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Page 1 of 17 ATA 67-00-00
ONE-TIME
INSPECTION S-92®HELICOPTER
ALERT SERVICE
BULLETIN NOTICE TO ALL PERSONS RECEIVING THIS DOCUMENT:
WARNING: THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF SIKORSKY 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AN UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, REPRODUCED, IN WHOLE OR IN PART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 FOR MANUFACTURE FOR ANYONE OTHER THAN SIKORSKY AIRCRAFT CORPORATION AND/OR ITS SUBSIDIARIES WITHOUT ITS WRITTEN CONSENT, AND THAT NO RIGHT IS GRANTED TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED HEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL AND CRIMINAL PENALTIES.
S-92®IS A REGISTERED TRADEMARK OF SIKORSKY AIRCRAFT CORPORATION.
ASB 92-67-006 February 16/16 Revision A ▪ February 19/16 SUBJECT: FLIGHT CONTROLS – Pushrods – One-Time Inspection of Main Rotor and Tail Rotor Servo Pushrods Section 1. PLANNING INFORMATION A. Effectivity S- 92A model helicopters with serial numbers 920006 through 920291.
B. Purpose To provide instructions to inspect for proper pushrod assembly.
C. Background Main rotor servo input pushrods and tail rotor servo pushrods were found with incorrect safety cable routing, incorrect jam nut torque, and/or incorrect locking device serrations and keys engagement.
D. Description Helicopter is prepared for inspection. Flight control rods are inspected for safety cable routing, engagement of serrations of locking device, engagement of keys on locking device, thread engagement, and torque of jamnuts. Non-compliant inspection results are documented on Pushrod Data Sheet. If any discrepancies are found, applicable pushrod is removed, reworked, reinstalled, or replaced. Rig check is performed, as required. Helicopter is returned to service.
E. Compliance Compliance is essential. The inspection outlined herein must be accomplished no later than May 16, 2016.
Sikorsky Aircraft Corporation 6900 Main StreetP.O. Box 9729 Stratford, Connecticut 06615-9129
(203) 386-4000 S-92 WARNING ‒ This information contains technical data subject to the EAR. Diversion contrary to US Law is prohibited. ECCN: 9E991
S-92 ALERT ASB 92-67-006 SERVICE BULLETIN Revision A ▪ February 19/16
Page 2 ATA 67-00-00
ONE-TIME
INSPECTION Section 1. PLANNING lNFORMATION (Continued) F. Approval Inspection item.
G. Manpower (Estimated) Task No. of Men No. of Hours Man-Hours* Inspection of Flight Control Pushrods 1 2.0 2.0 Rework of Flight Control Pushrods 1 2.0 2.0 Performance of Rig Check 2 1.0 2.0** Total Man-Hours 6.0 *Estimate does not include time required to prepare helicopter or return it to flight status.
**Estimated time is for passing a rig check on the first attempt.
H. Tooling Qty Nomenclature Part No. Source 1 Lighted Borescope Commercially available or equivalent (1) 1 Inspection Mirror Commercially available or equivalent (1) 1 Torque Wrench (30 - 150 in. lbs.) Commercially available or equivalent (1) 1 Torque Wrench (150 - 750 in.
lbs.)
Commercially available or equivalent (1)
(1) Available through normal supply channels.
I. Weight and Balance Not a ffected.
J. Electrical Load Data Not affected.
K. Software Load Data Not changed.
L. References
(1) Maintenance Manual, SA S92A-AMM-000, Task 21- 23-02-900-003/-004.
(2) Maintenance Manual, SA S92A-AMM-000, Task 53-70-00-900-001.
(3) Maintenance Manual, SA S92A-AMM-000, Task 54- 72-03-900-003/-004.
This document contains technical data subject to EAR. See WARNING and classifications on first page.
ASB 92-67-006 S-92 ALERT Revision A ▪ February 19/16 SERVICE BULLETIN
Page 3 ATA 67-00-00
ONE-TIME
INSPECTION Section 1. PLANNING INFORMATION (Continued)
(4) Maintenance Manual, SA S92A-AMM-000, Chapter/Section 67- 00-07.
(5) Maintenance Manual, SA S92A-AMM-000, Task 67- 11-04-960-009.
(6) Maintenance Manual, SA S92A-AMM-000, Task 67- 12-03-960-005.
