S-76 ALERT SERVICE BULLETIN

(b) Temporary Revision No. 5-164 against Airworthiness Limitations and Inspection Requirements Manual SA 4047-76B-2-1, Chapter/Section 5-20-00, 1250-Hour Inspection Checklist, reissued concurrently with this ASB. (c) Temporary Revision No. 5-165 against Airworthiness Limitations and Inspection Requirements Manual SA 4047-76B-2-1, Chapter/Section 5-20-00, Calendar Inspection Checklist, reissued concurrently with this ASB. (d) Temporary Revision No. 65-40 against Maintenance Manual SA 4047-76B-2, Chapter/Section 65-12-02, Spindle Assemblies, reissued concurrently with this ASB. (4) S-76C Model Helicopters: (a) Temporary Revision No. 5-166 against Airworthiness Limitations and Inspection Requirements Manual SA 4047-76C-2-1, Chapter/Section 5-20-00, 25-Hour Inspection Checklist, reissued concurrently with this ASB. (b) Temporary Revision No. 5-167 against Airworthiness Limitations and Inspection Requirements Manual SA 4047-76C-2-1, Chapter/Section 5-20-00, 1250-Hour Inspection Checklist, reissued concurrently with this ASB. S-76 ALERT ASB 76-65-67A SERVICE BULLETIN Revision A ▪ July 18/12 Page 4 ATA 65-12-02 ONE-TIME INSPECTION Section 1. PLANNING lNFORMATION (Continued) (c) Temporary Revision No. 5-168 against Airworthiness Limitations and Inspection Requirements Manual SA 4047-76C-2-1, Chapter/Section 5-20-00, Calendar Inspection Checklist, reissued concurrently with this ASB. (d) Temporary Revision No. 65-36 against Maintenance Manual SA 4047-76C-2, Chapter/Section 65-12-02, Spindle Assemblies, reissued concurrently with this ASB. M. Publications Affected (1) Airworthiness Limitations and Inspection Requirements Manual, SA 4047-76-2-1, Chapter/Section 5-20-00. (2) Maintenance Manual SA 4047-76-2, Chapter/Section 65-12-02. (3) Airworthiness Limitations and Inspection Requirements Manual, SA 4047-76B-2-1, Chapter/Section 5-20-00. (4) Maintenance Manual SA 4047-76B-2, Chapter/Section 65-12-02. (5) Airworthiness Limitations and Inspection Requirements Manual, SA4047-76C-2-1, Chapter/Section 5-20-00. (6) Maintenance Manual SA 4047-76C-2, Chapter/Section 65-12-02. N. Attachment None. Section 2. MATERIAL INFORMATION A. Basis for Material Data Per helicopter. B. Bill of Material None. ASB 76-65-67A S-76 ALERT Revision A ▪ July 18/12 SERVICE BULLETIN Page 5 ATA 65-12-02 ONE-TIME INSPECTION Section 2. MATERIAL INFORMATION (Continued) C. Consumable Material Qty Nomenclature Part No. Source As Req’d White Paint Krylon® 51501 Gloss White or an equivalent acrylic enamel gloss white paint (1)(2) (Alternate) Plasti-Kote® 1109 Gloss White (2)(9) (Alternate) Krylon® Industrial Tough Coat (2)(10) As Req’d Low-Lint Cloth A-A-59323, Type II or equivalent (2) As Req’d Isopropyl Alcohol Commercial grade or equivalent (2) As Req’d Masking Tape Commercial grade or equivalent (2) As Req’d Permanent Marker Commercial grade or equivalent (2) As Req’d Couplant Ultragel or equivalent (2)(7) As Req’d FPI Kit ZL-27A or equivalent (3)(6)(8) (Alternate) 985-P13 or equivalent (4)(6)(8) (Alternate) FP-95A or equivalent (5)(6)(8) As Req’d Developer ZP-9F or equivalent (3)(6)(8) (Alternate) 9D1B or equivalent (4)(6)(8) (Alternate) D-70 or equivalent (5)(6)(8) As Req’d Class 2 Solvent SKC-S or equivalent (3)(6)(8) (Alternate) 9PR50 or equivalent (4)(6)(8) (Alternate) E-59 or equivalent (5)(6)(8) 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. S-76 ALERT ASB 76-65-67A SERVICE BULLETIN Revision A ▪ July 18/12 Page 6 ATA 65-12-02 ONE-TIME INSPECTION Section 2. MATERIAL INFORMATION (Continued) (1) Available through Krylon. Website: www.krylon.com/ (2) Procure through local supply. (3) Manufactured by Magnaflux. Website: http://www.magnaflux.com/ (4) Manufactured by Chemetall. Website: http://www.chemetall.com/ (5) Manufactured by Met-L-Chek. Website: http://www.met-l-chek.com/ (6) For fluorescent penetrant, class 2 solvent and developer, equivalent materials shall be approved as Type 1, Method C, Level 3 sensitivity in accordance with SAE AMS2644 and listed for use in QPL-AMS2644. (7) For ultrasonic inspection only. (8) For FPI only. (9) Manufactured by Plasti-Kote®. Website: http://www.paint-markers.co.uk/ (10) Available through Krylon Products Group. Website: www.kpg-industrial.com/ Section 3. ACCOMPLISHMENT INSTRUCTIONS A. Prepare helicopter for inspection: (1) Turn off all helicopter electrical