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This text is OCR from a scan. OCR can misread letters and numbers. © Sikorsky. Filed by the FAA in regulations.gov docket FAA-2009-1130; AD 2009-25-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
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Sikorsky Aircraft Corporation Sikorsky 6900 Main Street P.O. Box 9729 A United Technologies Company Stratford, Connecticut 06615-9129
(203) 386-4000
ALERT SERVICE BULLETIN
THIS ALERT SERVICE BULLETIN IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION AND IS PROTECTED UNDER THE COPYRIGHT LAWS OF THE SIKORSKY ALICOPTERS AND SIKORSKY AUTHORIZED GISTIC AND STAVICE SINTERS FOR THE PURPOSE OF FOSTERING HE SAFE AND EFFICIENED AND OTHER COUNTRIES.
DISCLOSED, REPRODUCED, LIMITED DISTRIBUTION • SIKORSKY AIRCRAFT CORPORATION 1999
ALL RIGHTS RESERVED No. 92-63-018 Subject: ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One-Time Visual Inspection of Filter Bowl Elements
1. PLANNING INFORMATION A. Effectivity S-92A model helicopters delivered with serial numbers 920006 through 920109 which have undergone a replacement of the Main Gearbox lube system filter.
Component Filter Assembly, MGB Lube System 92351-15802-101 B. Purpose To perform a one-time visual inspection for damaged oil filter elements and replacement of double bypass valve packings.
Background An incorrect part number identification for the Main Gearbox oil filter double bypass valve assembly packing has been discovered in the S-92 maintenance manual. If the incorrect packing has been installed, it is possible to cause damage to the oil filter elements during the installation process. Operation with a damaged oil filter element is potentially detrimental to the oil filter attaching studs.
C. Description Helicopter is prepared for maintenance. Central cover is removed, if required. MGB oil filter assembly is removed and primary and secondary filter elements are inspected for damage.
Double bypass valve packing is removed and replaced. If filter elements are found to be damaged, filter bowl mounting studs and filter elements are replaced. MGB Lube System July 01/09 Page 1 of 15 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
1. PLANNING INFORMATION (Continued) Filter Assembly is installed into MGB and main transmission is serviced. A ground test procedure is performed, and helicopter is returned to service.
D. Compliance Compliance is essential. The one-time inspection outlined herein is to be accomplished within 7 days from the issue date of this ASB.
E. Approval The change effected by this document is classified as Major, and is FAA approved in accordance with the applicable requirements of Federal Aviation Regulations FAR 29. This constitutes EASA approval under the terms of the current interim procedures for working with the European Community on airworthiness certification and continued airworthiness. The repair data provided in this document is automatically approved by ED Decision 2004/04/CF, as amended by ED Decision 2007/001/C. Reference to the ED Decisions mentioned above shall be made in the release documents issued by the EASA 145 approved organization, releasing the F. Manpower (Estimated) No. of Men No. of Hours *Man-Hours Removal of Oil Filter 1 0.50 0.50 Assembly Removal of Filter Bowl 1 1.50 1.50 Mounting Assembly Studs Install Filter Bowl 1 1.50 1.50 Mounting Assembly Studs Reinstallation of Oil 1 0.50 0.50 Filter Assembly NOTE: *Estimate does not include time required to prepare helicopter or return it to flight status.
G. Material One-quart container, or equivalent.
H. Tooling NOTE: For tooling availability, contact Helicopter Support Inc. Refer to Material Information section of this ASB.
(1) Lockring Cutter, BT309, or equivalent.
July 01/09 Page 2 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
1. PLANNING INFORMATION (Continued)
(2) Lockring Drive Tool, S101D12, M101D12N, or equivalent.
(3) Stud Install Wrench, R1105W, or equivalent.
(4) Housing, Tapered Collet 1/4- 28, CG500-4, or equivalent.
Weight and Balance None.
J. Electrical Load Data Not affected.
K. Software Load Data Not applicable.
References
(1) Maintenance Manual, SA S92A-AMM-000, Chapter/Section 63-24-02-900-002.