(7) Maintenance Manual, SA S92A-AMM-000, Task 67- 14-04-960-002.
(8) Maintenance Manual, SA S92A-AMM-000, Task 67- 14-05-900-001/-002.
(9) Maintenance Manual, SA S92A-AMM-000, Task 67-14-06-960-001.
(10) Maintenance Manual, SA S92A-AMM-000, Task 67- 21-04-960-007.
(11) Maintenance Manual, SA S92A-AMM- 000, Task 67-23-01-960-007.
M. Publications Affected
(1) Temporary Revision No. 5- 173 against Maintenance Manual, SA S92-AWL-000, Task 5- 20-00-200-007, is issued concurrently with this ASB.
(2) Temporary Revision No. 67- 09 against Maintenance Manual, SA S92-AMM-000, Task 67- 11-04-960-009, will be issued at a later date.
(3) Temporary Revision No. 67- 10 against Maintenance Manual, SA S92-AMM-000, Task 67- 12-03-960-005 and 67-12-03-300-002, will be issued at a later date.
(4) Temporary Revision No. 67- 11 against Maintenance Manual, SA S92-AMM-000, Task 67- 14-04-960-002, will be issued at a later date.
(5) Temporary Revision No. 67- 12 against Maintenance Manual, SA S92-AMM-000, Task 67- 14-06-960-001, will be issued at a later date.
(6) Temporary Revision No. 67- 13 against Maintenance Manual, SA S92-AMM-000, Task 67- 21-04-960-007, will be issued at a later date.
(7) Temporary Revision No. 67- 14 against Maintenance Manual, SA S92-AMM-000, Task 67- 23-01-960-007, will be issued at a later date.
(8) Temporary Revision No. 67- 15 against Maintenance Manual, SA S92-AMM-000, Task Chapter/Section 67-00-00, is issued concurrently with this ASB.
N. Attachment None.
This document contains technical data subject to EAR. See WARNING and classifications on first page.
S-92 ALERT ASB 92-67-006 SERVICE BULLETIN Revision A ▪ February 19/16
Page 4 ATA 67-00-00
ONE-TIME
INSPECTION Section 2. MATERIAL INFORMATION A. Basis for Material Data Per helicopter.
B. Bill of Material None.
C. Consumable Material
Qty Nomenclature Part No. Source A/R 0.02 Inch Diameter Safety Cable Commercially available or equivalent (1) A/R 0.02 Inch Diameter Safety Wire Commercially available or equivalent (1)
(1) Procure locally.
Section 3. ACCOMPLISHMENT INSTRUCTIONS
A. Prepare helicopter for modification:
(1) Turn off all helicopter electrical and hydraulic power.
(2) Engage rotor brake.
TO PREVENT ELECTRICAL SHOCK OF PERSONNEL OR POSSIBLE
DAMAGE TO HELICOPTER COMPONENTS, MAKE SURE TO TURN OFF ALL ELECTRICAL POWER.
WHEN ANY COMPONENT OF ANY FLIGHT CONTROL SYSTEM IS
DISCONNECTED, REMOVED, AND REINSTALLED OR REPLACED,
A RIGGING CHECK OF THE AFFECTED SECTION MUST BE MADE
TO BE SURE THAT CONTROL RANGES ARE WITHIN SPECIFIED LIMITS.
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.
This document contains technical data subject to EAR. See WARNING and classifications on first page.
ASB 92-67-006 S-92 ALERT Revision A ▪ February 19/16 SERVICE BULLETIN
Page 5 ATA 67-00-00
ONE-TIME
INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(3) Open main rotor pylon sliding fairing. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 53-70-00-900-001).
(4) Remove tail rotor servo fairing assembly. (Refer to Maintenance Manual, SA S92A-AMM- 000, Task 54-72-03-900-003).
(5) Remove mixer top plate. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 67- 14- 05-900-001).
(6) If necessary, remove air conditioning crossover duct (92309-04818-101/-104). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 21-23-02-900-003).
(7) If necessary, remove applicable interior panels. (Refer to Maintenance Manual, SA S92A- AMM-000, Chapter 25).
NOTE: Perform all of the following inspections before correcting any non-conformities.