and hydraulic power. (2) Engage rotor brake. (3) Using isopropyl alcohol and a clean, low-lint cloth, clean all spindle/cuff assembly or blade fold cuff assembly inspection area surfaces (Figure 1, Sheets 1 and 2). NOTE: • For spindle/cuff assemblies or blade fold cuff assemblies with 1900 flight hours or more, proceed to section B. • For spindle/cuff assemblies or blade fold cuff assemblies with less than 1900 flight hours, proceed to section C. ASB 76-65-67A S-76 ALERT Revision A ▪ July 18/12 SERVICE BULLETIN Page 7 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) B. Perform NDI per one of the following methods: NOTE: • Person performing NDI must be certified to Level 2, per NAS 410 or equivalent. If inspectors of other certification levels are utilized as permitted by NAS 410 or equivalent, this decision is the responsibility of the operator and their responsible Level 3 personnel. • Eddy Current inspection, FPI and ultrasonic inspection are acceptable alternates to each other. • Following applies to all spindle/cuff assemblies and blade fold cuff assemblies, including spares. (1) Perform Eddy Current inspection as follows: (a) Calibrate Eddy Current flaw detector (Phasec 3d or equivalent) (Figure 2): Parameter Setting Probe drive Low Phase As required Differential gain X-axis -8db Filter High Pass DC Low Pass 30 Hz Gain 50 dB/As required Frequency 2 MHz 1. Hold probe end perpendicular to surface of titanium reference standard in an area free of notches and balance/null the instrument. 2. Raise probe slightly from surface of titanium reference standard and observe the direction of lift-off signal. 3. Adjust phase control until lift-off signal moves to the left of the screen as the probe is raised from surface. 4. Maintaining probe perpendicular to surface of titanium reference standard, scan probe tip across 0.040 inch (1mm) deep EDM notches and observe amplitude of indications on screen. S-76 ALERT ASB 76-65-67A SERVICE BULLETIN Revision A ▪ July 18/12 Page 8 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 5. Adjust vertical\horizontal gain to produce a 40 percent vertical signal with approximately a 45 degree phase angle separate from lift off response. (b) Perform Eddy Current inspection: 1. Place probe on spindle/cuff assembly or blade fold cuff assembly inspection area and press null button. Maintain the probe perpendicular to surface and scan inspection area (Figure 1, Sheets 1 and 2). a If no crack indications are found exceeding the response from the 0.020 inch notch, proceed to section D. b Reject any crack indications exceeding the response from the 0.020 inch notch. Map out crack indications on cuff plate surface using a permanent marker (commercial grade or equivalent). Submit locations to Sikorsky Aircraft Corporation. Any repeatable crack indication is suspect and shall be investigated as follows: 1. Lift main rotor blade off of droop stop and verify crack indications using visual, FPI and/or ultrasonic inspection as necessary. a. If cracks are verified, remove spindle/cuff assembly or blade fold cuff assembly from service. Refer to applicable maintenance manual. b. If visual, FPI and/or ultrasonic inspections do not confirm suspect cracks, contact Customer Service Engineering at 1- 800-WINGED-S or 1-203-416-4299 for further instruction. (2) Perform FPI inspection as follows: NOTE: • FPI shall be performed using only a Type 1, Method C, Level 3 process with Form D developer in accordance with ASTM E 1417. • All fluorescent penetrant, class 2 solvent and developer shall be from the same manufacturer. (a) Brush or swab fluorescent penetrant (ZL-27A, 985-P13, FP-95A or equivalent) on inspection area (Figure 1, Sheets 1 and 2). (b) After fluorescent penetrant dwell period, remove surplus fluorescent penetrant using a clean, low-lint cloth (A-A-59323 or equivalent), pressing firmly and wiping in one direction. Perform fluorescent penetrant removal under black light to ensure adequate removal but not over-removal. NOTE: Do not apply the class 2 solvent directly to NDI inspection area and do not allow solvent to flood or pool. (c) Use a clean, low-lint cloth (A-A-59323 or equivalent) dampened with class 2 solvent (SKC-S 9PR50, E-59 or equivalent) to perform a final wipe. Observe cleaned area under black light to evaluate penetrant removal step. ASB 76-65-67A S-76 