford, Connecticut 06615-9129 (203) 386-4000

### S-92 ALERT ASB 92-63-034 

### SERVICE BULLETIN Basic Issue ▪ March 08/12

Page 2 ATA 63-20-00 ONE-TIME INSPECTION Section 1. PLANNING lNFORMATION (Continued) E. Approval Inspection item. F. Manpower (Estimated)
Task No. of Men No. of Hours Man-Hours * Remove cowling and covers 1 1.0 1.0 Perform inspection 1 1.0 1.0 Total Man-Hours 2.0 *Estimate does not include time required to prepa re helicopter or return it to flight status.
G. Material (1) Phasec 3d flaw detector (or equivalent). (2) VM Products 2502RAFX-1/8 x 8 probe (or equivalent). H. Tooling (1) Permanent marker (or equivalent). (2) Nonmetallic scrape r (or equivalent). (3) Soft bristled brush (or equivalent). I. Weight and Balance Not affected. J. Electrical Load Data Not affected. K. Software Load Data Not changed. L. References (1) Maintenance Manual SA S92A-AMM-000 , Chapter/Section 54-40-01-900-001/-002. (2) Maintenance Manual SA S92A-AMM-000 , Chapter/Section 63-20-01-900-001/-002. M. Publications Affected None.ASB 92-63-034 

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Page 3 ATA 63-20-00 ONE-TIME INSPECTION Section 1. PLANNING lNFORMATION (Continued) N. Attachment None. Section 2. MATERIAL INFORMATION A. Basis for Material Data Per helicopter. B. Bill of Material Qty Nomenclature Part No. Source 1 Magnesium Reference Block EWR213573-101, or equivalent (1) (1) For part availability and lead time r equirements contact your Customer Service Representative at Helicopter Support Inc. (HSI ). Submit a purchase order referencing this ASB number and the helicopter serial number(s) on which these parts will be used. This will allow HSI and the operator to track shipment and receipt of parts. Orders will be accepted by letter, telephone, facsimile (FAX) or through the HSI website: www.HSIUS.com . For prompt shipment, reference address of each sh ipping destination. Direct your order to: HELICOPTER SUPPORT INC. 124 Quarry Road P.O. Box 11068 Trumbull, Connecticut 06611 U.S.A. Attn: Customer Service FAX: (203) 416-4291 Telephone: (203) 416-4000 HSI website: www.HSIUS.com

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Page 4 ATA 63-20-00 ONE-TIME INSPECTION Section 2. MATERIAL INFORMATION (Continued) C. Consumable Material

Qty Nomenclature Part No. Source As Req’d Teflon Tape OML 1005 or equivalent (1) As Req’d Low Lint Cloth A-A-59323 Type II or equivalent (1) As Req’d Acetone O-A-51 or equivalent (1) As Req’d Paint Stripper MIL-R-81294 or equivalent (2) As Req’d Epoxy Primer MIL-PRF-85582D or equivalent Alternate MIL-P-23377 or equivalent (3) As Req’d Polyurethane Coating 36231 MIL-PRF-85285E or equivalent (3) (1) Procure from local supply. (2) Available from Chemsol. Website: www.chemsol.com

. (3) Available from Trans Chem. Website: www.trans-chem.com

. Section 3. ACCOMPLISHMENT INSTRUCTIONS A. Prepare helicopter for inspection: (1) Turn off all helicopter electrical and hydraulic power. (2) Engage rotor brake. (3) Remove center cover, if required. Refer to Maintenance Manual SA S92A-AMM-000, Chapter/Section 54-40-01-900-001. 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.ASB 92-63-034 

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Page 5 ATA 63-20-00 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) B. Calibrate eddy current flaw det ector (Phasec 3d, or equivalent): NOTE: The person performing eddy current inspecti on must be certified to Level 2 in the method for the purpose of conducting the input gear box inspection. If inspectors of other certification levels are utilized as perm itted by NAS 410 or equivalent, this decision is the responsibility of the operator and their responsible Level 3 supervisor.
Parameter Settings for Main Module Probe drive Low Phase 88 deg/as required Differential gain - Filter DC/100 Low Pass - Gain 33/43 Frequency 100KHz Probe Bridge (1) Place 0.2 mm Teflon tape (OML 1005, or equi valent) over notches in magnesium reference block (EWR213573-101, or equivalent) to simula te lift-off from paint or Rockhard coating. Estimate amount of tape required by compari ng lift-off from magnesium reference block to lift-off over the area of interest. (2) Hold probe end (2502RAFX-1/8 x 8, or equivalent) perpendicular to surface of magnesium reference block (EWR213573-101, or equival ent) in a flat area away from calibration notches. Balance (null) the instrument, plac ing “dot” approximately one screen division vertically from bottom of screen and two screen divisions horizontally from right side of screen. See Figure 1. (3) Raise probe (2502RAFX-1/8 x 8, or equival ent) slightly from surface of magnesium reference block (EWR213573-101, or equivalent) and observe direction of lift-off signal. (4) Adjust phase control until lift-off signal move s to the left of screen as probe (2502RAFX-1/8 x 8, or equivalent) is raised from surface. (5) Maintaining probe (2502RAFX-1/8 x 8, or equivalent) perpendicular to surface of magnesium reference block (EWR213573-101, or equivalent), scan probe tip across 0.008-inch (0.2 mm), 0.020-inch (0.5 mm) and 0.040-inch (1 mm) deep EDM notches, and observe amplitude of indications on screen. (6) Adjust gain until amplitude of signal from 0.040-inch (1 mm) EDM notch is at least two vertical screen divisions on CRT screen. See Figure 1.