B. Inspect flight control pushrods listed in Table 1 as follows (Figure 1):
(1) Visually inspect adjustable ends of pushrods for proper safety cable routing. Right hand threads shall have safety cable routed as shown in Figure 2. Left hand threads shall have safety cable routed as shown in Figure 3. If safety cable is installed incorrectly, record results on Pushrod Data Sheet. (Refer to Pushrod Data Sheet, step K.).
NOTE: Use of a lighted borescope (commercially available or equivalent) may aid during inspection.
(a) For upper deck quadrant pushrod (92400-04802-105) only, if safety cable is incorrect, access must be gained to the pushrod and steps B.(2), B.(3), and B.(4) must be performed. Steps B.(3)(a) and B.(4)(a) cannot be applied.
NOTE: Use of a lighted borescope (commercially available or equivalent) may aid while inspecting upper deck quadrant pushrod (92400-04802-105).
(2) Where locking devices are used, visually inspect adjustable ends of pushrods for proper engagement of serrations and keys of the locking device. If serrations and keys of locking device are not properly engaged, record results on Pushrod Data Sheet. (Refer to Pushrod Data Sheet, step K.). (Refer to Figure 4).
(3) Inspect adjustable ends of pushrods for minimum thread engagement. Check that adjustable rod end, or clevis, is threaded beyond the inspection hole and that 0.02 inch diameter safety wire (commercially available or equivalent) cannot be inserted through the hole.If adjustable ends of pushrods do not have proper thread engagement, record results on Pushrod Data Sheet. (Refer to Pushrod Data Sheet, step K.).
This document contains technical data subject to EAR. See WARNING and classifications on first page.
S-92 ALERT ASB 92-67-006 SERVICE BULLETIN Revision A ▪ February 19/16
Page 6 ATA 67-00-00
ONE-TIME
INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) NOTE: Use of a lighted borescope (commercially available or equivalent) may aid while inspecting upper deck quadrant pushrod (92400-04802-105).
(a) For upper deck quadrant pushrod (92400-04802-105) only, if safety cable is installed correctly, locking devices pass visual inspection, and an acceptable maintenance phase inspection that would allow access to the pushrod does not coincide with the accomplishment of this ASB, step B.(3) can be deferred until the pushrod is accessible and step B.(3)(b) and B.(3)(c) can be performed as an alternate means of compliance. The procedure in step B.(3) above shall be accomplished the next time the pushrod is accessible, not to exceed the next 1500 hour inspection if not done at this time
(b) If B.(3) is deferred for the upper deck quadrant pushrod (92400-04802-105), a visual inspection is required to confirm that threads are visible in the inspection hole. If threads are not visible, record results on Pushrod Data Sheet and proceed to step B.(4). Step B(4)(a) cannot be applied.
(c) If B.(3) is deferred for the upper deck quadrant pushrod (92400-04802-105), record the inspection requirement in the helicopter logbook.
NOTE: Do not turn pushrod tube to determine looseness of jamnut or fasteners.
(4) For all adjustable pushrods, check jamnut for looseness using finger pressure with safety cable removed. Jamnut shall not turn in either direction. If jamnut moves with finger pressure, record results on Pushrod Data Sheet. (Refer to Pushrod Data Sheet, step K.).
(a) For upper deck quadrant pushrod (92400-04802-105) only, if safety cable is installed correctly, locking devices pass visual inspection, threads are visible through the inspection hole, and an acceptable phase inspection that would allow access to the pushrod does not coincide with the accomplishment of this ASB, step B.(4) can be deferred until the pushrod is accessible and step B.(4)(b) and B.(4)(c) can be performed as an alternate means of compliance. The procedure in step B.(4) above shall be accomplished the next time the pushrod is accessible, not to exceed the next 1500 hour inspection if not done at this time.
(b) If B.(4) is deferred for the upper deck quadrant pushrod (92400-04802-105), a visual inspection in the interim is required to confirm that there is no clearance between the jam nut, locking device, and pushrod insert around the entire periphery of these items. If clearance is present, gain access to the pushrod and check jamnut for looseness using finger pressure, with safety cable removed. Jamnut shall not turn in either direction. If jamnut moves with finger pressure, record results on Pushrod Data Sheet.
(c) If B.(4) is deferred for the upper deck quadrant pushrod (92400-04802-105), record the inspection requirement in the helicopter logbook.
This document contains technical data subject to EAR. See WARNING and classifications on first page.