ALERT Revision A ▪ July 18/12 SERVICE BULLETIN Page 9 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) NOTE: Developer shall be applied as a uniform thin coating over entire surface to be inspected. If developer coating thickness is too heavy such that surface is completely masked, the area shall be cleaned and reprocessed. Minimum and maximum development times are 10 minutes to one hour respectively. (d) Apply non-aqueous developer (ZP-9F, 9D1B, D-70 or equivalent) by spraying. The developer container shall be agitated vigorously prior to and during application. NOTE: Make sure the inspection area is not exposed to ambient white light for FPI procedure. (e) Conduct inspection with less than two foot-candles (20 lux) of ambient white light. 1. If no crack indications are found proceed to step D. 2. Map out crack indications on cuff plate surface using a permanent marker (commercial grade or equivalent). Submit locations to Sikorsky Aircraft Corporation. Any crack indication is suspect and shall be investigated as follows: 1. Lift main rotor blade off of droop stop and verify crack indications using visual, Eddy Current and/or ultrasonic inspection as necessary. a. If cracks are verified, remove spindle/cuff assembly or blade fold cuff assembly from service. Refer to applicable maintenance manual. b. If visual, Eddy Current and/or ultrasonic inspections do not confirm suspect cracks, contact Customer Service Engineering at 1-800- WINGED-S or 1-203-416-4299 for further instruction. (3) Perform ultrasonic inspection as follows: (a) Calibrate flaw detector (Olympus or equivalent): Parameter Setting Pulse Echo Pulse Echo Frequency 10 MHz Range 2 inch Delay As necessary Gain Corner reflector to 100% Velocity 0.1207 in/μS Reject Off 1. Using a two inch range with 0.1207 in/μS velocity, set search unit index point at “Zero” onscreen. S-76 ALERT ASB 76-65-67A SERVICE BULLETIN Revision A ▪ July 18/12 Page 10 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) 2. Maximize corner reflector and adjust gain for 100% full screen height using inside corner (Figure 3). (b) Perform ultrasonic inspection: 1. Add 12 dB to calibration sensitivity. Back reflection monitoring is set to N/A. 2. Scan inspection area in all directions (Figure 1, Sheets 1 and 2). a If no crack indications are found proceed to section D. b Map out crack indications on cuff plate surface using a permanent marker (commercial grade or equivalent). Submit locations to Sikorsky Aircraft Corporation. Any crack indication is suspect and shall be investigated as follows: 1. Lift main rotor blade off of droop stop and verify crack indication using visual, Eddy Current and/or FPI inspections as necessary. a. If cracks are verified, remove spindle/cuff assembly or blade fold cuff assembly from service. Refer to applicable maintenance manual. b. If visual, Eddy Current and/or FPI inspection do not confirm suspect cracks, contact Customer Service Engineering at 1- 800-WINGED-S or 1-203-416-4299 for further instruction. C. Perform one-time visual inspection on spindle/cuff assemblies or blade fold cuff assemblies with less than 1900 flight hours as follows: (1) Using 5x or 10x magnifying glass (or equivalent), inspect white paint application area for cracks. (a) If cracks are found, remove spindle assembly or blade fold cuff assembly from service. Reference applicable maintenance manual. Contact Customer Service Engineering at 1-800-WINGED-S or 1-203-416-4299 and provide location of crack and spindle assembly or blade fold cuff assembly operating time. (b) If no cracks are found, proceed to section D. D. Apply white paint (Krylon® 51501 Gloss White, Plasti-Kote® 1109 Gloss White, Krylon Industrial Tough Coat, or an equivalent acrylic enamel gloss white paint) as follows: (1) If an FPI was performed thoroughly clean inspected area using isopropyl alcohol and a clean, low-lint cloth prior to application of white paint. (2) Mask white paint application area with masking tape (commercial grade or equivalent) (Figure 4, Sheets 1 and 2). ASB 76-65-67A S-76 ALERT Revision A ▪ July 18/12 SERVICE BULLETIN Page 11 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) (3) Apply white paint to masked area (Figure 4, Sheets 1 and 2). Let paint dry at room temperature for one hour minimum. (4) Remove masking tape. E. Return helicopter to service. F. Record of compliance: (1) Make helicopter logbook entries to show compliance with this ASB as follows: (a) Make helicopter level logbook entry on form SA7343-15. (b) When ASB modifies a component that can be removed from this helicopter: 1. Make component log card entries on forms SA7343-22 & SA7343-21 as applicable. 