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ERICKSON AIR-CRANE
INCORPORATED FAA TYPE CERTIFICATE NO. H6EA TC TYPE CERTIFICATE NO. H-91 SERVICE BULLETIN 64B10-3
TRANSMITTAL SHEET SUBJECT: SERVICE BULLETIN NO. 64B10-3, ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin This page transmits Revision D, dated October 15/2007, to Service Bulletin No.
64B10-3, dated April 21/95.
Please insert the attached pages, which are a complete reissue of Service Bulletin No.
64B10-3. Destroy the superseded pages so that the contents will be as follows:
Page No. ReviSion Date 1 through 14 October 15/2007 The text changed by this revision is indicated by a vertical line in the left-hand margin of the page.
REVISION FEATURES: To designate the type of Service Bulletin on title page heading, added "(E)" for essential.
Section 1. PLANNING INFORMATION, Paragraph A. NOTE deleted "Co.", paragraph C. removed "S" from "(S45°/60° steel)". Paragraph D., NOTE, reworded and changed "ASTM E-1444-93" to "ASTM E-1444 (latest revision)" and deleted last part of sentence. Deleted paragraph G. Materials and renumbered remaining paragraphs.
Updated paragraph G. Special Equipment to read "Special Tools", updated list if tools.
Updated paragraph J., references to current manual usage.
Section 2. ACCOMPLISHMENT INSTRUCTIONS, CAUTION changediASMT TC-1A LEVEL II" to 'ASNT SNT-TC-1A LEVEL II, ISO 9712 LEVEL II".
Paragraph A., NOTE, reworded and changed "ASTM E-1444-93" to "ASTM E-1444" and deleted last part of sentence. Paragraph A., (3) added "Remove plugs and", and changed "(Fed Spec P-D-680, Type 2)" to "(MIL-PRF-680, Type II or III)". Paragraph A., (4) reworded sentence and added NOTE. Paragraph B., (2) changed "BR 0504-S45/S60)" to "(6455-40234-001)" and "(BNC-to-BNC)" to "(BNC-BNC)", (3) changed "(ESMT-K3-7043)" to "(6470-11175-001)". Paragraph B., (4) NOTE's 3100 WILLOW SPRINGS ROAD • P.O. BOX 3247 • CENTRAL POINT, OR 97502 • (541) 664-5544 • FAX (541) 664-2312 www.ericksonaircrane.com
Erickson Air-Crane Incorporated Barbara F. Stiger Technical Publications Manager changed "CRT" to "A-scan". Paragraph B., (5) changed "(Hamikleer 712-2, SAE 30 WT. Oil, or equivalent)" to "(Sonotech Soundsafe, SAE 30 WT. Oil, or equivalent)" and corrected figure reference. Paragraph B., (9), (e) changed "CRT" to "screen" and changed NOTE, "Stavely Sonic-Model-139-P" to "Sonic 1000S/1200S series".
Paragraph B. (10), added "(Figure 5)" reference. Paragraph C. (1), NOTE changed "Move" to "Rotate", CAUTION, added "PROBE SELECTOR". Paragraph C. (2) NOTE's changed "CRT" to "LCD". Paragraph C. (3), reworded and updated information. Paragraph C. (8) was changed to a "NOTE", replaced "suspicion" to "indication", and moved below new paragraph (11), remaining paragraphs were renumbered. Updated specifications in new paragraphs C. (12), (13). Replaced all of the Figures in this section with new illustrations and added Figure 7.
Section 3. MATERIAL INFORMATION, Updated all of the materials and specifications found in Section 3.
ERICKSON AIR-CRANE
INCORPORATED FAA TYPE CERTIFICATE NO. HEA TC TYPE CERTIFICATE NO. H-91 Service Bulletin NO. 64B10-3 (E) SUBJECT: ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
1. PLANNING INFORMATION A. Effectivity Model: S-64E Series Component: S1510-23099-1 Horizontal Hinge Pin S1510-23099-001 Horizontal Hinge Pin NOTE: Erickson Air-Crane expanded dash (-) number ending of part number from one digit to three digits, although the two part configurations are identical and interchangeable.
B. Reason To detect possible circumferential cracks in two specific areas of the shank diameter of the horizontal hinge pin.
C. Description The ultrasonic inspection (UT) method is used to detect possible circumferential cracks in two areas of the horizontal hinge pin. The inspection is performed using the contact method and angle beam ultrasonic techniques in the bore of each hinge pin (Figure 1). The angle beam inspection is performed using a dual 5 MHz - 1/4 inch (45/60° steel) contact bore probe transducer assembly (Figure 2). The probe is selectively switched to the aft transducer (45°) position used for the smaller diameter inspection, or to the forward transducer (60°) position used for the larger diameter inspection. This inspection may be done with the hinge pin installed on the helicopter.
