t 

Sikorsky 

A United Technologies Company 

Sikorsky Aircraft Corporation 

6900 Main Street 

P.O. Box 9729 

Stratford, Connecticut 06615-9129 

(203)386-4000 

EBULLETIN 

THIS ALERT SERVICE BULLETIN IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION AND IS PROTECTEO UNDER THE COPYRIGHT LAWS OF THE 

UNITED STATES AND OTHER COUNTRIES. THIS ALERT SERVICE BULLETIN IS DISTRIBUTED ONLY TO OWNERSIOPERATORS OF COMMERCIALLY-CERTIFIED 

SIKORSKY HELICOPTERS AND SIKORSKY-AUTHORIZED LOGISTIC AND SERVICE CENTERS FOR THE PURPOSE OF FOSTERING THE SAFE AND EFFICIENT 

OPERATION OF SUCH HELICOPTERS AND UNDER THE EXPRESS CONDITION THAT THE CONTENTS OF THIS ALERT SERVICE BULLETIN ARE NOT TO BE 

DISCLOSED, REPRODUCED, OR DISTRIBUTED, IN WHOLE OR IN PART, TO ANY THIRD PARTY, OR ADAPTED AS A DERIVATIVE WORK, WITHOUT THE 

EXPRESS DOCUMENTED CONSENT OF SIKORSKY AIRCRAFT CORPORATION. ANY ACT IN VIOLATION OF APPLiCABLE LAW MAY RESULT IN CIVIL AND/OR 

CRIMINAL PENALTIES. 

LIMITED DISTRIBUTION r SIKORSKY AIRCRAFT CORPORATION 1999 

ALL RIGHTS RESERVED 

No. 92-63-020 

Subject: ROTOR DRIVES - Main Module Assembly - Main Gearbox Assembly - One-Time Visual 

Inspection of the Mounting Feet Pad, Foot Ribs and to Implement a 10-Hour Recurring 

Visual Inspection 

1. PLANNING INFORMATION 

A. Effectivity 

S-92A model helicopters with a main gearbox assembly 92351-15000-042/-043 using main 

gearbox housing 92351-15110-042/-043/-044/-045. 

B. Purpose 

To perform a one-time visual inspection of main gearbox assembly mounting feet pad and 

foot ribs for cracks. Also, to implement a new 10-hour recurring visual inspection. 

C. Description 

Helicopter is prepared for maintenance. Foot pad face, top of pad around bolt bushing, 

and all surfaces of each foot rib are visually inspected for cracks. If a crack is suspected 

a Fluorescent Penetrant Inspection (FPI) or Dye Penetrant Inspection (alternate) is 

performed. If crack is found, replace main gearbox prior to next flight. If no crack is found, 

a 10-hour recurring visual inspection is implemented. Helicopter is returned to service. 

D. Compliance 

Compliance is essential. Sikorsky Aircraft Corporation recommends the one-time visual 

inspection be performed within 10 flight-hours from the issue date of this Alert Service 

Bulletin (ASB). 

A 10-Hour recurring visual inspection is imposed until further notice. 

September 11/09 Page 1 of 11 63-20-01 
ME OEM MOVDa 

No. 92-63-020 

ROTOR DRIVES - Main Module Assembly - Main Gearbox Assembly - One-Time Visual Inspection of the 

Mounting Feet Pad, Foot Ribs and to Implement a 10-Hour Recurring Visual Inspection 

1. PLANNING INFORMATION (Continued) 

E. Approval 

Inspection item 

F. Manpower (Estimated) 

No. of Men No. of Hours 'Man-Hours 

Inspection of Main 1 2.0 2.0 

Gearbox Housing 

Mounting Feet 

and Foot Ribs for Cracks 

xEstimate does not include time required to prepare helicopter or return it to flight status. 

G. Material 

None. 

H. Tooling 

(1) 18-inch inspection mirror with a two inch diameter glass or larger, (or equivalent). 

(2) Non-metallic pick or probe, (or equivalent). 

(3) Spray bottle, (or equivalent). 

(4) Strong (non-LED, white light) flashlight, (or equivalent). 

(5) Soft bristled brush, (or equivalent). 

I. Weight and Balance 

Not affected. 

J. Electrical Load Data 

Not changed. 

K. Software Load Data 

Not applicable. 

L. References 

(1) Maintenance Manual SA S92A-AMM-000, Chapter 20-06-00-910-005. 