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### SERVICE BULLETIN Basic Issue ▪ March 08/12

Page 6 ATA 63-20-00 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) C. Perform eddy current inspection: (1) Observe following common techniques: (a) Place probe at inspection location and balance (null) the instrument. Re-adjust phase as necessary. (b) Maintain probe perpendicular to surface and scan inspection location. Do not exceed two inches per second scan speed, and move probe in 1/8 (0.125) inch increments, taking care to avoid edges. (c) When scan of inspection location is complete, repeat scan in a direction approximately 90 degrees from first scan. (d) Any repeatable linear eddy current response equal to or greater than that of the 0.020-inch (0.5 mm) deep notch response from the magnesium reference block is a suspect linear indication. (e) Do not inspect nuts or other attaching hardware. (f) Re-verify calibration of eddy current flaw detector (Phasec 3d, or equivalent) following completion of inspection. (2) Inspect main module assembly: (a) Inspect surfaces adjacent to Lee plug. See Figure 2. (b) If no suspect linear indication is found no further action is required. Proceed to Paragraph E. (c) If any suspect linear indication is found, proceed as follows: 1. Map suspect area on part surface with a permanent marker. 2. Fill out data sheet and return data sheet to Sikorsky Aircraft Corporation.ASB 92-63-034 

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Page 7 ATA 63-20-00 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 3. Strip paint from mapped area (ma pped by permanent marker) as follows:

a Apply a heavy coating of paint stripper (MIL-R-81294, or equivalent) to mapped area using a soft bristled brush. b Allow paint stripper to remain on surface until paint film has been softened or lifted. Gently scrub surface with a small cleaning brush to loosen paint in stubborn areas.

c Remove softened paint and paint stripper with a nonmetallic scraper. d Repeat steps a through c until all paint has been removed from suspect crack area.

e Rinse thoroughly with clean, fresh water and wipe dry with clean low lint cloth (A-A-59323 Type II, or equivalent). 4. Perform FPI of mapped area:

a If FPI confirms a linear indication (crack) in main module assembly, remove main module assembly from service. Refer to Maintenance Manual SA S92A-AMM-000, Chapter /Section 63-20-01-900-001/-002. Proceed to Paragraph D. b If FPI does not confirm any linear indica tions, reapply protective finish to stripped paint area. Proceed to paragraph D. D. Following FPI, reapply protective finish as follows: (1) Clean stripped area with acetone (O-A-51, or equivalent) and a clean low lint cloth (A-A59323 Type II, or equivalent). (2) Apply two coats of activated epoxy primer (MIL-PRF-85582D or equivalent, alternate MILP-23377 or equivalent). (a) Each coat of activated epoxy primer (M IL-PRF-85582D or equivalent, alternate MILP-23377 or equivalent) shall have a film th ickness of 0.3 – 0.6 mils (0.0003 – 0.0006 inch). (b) Allow each coat of activated epoxy prim er (MIL-PRF-85582D or equivalent, alternate MIL-P-23377 or equivalent) to dry for a minimum of one hour.

### S-92 ALERT ASB 92-63-034 

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Page 8 ATA 63-20-00 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) NOTE: Topcoat should not exceed 4.5 mils (0.0045 inch) thickness. (3) Apply three coats of gray high solids polyurethane coating 36231 (MIL-PRF-85285E, or equivalent). (a) Each coat of gray high solids polyurethane coating 36231 (MIL-PRF-85285E, or equivalent) should have a dry film thickness of 0.9 – 1.5 mils (0.0009 – 0.0015 inch). (b) Allow each coat of gray high solids polyurethane coating 36231 (MIL-PRF-85285E, or equivalent) to dry for a minimum of two hours. E. Return helicopter to flight status: (1) Install center cover, if required. Re fer to Maintenance Manual SA S92A-AMM-000, Chapter/Section 54-40-01-900-002. (2) Return helicopter to service. F. 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. If a component modified by this ASB does not have a log card and the ASB does not create one, then annotate co mpliance on the next higher assembly that the component belongs to which does have a log card. NOTE: If access to www.Sikorsky360.com is unavailable, complete attached ALERT SERVICE BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation. (2) Make an appropriate electronic compliance entry in the E-Notification section at www.Sikorsky360.com . Refer to User Guide located on the www.Sikorsky360.com/ENotification Search page.ASB 92-63-034 

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Page 9 ATA 63-20-00 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)

EDDY CURRENT INDICATIONS FOR MAGNESIUM REFERENCE BLOCK FIGURE 1 SA **TD263 7** 

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Page 10 ATA 63-20-00 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)

MAIN MODULE ASSEMBLY INSPECTION FIGURE 2 SA **TD2664 STATIONARY**  **SCISSORS (REF) DETAIL A** 

**MAIN MODULE ASSEMBLY (REF)**  **INSPECT LEE PLUG BOSS, CORED PASSAGES AND**  **ADJACENT SURFACES.**

**DETAIL A (SOME PARTS OMITTED FOR CLARITY)** ASB 92-63-034 

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Page 11 ATA 63-20-00 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) Eddy Current Inspection Data Sheet. Record following information for each helicopter. Return this data sheet to Si korsky Aircraft Corporation.
1. Customer/Operator Name:

2. Helicopter Serial Number:

3. Date Eddy Current Inspection is Performed:

4. Helicopter Total Time Since New:

5. Main Module Assembly Serial Number:

6. Main Module Assembly Flight Hours:

7. Please use the following Table to record eddy current inspection results.

Inspection Area Linear Indication Found? Linear Indication Confirmed by FPI? Main Module Assembly

### (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

___________ ___________ ___________ ___________ ___________ ___________

___________ ___________ ___________ ___________ ___________ ___________ No. 92-63-034 ROTOR DRIVES – Main Gear Box – Main Module Assembly – Perform OneTime Eddy Current Inspection of Main Module Assembly for CracksNo 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