2. If a component modified by this ASB does not have a log card and the ASB does not create one, then annotate compliance on the next higher assembly that the component belongs to which does have a log card. NOTE: If access to www.Sikorsky360.com is unavailable, complete attached ALERT SERVICE BULLETIN COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation. (2) Make an appropriate electronic compliance entry in the E-Notification section at www.Sikorsky360.com. Refer to User Guide located on the www.Sikorsky360.com/E- Notification Search page. S-76 ALERT ASB 76-65-67A SERVICE BULLETIN Revision A ▪ July 18/12 Page 12 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) NDI INSPECTION AREAS (SPINDLE/CUFF ASSEMBLY) FIGURE 1, SHEET 1 OF 2 NDI INSPECTION AREA - 4 PLACES UPPER AND LOWER PLATES, SA TD2708A BOTH LEADING AND TRAILING EDGES NDI INSPECTION AREA - 2 PLACES UPPER AND LOWER PLATES NOTE BLADE NOT SHOWN FOR CLARITY. ASB 76-65-67A S-76 ALERT Revision A ▪ July 18/12 SERVICE BULLETIN Page 13 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) NDI INSPECTION AREAS (BLADE FOLD CUFF ASSEMBLY) FIGURE 1, SHEET 2 OF 2 NDI INSPECTION AREA - 4 PLACES UPPER AND LOWER PLATES, BOTH LEADING AND TRAILING EDGES NDI INSPECTION AREA - 2 PLACES UPPER AND LOWER PLATES NOTE BLADE NOT SHOWN FOR CLARITY. SA TD2788_1 S-76 ALERT ASB 76-65-67A SERVICE BULLETIN Revision A ▪ July 18/12 Page 14 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) EDDY CURRENT INSPECTION METHOD FIGURE 2 SA XXxxxxPP TD2739 ASB 76-65-67A S-76 ALERT Revision A ▪ July 18/12 SERVICE BULLETIN Page 15 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) ULTRASONIC INSPECTION METHOD FIGURE 3 SA TD2378 LOWER PLATE PROBE PLACED AT INSIDE CORNER OF LOWER PLATE SENSITIVITY SET TO 100% FULL SCREEN HEIGHT S-76 ALERT ASB 76-65-67A SERVICE BULLETIN Revision A ▪ July 18/12 Page 16 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) WHITE PAINT APPLICATION AREA (SPINDLE/CUFF ASSEMBLY) FIGURE 4, SHEET 1 OF 2 WHITE PAINT APPLICATION AREA WHITE PAINT APPLICATION AREA LEADING EDGE OF LOWER CUFF PLATE ONLY SA TD2708 NOTE BLADE NOT SHOWN FOR CLARITY. ASB 76-65-67A S-76 ALERT Revision A ▪ July 18/12 SERVICE BULLETIN Page 17 ATA 65-12-02 ONE-TIME INSPECTION Section 3. ACCOMPLISHMENT INSTRUCTIONS (Continued) WHITE PAINT APPLICATION AREA (BLADE FOLD CUFF ASSEMBLY) FIGURE 4, SHEET 2 OF 2 WHITE PAINT APPLICATION AREA NOTE BLADE NOT SHOWN FOR CLARITY. SA TD2788_2 WHITE PAINT APPLICATION AREA LEADING EDGE OF LOWER CUFF PLATE ONLY (Fold over and tape closed) SIKORSKY AIRCRAFT CORPORATION FACSIMILE NUMBER (860) 998-7565 EMAIL ADDRESS: GPSIKSASProductSafet@utc.com ATTENTION: SAS PRODUCT SAFETY MANAGER SIKORSKY AEROSPACE SERVICES (Fold Up to Arrows) IMPORTANT NOTICE Upon COMPLIANCE with the attached ASB, Sikorsky requests your cooperation in completing and returning this ENTIRE PAGE by MAIL, FAX, or scan & EMAIL. If you have internet access, you may go to www.sikorsky.com to record your compliance. 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: ________________ Compliance Record Card TITLE: ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ OWNER/OPERATOR: _____________________________________________________ SUBMITTED BY: ___________________________ DATE: ____________________ FOLLOWING SERIAL NUMBERS ARE NOT AFFECTED BY THIS ASB ASB HAS BEEN COMPLIED WITH ON THE FOLLOWING SERIAL NUMBERS ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ No. 76-65-67A ROTORS – Spindle Assemblies – One-Time Non-Destructive Inspection (NDI) of Spindle/Cuff Assembly and Application of White Paint to Enhance Existing Inspection Procedure No Postage Necessary BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT 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: S328A ATTENTION: SAS PRODUCT SAFETY MANAGER SIKORSKY AEROSPACE SERVICES Please complete the form on the reverse side and FAX to FACSIMILE NUMBER (860) 998-7565 Or scan and email to: EMAIL ADDRESS: GPSIKSASProductSafet@utc.com or fold and return ENTIRE form to Sikorsky Aircraft Corporation