(2) Maintenance Manual SA S92A-AMM-000, Chapter 20-06-00-910-006. 

September 11/09 Page 2 63-20-01 
WE OWN MUM 

No. 92-63-020 

ROTOR DRIVES - Main Module Assembly - Main Gearbox Assembly - One-Time Visual Inspection of the 

Mounting Feet Pad, Foot Ribs and to Implement a 10-Hour Recurring Visual Inspection 

1. PLANNING INFORMATION (Continued) 

(3) Maintenance Manual SA S92A-AMM-000, Chapter 54-40-01-900-001. 

(4) Maintenance Manual SA S92A-AMM-000, Chapter 54-40-01-900-002. 

(5) Maintenance Manual SA S92A-AMM-000, Chapter 54-40-01-900-003. 

(6) Maintenance Manual SA S92A-AMM-000, Chapter 54-40-01-900-004. 

(7) Maintenance Manual SA S92A-AMM-000, Chapter 54-40-02-900-001. 

(8) Maintenance Manual SA S92A-AMM-000, Chapter 54-40-02-900-002. 

(9) Maintenance Manual SA S92A-AMM-000, Chapter 63-20-01-900-001 or 63-20-02-900-001. 

(10) Structural Repair Manual SA S92A-SRM-000, Chapter 20-10-00. 

M. Publications Affected 

(1) Maintenance Manual SA S92A-AWL-000, Temporary Revision No. 5-47, add to the 10- 

Hour Inspection Checklist. 

(2) Maintenance Manual SA S92A-AWL-000, Temporary Revision No. 5-48, revises the 50- 

Hour Inspection Checklist. 

(3) Maintenance Manual SA S92A-AWL-000, Temporary Revision No. 5-49, revises the 500- 

Hour Inspection Checklist. 

(4) Maintenance Manual SA S92A-AMM-000, Chapter 63-20-01. Temporary Revision No. 63- 

22 revises the Inspection of Main Gearbox. 

N. Attachment 

None. 

September 11/09 Page 3 63-20-01 
paNE OTHN MEaOa 

No. 92-63-020 

ROTOR DRIVES - Main Module Assembly - Main Gearbox Assembly - One-Time Visual Inspection of the 

Mounting Feet Pad, Foot Ribs and to Implement a 10-Hour Recurring Visual Inspection 

2. MATERIAL INFORMATION 

A. Basis for Material Data 

Per helicopter. 

B. Bill of Material 

None. 

C. Consumable Material 

WARNING 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. 

INSTRUCTIONS/ 

QTY KEY WORD NOMENCLATURE DISPOSITION 

AS REQ'D BRULIN CLEANER SD 1291, OR EQUIVALENT (1) 

AS REQ'D CLEAN, LOW-LINT CLOTH A-A-59323, OR EQUIVALENT (2) 

AS REQ'D CORROSION PREVENTIVE MIL-DTL-85054, OR (3) 

COMPOUND EQUIVALENT 

AS REQ'D DYE PENETRANT ALTERNATE USE TO FPI, (2) 

INSPECTION OR EQUIVALENT 

AS REQ'D FLUORESCENT PENETRANT (FPI) KIT, OR EQUIVALENT (2) 

INSPECTION (FPI) KIT 

AS REQ'D SOAP SOLUTION WATER/SOAP SOLUTION, (2) 

(HALF WATER AND HALF 

SOAP) 

September 11/09 Page 4 63-20-01 
ME M®OR MUM 

No. 92-63-020 

ROTOR DRIVES - Main Module Assembly - Main Gearbox Assembly - One-Time Visual Inspection of the 

Mounting Feet Pad, Foot Ribs and to Implement a 10-Hour Recurring Visual Inspection 

2. MATERIAL INFORMATION 

(1) Manufactured by Brulin Corporation, Indianapolis, IN. Telephone Numbers: (317) 923-3211 

or 800-776-7149. 

(2) Procure from local supply. 

(3) Manufactured by NS&L, Website: http://www.nationalsealants.com/contact.html. 

3. ACCOMPLISHMENT INSTRUCTIONS 

A. Perform a one-time visual inspection of main gearbox assembly mounting feet and foot rib for 

cracks as follows: 

(1) Prepare helicopter for maintenance. 

(2) Turn off all electrical and hydraulic power. 

