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# 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