(2) Maintenance Manual, SA S92A-AMM-000, Chapter/Section 54-40-01.
(3) Maintenance Manual, SA S92A-AMM-000, Chapter/Section 63-20-00-610-001.
(4) Maintenance Manual, SA S92A-AMM-000, Chapter/Section 63-24-02-900-002.
(5) Functional Check Flight Procedures Manual, SA S92A-FCP-000.
M. Publications Affected Temporary Revision No. 63-19 against Maintenance Manual, SA S92A-AMM-000, Chapters/ Sections 63-24-02, has been issued to revise removal and installation procedures of lube system filter bowl components.
N. Attachment None.
July 01/09 Page 3 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
2. MATERIAL INFORMATION A. Basis for Material Data Per helicopter.
B. Bill of Material New Part No. Qty Key Word Old Part No. Instructions/ Disposition M83248/1-033 1 Packing M83248/1-033 (1) SS5086-04 Nut SS5086-04 (1) SLS11FJ101- Stud SLS11FJ101- (1) 11SN12A 11SN12A (DMYNO-97393- (DMYNO-97393-
503) 503) MS51990-105P Lockring MS51990-105P (1) 70351-38801-102 1 Filter Element, 70351-38801-102 (1) Primary 70351-38801-103 1 Filter Element, 70351-38801-103 (1) Secondary M83248/1-134 2 Packing M83248/1-134 (1) M83248/1-238 Packing M83248/1-238 (1) M83248/1-022 1 Packing M83248/1-022 (1)
(1) For cost of parts, tooling, and lead time requirements, contact your Customer Service Representative at Helicopter Support, Inc (HSI). Submit a purchase order referencing the ASB number and helicopter serial numbers upon which these 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 HSI website: www.HSIUS.com. For prompt shipment, reference address of each shipping destination. Direct your order to:
HELICOPTER SUPPORT INC.
124 Quarry Road P.O. Box 11068 Trumbull, CT 06611 July 01/09 Page 4 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
2. MATERIAL INFORMATION Attn: Customer Service FAX: (203) 416-4291 Telephone: (203) 416-4000 HSI website: www.HSIUS.com 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 ISOPROPYL ALCOHOL COMMERCIAL GRADE OR (1)
EQUIVALENT AS REQ'D Q-TIP COMMERCIAL GRADE OR (1)
EQUIVALENT AS REQ'D LINT FREE CLOTH CCC-C-440 OR EQUIVALENT (1) AS REQ'D LUBRICATING OIL DOD-PRF-85743 (1)
OR EQUIVALENT AS REQ'D CLEAR EPOXY MIL-PRF-22750 (2)
OR EQUIVALENT AS REQ'D EPOXY PRIMER MIL-P-85582, (3) MIL-P-23377,
OR EQUIVALENT AS REQ'D SEALING COMPOUND AMS 3265 TYPE 2 (4)
CHEM SEAL (CS) 5500CI CLASS B
OR EQUIVALENT
(1) Locally procure.
(2) Manufactured by Chesapeake Bay Coatings, Website: http://chesapeakebaycoatings.com/ July 01/09 Page 5 63-24-01
ALERT SERVICE BULLET IN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
2. MATERIAL INFORMATION
(3) Manufactured by Trans Chem Coatings-Industrial Finishes, Website: http://www.transchem.com/
(4) Manufactured by Flamemaster, Website: http://www.flamemaster.com/
3. ACCOMPLISHMENT INSTRUCTIONS A. Perform one-time inspection of MGB Lube System Filter Assembly as follows:
(1) Prepare helicopter for maintenance.
(2) Turn off electrical and hydraulic power.
(3) Remove central cover, if required. Refer to Maintenance Manual, SA S92A-AMM-000, Chapter/Section 54-40-01.
(4) Remove MGB Lube System Filter Assembly 92351-15802-101. Refer to Maintenance Manual, SA S92A-AMM-000, Chapter/Section 63-24-02, T-Rev 63-19.
(5) Visually inspect primary filter element (70351-38801-102) for damage as follows:
NOTE: The following criteria constitutes damage.