WARNING TO PREVENT ELECTRICAL SHOCK OF PERSONNEL, MAKE 

SURE TO DEENERGIZE ELECTRICAL POWER. 

(3) Deenergize all electrical power. 

WARNING TO PREVENT INJURY OF PERSONNEL, MAKE SURE TO 

DEENERGIZE HYDRAULIC POWER. 

(4) Deenergize all hydraulic power. 

(5) At each mounting foot, apply soap/water solution (half water and half soap) via a spray 

bottle, (or equivalent). Using clean, low-lint cloth (or equivalent), wipe dry and remove all 

oil, dirt, and debris from each mounting foot. 

(6) Using a strong white light non-LED flashlight (or equivalent), and inspection mirror, (or 

equivalent), visually inspect each mount foot for cracks. Inspect the follow areas: Refer to 

Figure 1 for definition of areas, and Figure , 2, 3, and 4 for examples of cracks. 

(a) Foot pad face. 

(b) Top of pad around bolt bushing. 

(c) AII surfaces of each foot rib. 

NOTE: Immediately contact Customer Service Engineering at 1-800-WINGED-S or 1- 

203-416-4299, to report any crack with the following information: Date 

Inspection Performed, Customer/Operator Name, Installed on Helicopter Serial 

Number, Main Gearbox Serial Number, Main Gearbox Total Time, Helicopter 

Total Time, Location of Crack. 

September 11/09 Page 5 63-20-01 
ME UaOTR MUM 

No. 92-63-020 

ROTOR DRIVES - Main Module Assembly - Main Gearbox Assembly - One-Time Visual Inspection of the 

Mounting Feet Pad, Foot Ribs and to Implement a 10-Hour Recurring Visual Inspection 

3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 

(d) If crack is clearly visible, replace main gearbox prior to next flight. Refer to 

Maintenance Manual SA S92A-AMM-000, Chapter 63-20-01-900-001 or 63-20-02-900- 

001. 

(e) If crack is suspected, perform Fluorescent Penetrant Inspection (FPI). Proceed to 

section B. 

(7) Visually inspect each mounting foot area for corrosion (bubbled paint) and/or paint 

discoloration. Treat corrosion. Refer to Structural Repair Manual SA S92A-SRM-000, 

Chapter 20-10-00. 

(8) Return helicopter to service. 

B. Fluorescent Penetrant Inspection (FPI): 

NOTE: This follow-on inspection is to be performed only if a crack is suspected. 

(1) Gain direct visual access to suspected area(s) by removing covers, panels, and/or 

components as required. 

(a) Remove LH and RH lower covers. Refer to Maintenance Manual SA S92A-AMM-000, 

Chapter 54-40-02-900-001. 

(b) Remove center cover. Refer to Maintenance Manual SA S92A-AMM-000, Chapter 54- 

40-01-900-001. 

(c) Remove rear cover. Refer to Maintenance Manual SA S92A-AMM-000, Chapter 54-40- 

01-900-003. 

NOTE: Do not remove sealant around mounting foot pads and mounting bolt heads 

when performing FPI. 

(2) Using clean, low-lint cloth (or equivalent), and Brulin cleaner (or equivalent), clean 

suspected area. 

(3) Using a soft bristle brush, (or equivalent) clear any remaining dirt or debris from 

inspection areas. If paint is flaked or chipped, use brush bristles or non-metallic pick or 

probe (or equivalent) to remove flakes. 

(4) Visually confirm start and stop locations of suspected crack. 

NOTE: Dye Penetrant Inspection may be used as an alternate to FPI. Refer to 

Maintenance Manual SA S92A-AMM-000, Chapter 20-06-00-910-006. 

September 11 /09 Page 6 63-20-01 
WE MEN NOR 

No. 92-63-020 

ROTOR DRIVES - Main Module Assembly - Main Gearbox Assembly - One-Time Visual Inspection of the 

Mounting Feet Pad, Foot Ribs and to Implement a 10-Hour Recurring Visual Inspection 

3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 

(5) Perform FPI of area to confirm direct visual inspection findings. Refer to Maintenance 

Manual SA S92A-AMM-000, Chapter 20-06-00-910-005. 

NOTE: Immediately contact Customer Service Engineering at 1-800-WINGED-S or 1-203- 

416-4299, to report any crack with the following information: Date Inspection 

Performed, Customer/Operator Name, Installed on Helicopter Serial Number, Main 

Gearbox Serial Number, Main Gearbox Total Time, Helicopter Total Time, 

Location of Crack. 