ASB 92-67-006 S-92 ALERT Revision A ▪ February 19/16 SERVICE BULLETIN
Page 7 ATA 67-00-00
ONE-TIME
INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) PUSHROD IDENTIFICATION - TABLE 1
NOMENCLATURE PART NUMBER TORQUE VALUE TASK NUMBER Yaw Boost Input Pushrod 92400-04801-108 60-100 inch pounds 67-21-04-960-007 Pitch Boost Input Pushrod 92400-04801-107 43 inch-pounds 67-11-04-960-009 Collective Boost Input Pushrod 92400-04801-107 350 inch-pounds 67-12-03-960-005 Roll Boost Input Pushrod 92400-04801-109 43 inch pounds 67-11-04-960-009 Yaw Boost Out Pushrod 92400-04802-109 40-46 inch-pounds 67-14-04-960-002 Roll Boost Out Pushrod 92400-04803-103 40-46 inch-pounds 67-14-04-960-002 Pitch Boost Out Pushrod 92400-04803-102 40-46 inch-pounds 67-14-04-960-002 Collective Boost Out Pushrod 92400-04802-108 40-46 inch-pounds 67-14-04-960-002 Limiter Pushrod 92400-04803-106 40-46 inch-pounds 67-14-04-960-002 Pitch to Roll Pushrod 92400-04803-107 40-46 inch-pounds 67-14-04-960-002 Left Hand Main Rotor Servo Pushrod 92400-04801-110 350 inch-pounds 67-14-06-960-001 Forward Main Rotor Servo Pushrod 92400-04801-111 350 inch-pounds 67-14-06-960-001 Right Hand Main Rotor Servo Pushrod 92400-04801-112 350 inch-pounds 67-14-06-960-001 Upper Deck Quadrant Pushrod 92400-04802-105 60-100 inchpounds 67-21-04-960-007 Tail Rotor Servo Input Pushrod 92400-04802-107 40-46 inch-pounds 67-23-01-960-007
NOTE: If safety cable is routed properly, keys and serrations are properly engaged, thread is properly engaged, and jamnut does not move, proceed to step D.
C. Disposition of Non-Conforming Material:
(1) If jamnut inspected in step B.(4) failed the finger pressure check, perform the following:
(a) Remove and replace pushrod per applicable AMM task. If a replacement part is not readily available, contact Sikorsky Aircraft Corporation for inspection instructions to determine if pushrod may be suitable for limited use.
(2) If threads inspected in step B.(3) are not properly engaged, perform the following:
(a) Gain access to applicable control rod, as required.
(b) Remove applicable pushrod. (Refer to task listed in Table 1).
(c) Measure and record length from mounting centers.
This document contains technical data subject to EAR. See WARNING and classifications on first page.
S-92 ALERT ASB 92-67-006 SERVICE BULLETIN Revision A ▪ February 19/16
Page 8 ATA 67-00-00
ONE-TIME
INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(d) Measure and record rod end, or clevis, orientation.
(e) If required, remove safety cable.
NOTE: Make sure serrations and key are properly engaged.
(f) Reassemble rod end, jamnuts, and locking device.
(g) Adjust to recorded length and rod end, or clevis, orientation.
(h) Install applicable pushrod. (Refer to task listed in Table 1).
(i) Check that adjustable rod end, clevis, and adjuster are threaded beyond the inspection hole such that a 0.02 inch diameter safety wire cannot be inserted through hole.
(j) Using torque wrench (commercially available or equivalent), torque jamnut. (Refer to task and torque value listed in Table 1).
NOTE: Make sure safety cable is routed in the proper direction for left hand or right hand thread. (Refer to Figures 2 and 3).
(k) Install safety cable.
(l) If required, perform quick rigging check. (Refer to Maintenance Manual, SA S92A- AMM-000, Chapter/Section 67-00-07).
(m) Proceed to step E.
(3) If serrations and keys of the locking device inspected in step B.(2) are not properly engaged, perform the following:
(a) Gain access to applicable control rod, as required.
(b) If required, remove safety cable.
(c) Back off jamnut and inspect locking device for damage. Replace locking device as required. (Refer to task listed in Table 1).
(d) Using torque wrench (commercially available or equivalent), torque jamnut. (Refer to task and torque value listed in Table 1) NOTE: Make sure safety cable is routed in the proper direction for left hand or right hand thread. (Refer to Figures 2 and 3).