(a) Presence of "wavy" pleats - pleats should be straight and parallel with each other.
Refer to Figure 1.
(b) Presence of internal buckling - interior of filter element should be free from cracks and buckling. Refer to Figure 2.
(c) Presence of indented dimples - dimples on filter element should extend out of the surface rather than be pushed into the surface. Refer to Figure 3.
(6) If primary filter element (70351-38801-102) does not exhibit damage using the above criteria, proceed to secondary filter element inspection in Step (8).
If primary filter element (70351-38801-102) exhibits damage using the above criteria, or if operator suspects that aircraft has flown with damaged elements since compliance with ASB 92-63-014A, oil filter elements, packings, and filter bowl mounting studs must be July 01/09 Page 6 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
3. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(8) Visually inspect secondary filter element (70351-38801-103) for damage as follows:
NOTE: The following criteria constitutes damage.
(a) Presence of "wavy" pleats - pleats should be straight and parallel with each other.
Refer to Figure 4.
(b) Presence of elongated cup - cup at end of element should not appear stretched or elongated. Refer to Figure 5.
(9) If secondary filter element (70351-38801-103) does not exhibit damage using the above criteria, proceed to packing replacement in Section B.
(10) If secondary filter element (70351-38801-103) exhibits damage using the above criteria, or if operator suspects that aircraft has flown with damaged elements since compliance with ASB 92-63-014A, oil filter elements, packings, and filter bowl mounting studs must be B. Replace MGB Lube System Filter Assembly packing as follows:
Remove double bypass valve (AA-C367BV-16D09A). Refer to Maintenance Manual, SA S92A-AMM-000, Chapter/Section 63-24-02, T-Rev 63-19.
(2) Remove packing (M83248/1-033) from double bypass valve (AA-C367BV-16D09A) and install new packing (M83248/1-033) using packing installation tool (WE301K).
Install remainder of MGB Lube System Filter Assembly elements per Maintenance Manual, SA S92A-AMM-000, Chapter/Section 63-24-02, T-Rev 63-19 using new packings.
(4) Proceed to Section C. Step (20).
C. Replace MGB Lube System Filter Assembly elements and mounting studs as follows:
WARNING TAKE ANY STEPS NECESSARY TO ENSURE THAT NO FOREIGN
OBJECTS FALL INTO THE GEARBOX DURING THE REMOVAL AND REPLACEMENT OF STUDS AND LOCKRINGS.
NOTE: This procedure is to be used for removal and installation of all three Lube System Filter Assembly studs.
(1) Remove packing (M83248/1-238).
July 01/09 Page 7 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
3. ACCOMPLISHMENT INSTRUCTIONS (Continued) NOTE: Housing must be free from damage or corrosion in order to proceed with stud replacement.
(2) Carefully inspect the three studs where they attach to the MGB housing.
(3) Mask MGB filter bowl inside diameter to prevent foreign objects from entering housing.
CAUTION CAUTION MUST BE USED WHEN DRILLING SO AS TO PREVENT DAMAGE FROM DRILLING TOO DEEP.
(4) Using hand drill and lockring cutter (BT309, or equivalent), cut lockring securing studs (SLS11FJ101-11SN12A, DMYNO-97393-503) (typical three places) as follows:
(a) Operate drill at slow speed.
Drill a short way through, and stop, checking cutter depth, (just enough to cut lockring).
(c) If lockring is not cut, repeat drilling, maintaining a slow drill speed, until lockring is either cut through, or cut enough so that it can be collapsed.
(a) Remove lockring.
CAUTION AVOID CONTACT WITH HOUSING WHEN USING REMOVAL TOOL.
(5) Using stud tool (Stud Install Wrench, R1105W, or equivalent) wind out stud (SLS11FJ101- 11SN12A, DMYNO-97393-503) by rotating counterclockwise, (typical three places). Return removed studs to HSI, refer to Material Information section of this ASB for shipping information.
(6) Thoroughly clean out tapped hole using Isopropyl Alcohol (commercial grade, or equivalent) and Q-tip (commercial grade, or equivalent), and shop air.