(a) If cracks are confirmed by FPI, replace main gearbox prior to next flight. Refer to 

Maintenance Manual SA S92A-AMM-000, Chapter 63-20-01-900-001 or 63-20-02-900- 

001. 

NOTE: Corrosion Preventive Compound MIL-PRF-16173 may be used as an alternate 

to Corrosion Preventive Compound MIL-DTL-85054. 

(b) If cracks are not found apply corrosion preventive compound (MIL-PRF-16173, or 

equivalent) to mounting feet. 

(6) Install covers, panels, and/or components previously removed: 

(a) LH and RH lower covers. Refer to Maintenance Manual SA S92A-AMM-000, Chapter 

54-40-02-900-002. 

(b) Center cover. Refer to Maintenance Manual SA S92A-AMM-000, Chapter 54-40-01-900- 

002. 

(c) Rear cover. Refer to Maintenance Manual SA S92A-AMM-000, Chapter 54-40-01-900- 

004. 

(7) Make sure area is clean and free of foreign objects. 

(8) Return helicopter to service. 

C. Record of Compliance 

(1) Make an appropriate logbook entry to show compliance with this ASB 92-63-020. 

(2) Upon compliance with this Alert Service Bulletin, complete attached ALERT SERVICE 

BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation. 

September 11/09 Page 7 63-20-01 
ME ONE o TaaRoa 

N o. 92-63-020 

FOOT RIBS: 

FOR THE 92351-15110-042 

THERE ARETHREE MAIN 

GEARBOX HOUSING RIBS 

TO BE INSPECTED. 

(VERTICAL) (HORIZONTAL) 

TYPICAL 4 PLACES 

MOUNTING FOOT AREA DEFINITION 

FIGURE 1 

September 11/09 Page 8 63-20-01 

TD1986 

$A 
ME ORM MOW 

No. 92-63-020 

EXAMPLE OF RIGHT 

HAND FOOT CRACK 

EXAMPLE OF CRACK IN MOUNTING FOOT PAD FACE 

FIGURE 2 

TD1987 

SA 

September 11/09 Page 9 63-20-01 
ME MEN TMaaRE 

No. 92-63-020 

EXAMPLE OF CRACK IN MOUNTING FOOT 

TD1988 

sn 

EXAMPLE OF CRACK IN MOUNTING FOOT PAD TOP 

FIGURE 3 

September 11/09 Page 10 63-20-01 
ME OdoE MUM 

N o. 92-63-020 

EXAMPLE OF FOOT RIB CRACK 

EXAMPLE OF CRACK IN MOUNTING FOOT PAD RIB 

FIGURE 4 

TD1989 

\4 

September 11/09 Page 11 63-20-01 
(Fold over and tape closed) 

SIKORSKY AIRCRAFT CORPORATION 

FACSIMILE NUMBER (860) 998 -7565 

ATTENTION: WCS PRODUCT SAFETY MANAGER 

WORLDWIDE CUSTOMER SERVICE 

j III I I III 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 is 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. 92-63-020 Compliance Record Card 

:• •: ~ C 11. ~ 11 ~ • - - u• Il. ~ - • ~ . - u• • ~ - u - 

Visual Inspection of the Mounting Feet Pad, Foot Ribs and to Implement a 10- 

Hour Recurring Visual Inspection 

OWNER/OPERATOR: 

SUBMITTED BY: DATE 

FOLLOWING SERIAI, NUMBERS ARE NOT AFFECTED BY THIS ASB 

ASB HAS BEEN COMPLIED WITH ON THE FOLLOWING SERIAL NUMBERS 

" " " 1 1111 11 11 1 i I 

(Fold LTp to Arrows) 

SA 7673-2 Rev B 
~

Sikorsky 

A Unitetl Technologies Company no Postage 

iNeeeSS3t'y 

BUSINESS REPLY MAIL 

FIRST- CLASS MAIL PERIVIIT 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: K100A 

ATTENTION: WCS PRODUCT SAFETY MANAGER 

WORLDWIDE CUSTOMER SERVICE 

Please complete the form on the reverse side and FAX to 

FACSEVULE NLJMBER (860) 998-7565 

or fold and return ENTIRE form to Sikorsky Aircraft Corporation