October 19/79
• Revision D - October 15/2007 Page 1 of 14 3100 WILLOW SPRINGS ROAD • P.O. BOX 3247 • CENTRAL POINT, OR 97502 • (541) 664-5544 • FAX (541) 664-2312 www.ericksonaircrane.com
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 Page 2 D. Compliance The manufacturer believes compliance to be essential and recommends accomplishment of the work outlined herein as follows:
(1) On all horizontal hinge pins with 1100 flight hours or more, within the next 20 flight hours or within 200 flight hours since last fluorescent magnetic particle inspection as specified in the below NOTE, ultrasonically inspect per Section 2. Accomplishment Instructions.
NOTE: Horizontal hinge pins are to be fluorescent magnetic particle inspected per ASTM E-1444 (latest revision), using wet continuous method and consisting of one or more distinct magnetizing operations.
CAUTION: IN NO CASE SHALL THE FLIGHT HOUR LIMITATION OR
YEAR CALENDAR TIME BE EXCEEDED PRIOR TO ACCOMPLISHING THE ULTRASONIC INSPECTION.
(2) At next 200 flight hours after initial ultrasonic inspection, or one year, whichever comes first, and every 200 flight hours thereafter, or at one year intervals, whichever comes first, ultrasonically inspect horizontal hinge pins per Section 2. Accomplishment Instructions.
E. Approval FAA Approval F. Manpower Preparation of ultrasonic 2 0.3 0.6 inspection per horizontal hinge pin Instrument calibration 1 0.3 0.3 Ultrasonic inspection per 1 0.3 0.3 horizontal hinge pin ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
1. PLANNING INFORMATION (Continued)
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 G. Special Tools Dual Transducer Bore Hinge Pin Reference Standard Sonic Portable Ultrasonic Flaw Detectors, 1000S/ 1200S series, or equivalent . May be purchased from Olympus NDT Inc., 48 Woerd Avenue, Waltham MA 02453.
H. Electrical Load Data Not affected I. Weight and Balance Not affected J. References Maintenance Manual for Model S-64E Helicopter Publication Number EAC007 K. Other Publications Affected None ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
1. PLANNING INFORMATION (Continued)
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 Page 4 WARNING: OBSERVE ALL CAUTIONS AND WARNINGS ON THE CONTAINERS WHEN USING CONSUMABLES. WHEN
APPLICABLE, WEAR 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, OR FLAME. MAKE CERTAIN
HELICOPTER IS PROPERLY GROUNDED AND FIRE FIGHTING EQUIPMENT IS READILY AVAILABLE PRIOR TO USE. FOR
ADDITIONAL INFORMATION ON TOXICITY, FLASHPOINT, AND
FLAMMABILITY OF CHEMICALS, CONSULT THE MANUFACTURER OF THE CONSUMABLES.
CAUTION: ULTRASONIC INSPECTION MUST BE PERFORMED BY
PROPERLY TRAINED PERSONNEL HAVING SPECIFIC
ULTRASONIC INSPECTION TRAINING EQUIVALENT TO ASNT SNT-TC-1A LEVEL II, ISO 9712 LEVEL II OR SPECIFIC TRAINING CONDUCTED BY THE TYPE CERTIFICATE HOLDER.
A. On all horizontal hinge pins with 1100 flight hours or more, within the next 20 flight hours or within 200 flight hours since last fluorescent magnetic particle inspection, ultrasonically inspect as follows:
NOTE: Horizontal hinge pins are to be fluorescent magnetic particle inspected per ASTM E-1444 using the wet continuous method and consisting of one or more distinct magnetizing operations.
(1) Position main rotor head to gain access to the threaded end of the horizontal hinge pin (Figure 1).
(2) Disconnect pitch control rod assembly (6410-21007-013) from the spindle horn to gain access to the hinge pin bore per Maintenance Manual.
(3) Remove plugs and clean hinge pin bore and exposed surface of corrosion preventive compound using a clean cloth, damp with solvent (MIL-PRF-680, Type II or III).
ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
2. ACCOMPLISHMENT INSTRUCTIONS
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 Figure 1. Inspection Areas Horizontal Hinge Pin C4146.IR.64B10-3D
(4) Using a light, check that the internal surface of the hinge pin to be inspected is clean and free from any foreign material or evidence of corrosion, which would prevent good surface contact of transducer assembly.
NOTE: If corrosion is found, remove and replace hinge pin.
(5) Comply with paragraphs B. through E.
B. Calibrate ultrasonic instrument for inspection of hinge pin as follows:
(1) Turn on ultrasonic instrument and allow to warm up as required by instrument manual.
(2) Connect dual transducer bore probe assembly (6455-40234-001) to instrument using interconnecting cable (BNC-BNC) as required. (Figure 2)
(3) Insert the dual transducer bore probe assembly completely into the Hinge Pin Standard (6470-11175-001). (Figures 3 and 4) CAUTION: MAKE SURE SWITCH IS NOT MOVED DURING TEST.
(4) Place dual transducer bore probe selector switch in the 45° mode position.
NOTE: The 45° mode position is used to inspect the 2.125 inch diameter area. See Figure 5 for a typical A-scan presentation.
NOTE: The 60° mode position is used to inspect the 2.250 inch diameter area. See Figure 6 for a typical A-scan presentation.
ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
2. ACCOMPLISHMENT INSTRUCTIONS
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 Page 6 ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
2. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(5) Fill syringe with couplant (Sonotech Soundsafe, SAE 30 WT. Oil, or equivalent) and thread syringe into couplant port. Depress plunger and rotate probe 360° to apply couplant to calibration area. (Figure 1)
(6) Adjust instrument to obtain a response from reference notch as probe is rotated at a rate not to exceed 10° per second.
(7) Maximize (peak) response from reference notch.
(8) Adjust instrument sensitivity control (gain) until a response of 80 percent full scale height (FSH) from notch is obtained.
(9) The following minimum instrument requirements should be maintained:
(a) Frequency - selected to match transducer assembly - 5 MHz.
NOTE: If equipment has broadband capability, stay within 2 to 10 MHz range; if frequency selection is not compatible, the next highest frequency to the transducer assembly should be used.
C4147.IR.64B10-3D Figure 2. Dual Transducer Probe Assembly (6455-40243-001)
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
2. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(b) Instrument Reject of Suppression Control - adjusted to obtain desired calibration response with minimum amplification and desired baseline noise.
(c) Damping- minimum.
(d) Gain/Sensitivity - adjusted to obtain desired calibration response with minimum amplification and desired baseline noise.
(e) Screen Range and Delay - selected to position calibration response and indications in center of 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 position (single).
(g) Pulse Repetition Frequency (PRF) - maximum.
(10) Rotate probe 90° in area of reference notch (not to exceed 10° per second) to verify detectability of reference notch at calibration level. (Figure 5) NOTE: This shall be the scanning rate used for inspection.
C. Ultrasonically inspect hinge pin as follows:
(1) Insert the dual transducer bore probe assembly completely into the bore of the hinge pin.
NOTE: Rotate blade up or down, as required, to gain access to bore with probe, and hold blade in this position.
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 Page 8 Figure 3. Transducer Assembly in Horizontal Hinge Pin C4148.IR.64B10-3D ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
2. ACCOMPLISHMENT INSTRUCTIONS (Continued) CAUTION: MAKE SURE PROBE SELECTOR SWITCH IS NOT MOVED DURING TEST.
(2) Place probe selector switch in the 45° mode position.
NOTE: The 45° mode position is used to inspect the 2.125 inch diameter area. See Figure 5 for typical LCD presentation.
NOTE: The 60° mode position is used to inspect the 2.250 inch diameter area. See Figure 6 for typical LCD presentation.
(3) Fill syringe with couplant (Sonotech Soundsafe, SAE 30 WT. Oil, or equivalent) and thread syringe into couplant port. Depress plunger and rotate probe 360° to apply couplant to calibration area (Figure 1).
(4) Rotate probe 360° to scan inspection area at a rate not to exceed 10° per second.
(5) A hinge pin having ultrasonic indications equal to or greater than 60 percent full scale height is suspect.
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 Figure 4. Configuration of Ultrasonic Hinge Pin Standard C4149.IR.64B10-3D ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
2. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(6) If hinge pin is suspect, recalibrate instrument on Hinge Pin Standard per paragraph B., and recheck pin per paragraph C.
(7) If rechecked pin has ultrasonic indications equal to or greater than 60 percent full scale height, using a felt marking pen, identify at threaded end of pin the locations of ultrasonic responses that exceed specified inspection criteria.
(8) Remove suspect hinge pin from service prior to further flight if pin has ultrasonic indication equal to or greater than the 60 percent full scale height. Contact Erickson Air-Crane, Product Support Department. Advise them of the suspect pin and forward suspect pin for further analysis.
ERICKSON AIR-CRANE SERVICE BULLETIN NO. 64B10-3 October 19/79 Revision D - October 15/2007 Page 10
TYPICAL A-SCAN PRESENTATION 80% FSH RESPONSE FROM 0.012 INCH NOTCH C4229.IRSB64B10-3 80% CALIBRATION
RESPONSE 60% REJECTION LEVEL ROTORS - Rotary Wing Head - Ultrasonic Inspection of Horizontal Hinge Pin
2. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(9) Replace suspect pin with a pin that meets the requirements of this Service Bulletin.
(10) Place probe selector switch in the 60° mode position and calibrate ultrasonic instrument per paragraph B., steps (3) through (10). (Figure 6)
(11) With probe selector switch in 60° mode position, ultrasonically inspect the 2.250 inch diameter area per steps (3) through (9) of this paragraph.
NOTE: If a crack-like indication appears between clock angles of 7:00 to 11:00, as viewed from threaded end of pin (Figure 7), it may be caused by echoes from the locking flat. To verify indication, remove spacer and screws and attempt to dampen signal by applying couplant to the area and rubbing with finger. If indication moves up and down amplitude-wise, it is considered non-relevant and hinge pin is acceptable.
Figure 5. Ultrasonic Response From Fabricated Notch in 2.125 Inch Diameter Area With Transducer at 45° Mode Position