(e) Install safety cable.
(f) If required, perform quick rigging check. (Refer to Maintenance Manual, SA S92A- AMM-000, Chapter/Section 67-00-07).
This document contains technical data subject to EAR. See WARNING and classifications on first page.
ASB 92-67-006 S-92 ALERT Revision A ▪ February 19/16 SERVICE BULLETIN
Page 9 ATA 67-00-00
ONE-TIME
INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)
(g) Proceed to step E.
(4) If safety cable inspected in step B.(1) is installed incorrectly, perform the following:
(a) Gain access to applicable control rod, as required.
(b) If required, remove safety cable.
(c) Using torque wrench (commercially available or equivalent), torque jamnut. Record if jamnut moves at minimum torque. (Refer to task and torque value listed in Table 1).
NOTE: Make sure safety cable is routed in the proper direction for left hand or right hand thread. (Refer to Figures 2 and 3).
(d) Install safety cable.
(e) Proceed to step E.
D. Disposition of Conforming Material:
NOTE: For upper deck quadrant pushrod (92400-04802-105) only, proceed to step E if inspections B.(3) and B.(4) were deferred. Add the torque wrench verification below to the logbook to be performed the next time the pushrod is accessible, not to exceed the next 1500 hour inspection if not done at this time, as an alternate means of compliance to step D.(1).
(1) If safety cable is routed properly, keys and serrations are properly engaged, thread is properly engaged, and jamnut does not move with finger pressure, perform the following:
(a) Using torque wrench (commercially available or equivalent), torque jamnut. (Refer t o task and torque value listed in Table 1).
NOTE: Make sure safety cable is routed in the proper direction for left hand or right hand thread. (Refer to Figures 2 and 3).
(b) Install safety cable.
E. Install tail rotor servo fairing assembly. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 54-72-03-900-004).
F. Install mixer top plate. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 67- 14-05-900-
002).
G. If removed, install air conditioning crossover duct (92309-04818-101/-104). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 21-23-02-900-004).
H. If removed, install applicable interior panels. (Refer to Maintenance Manual, SA S92A-AMM-000, Chapter 25).
This document contains technical data subject to EAR. See WARNING and classifications on first page.
S-92 ALERT ASB 92-67-006 SERVICE BULLETIN Revision A ▪ February 19/16
Page 10 ATA 67-00-00
ONE-TIME
INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) I. Close main rotor pylon sliding fairing. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 53 -70-00-900-001).
J. Return helicopter to service.
This document contains technical data subject to EAR. See WARNING and classifications on first page.
ASB 92-67-006 S-92 ALERT Revision A ▪ February 19/16 SERVICE BULLETIN
Page 11 ATA 67-00-00
ONE-TIME
INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) K. Pushrod Data Sheet:
(1) Report the non-conforming data, fax to facsimile number (860- 998-7565) or scan and email to: GPSIKSASProductSafet@utc.com.
(2) Record the following information for each pushrod, and attach labeled photographs showing the same:
Customer/Operator Name:
Helicopter Serial Number:
Pushrod Part Number:
Pushrod Serial Number:
Was safety cable installed correctly? _______Yes _______No Were locking device serrations properly engaged? _______Yes _______No Was locking device key properly engaged? _______Yes _______No Did adjustable ends of pushrod have proper thread engagement?_______Yes_______No Was jamnut properly torqued?_______Yes _______No
This document contains technical data subject to EAR. See WARNING and classifications on first page.
S-92 ALERT ASB 92-67-006 SERVICE BULLETIN Revision A • February 19/16 Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued)
RATE PUSHROD 92400-04803-107 SEE DETAIL E ITCH TO ROLI 92400-04803-103
SEE DETAIL B STRO ROLL BOOST OUT
PUSHROD
- SEE DETAIL D 92400-04802-109 YAW BOOST OUT
PUSHROD
SEE DETAIL C
SEE DETAIL A 92400-04801-107
COLLECTIVE BOOST DOSTOUT
DETAIL B 92400-04801-107
PITCH BOOST INPUT
PET OR COURANT
DETAIL A DETAIL C TD3731_1
COMPONENT LOCATION FIGURE 1 (SHEET 1 OF 2)
ATA ONE-TIME Page 12 67-00-00 INSPECTION This document contains technical data subject to EAR. See WARNING and classifications on first page.