(7) Visually inspect tapped holes for signs of damage. If any damage to threads is detected, stop work and contact a Sikorsky Field Service Representative, Customer Service Manager or Customer Service engineering at 1-800-WINGED-S or 1-203-416-4299 for assistance.
NOTE: • Presence of serrations on entire counterbore (360°) is acceptable.
• Serrations in housing must be intact, and mating serrations of lockring must line up exactly with serrations in housing.
• If rework of MGB housing is required, contact Sikorsky Field Service Representative, Customer Service Manager or Customer Service engineering at 1-800-WINGED-S or 1-203-416-4299.
July 01/09 Page 8 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
3. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(8) Visually inspect housing lockring counterbore to determine suitability for installation of new lockring.
(9) Locate serrations in MGB housing - teeth of new lockring (MS51990-105P) will be installed in exactly the same location.
NOTE: Stud shall be installed while epoxy primer is wet.
(10) Apply epoxy primer (MIL-P-85582, MIL-P-23377, or equivalent) onto threads of new stud.
NOTE: • External spline of stud should be .010-.020-inch below mounting surface.
• Make sure new lockring teeth align with serrations in housing.
(11) Thread new stud (SLS11FJ101-11SN12A, DMYNO-97393-503) into MGB housing tapped hole, using stud tool (Stud Install Wrench, R1105W, or equivalent).
(12) Install lockring by placing lockring over stud and onto MGB housing lockring counterbore so that lockring internal spline aligns with stud external spline.
(13) Set lockring into MGB housing lockring counterbore using lockring drive tool (S101D12, M101D12N, or equivalent).
(14) Clean and coat rock hard coating with clear epoxy (MIL-PRF-22750, or equivalent).
(15) Apply sealing compound (AMS 3265, Type 2, or equivalent) to lockring (MS51990-105P).
(16) Remove all squeeze-out in lockring counterbore using lint free cloth (CCC-C-440, or equivalent).
(17) Clean any residue using Isopropyl Alcohol (commercial grade, or equivalent) and lint free cloth (CCC-C-440, or equivalent).
(18) Remove masking from MGB filter bowl diameter.
(19) Reinstall MGB oil filter assembly using new secondary filter element (70351-38801-103), new primary filter element (70351-38801-102), and new packings as required. Refer to Maintenance Manual, SA S92A-AMM-000, Chapter/Section 63-24-02, T-Rev 63-19.
(20) Service main transmission. Refer to Maintenance Manual, SA S92A-AMM-000, Chapter/ Section 63-20-00-610-001.
(21) Examine components for security. Make sure area is clean and free of foreign objects.
(22) Reinstall central cover, if removed. Refer to Maintenance Manual, SA S92A-AMM-000, Chapter/Section 54-40-01.
July 01/09 Page 9 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018 ROTOR DRIVES - Main Module Assembly - Main Gearbox (MGB) Lube System Filter Components - One- Time Visual Inspection of Filter Bowl Elements
3. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(23) Do ground test procedures. Refer to Functional Check Flight Procedures Manual, SA S92A-FCP-000.
(24) Return helicopter to service.
D. Record of Compliance
(1) Make an appropriate logbook entry to show compliance with this ASB 92-63-018.
(2) Upon compliance with this ASB, complete attached ALERT SERVICE BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation.
July 01/09 Page 10 63-24-01
ALERT SERVICE BULLETIN No. 92-63-018
PRIMARY ELEMENT 70351-38801-102 MAJOR CRUSHING
OF PRIMARY ELEMENT NOT DAMAGED DAMAGED TD1674_1 INSPECTION CRITERIA FOR PRIMARY ELEMENT, "WAVY PLEATS" FIGURE 1 July 01/09 Page 11 63-24-01
ALERT SERVIGE BULLETIN No. 92-63-016
PRIMARY ELEMENT 70351-38801-102
NOT DAMAGED compression
DAMAGED
INSPECTION CRITERIA FOR PRIMARY ELEMENT, INTERNAL BUCKLING FIGURE 2 July 01/09 Page 12