SPECIAL SERVICE INSTRUCTIONS

Main Gear Box Oil Pressure Auto Bypass System and Activation of Aircraft Management System (AMS) 7.1 MGB OIL OUT Visual Warning, basic issue or later revision). • If necessary, rebuild braid terminators using best shop practices with precoiled band (600-052-1), tape (A-A-59163, DMYNO-6A669-001 and 3M-60), and insulating sleeve (SS7072M2000Z017). • Clamp size may be increased as needed. A. Prepare helicopter for maintenance: (1) Turn off all helicopter electrical and hydraulic power. (2) Engage rotor brake. (3) Remove overhead console circuit breaker panel (OVHD CNSL CB PNL). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 31-10-06-900-001). (4) If necessary, remove duct from top Left Hand (LH) cabin rack, top deck Left Hand Side (LHS) horse collar fairing, and top deck LHS cabin heater bleed air tube. (5) Remove the following access panels: (a) Left hand air inlet cover plate. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 71-62-05-900-001). (b) Left hand and right hand oil cooler access doors. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 52-43-02-900-001). (c) Oil cooler platform. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 63-25-01- 900-003). (d) Rear cover. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 54-40-01-900-003). TO PREVENT ELECTRICAL SHOCK OF PERSONNEL OR POSSIBLE DAMAGE TO HELICOPTER COMPONENTS, MAKE SURE TO TURN OFF ALL ELECTRICAL POWER. October 26, 2017 3 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 NOTE: • Refer to paragraphs B. through H. for helicopters with S/Ns 920006 through 920296. • Refer to paragraph I. for helicopters with S/Ns 920297 through 920304 and 920311 through 920314. B. Install modification kit clips and brackets installation (M/K CLIPS & BRKTS) (92070-20115-015) as follows (Refer to Figure 1): (1) Remove screws (SS5300C0809) and flat washers (NAS1149FN832P) from ceiling (92207- 01101-151) (Sheet 2, View D-D). (2) Trim ceiling (92207-01101-151) (two places) flush to existing edge. (3) Remove rivets (MS20470AD4) from overhead panel support assembly (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) (Sheet 1, Section A-A). (4) Match drill Right Hand (RH) circuit panel assembly (92070-20115-051) to overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) (Sheet 1, Section A-A) (six places). Hole diameters to be 0.200 - 0.210 inch (Sheet 2, View C-C). (5) Match drill panel (92070-20115-119) to overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) (six places). Hole diameters to be 0.200 - 0.210 inch. (6) Match drill RH hinge (92070-20115-118) to overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) (four places). Hole diameters to be 0.192 - 0.203 inch (Sheet 1, Section B-B). (7) Match drill LH hinge (92070-20115-117) to overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) (four places). Hole diameters to be 0.192 - 0.203 inch. (8) If necessary, trim panel (92070-20115-119) to achieve best fit. (9) Deburr all sharp edges and drilled holes. (10) Touch up trimmed edges as follows: (a) Clean trimmed areas using a low-lint cloth (A-A-59323 or equivalent) dampened with isopropyl alcohol (TT-I-735 or equivalent). (b) Apply chemical conversion coating (MIL-DTL-5541 Class 3 or equivalent) to trimmed areas. (c) Apply one coat of epoxy primer (MIL-PRF-23377, or Axalta (Formerly DuPont) Corlar 13580S, or equivalent) to all reworked edges. (d) Apply two coats of black paint (MIL-PRF-85285, FED-STD-595 color no. 37038 or equivalent) to reworked edges on panel (92070-20115-119). October 26, 2017 4 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 NOTE: • Sealing compound (AMS-3265 or equivalent) shall extend at least 0.25 inch beyond fastener, and be crowned at least 0.100 inch thick from fastener. • All permanent fasteners shall be wet installed using sealing compound (AMS-3265 or equivalent). (11) Using sealing compound (AMS 3265 or equivalent), install nutplates (MS21076L08N) at RH hinge (92070-20115-118) location with rivets (CCR244CS-3-02). (12) Using sealing compound (AMS 3265 or equivalent), install nutplates (MS21076L08N) at LH hinge (92070-20115-117) location with rivets (CCR244CS-3-02). (13) Using sealing compound (AMS 3265 or equivalent), install nutplate (MS21076L3N) on overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) with rivets (CCR244CS-3-02) (Section A-A). (14) Using sealing compound (AMS 3265 or equivalent), install nutplates (MS21076L04N) on overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) using rivets (CCR244CS-3-02). (15) Install rivets (CR3214-4-03 or AF3214-4-03) wet with sealing compound (AMS 3265 or equivalent) on overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609). (16) Install LH hinge (92070-20115-117) as follows: (a) Clean area using a low-lint cleaning cloth (A-A-59323 or equivalent) dampened with isopropyl alcohol (TT-I-735 or equivalent). NOTE: Do not prime or paint hatched area. (Refer to Figure 1, Note 4). (b) Apply chemical conversion coating (MIL-DTL-5541 Class 3 or equivalent) to surfaces that will mate with hinge. (c) Install LH hinge (92070-20115-117) on overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) with screws (MS27039-0807) and flat washers (NAS1149FN832P). (d) Perform electrical bonding check using milliohmmeter (R1L-E2 or equivalent) between points E and F. Resistance shall not exceed 2.5 milliohms (Sheet 2, View C-C). (e) Install LH hinge (92070-20115-117) on panel (92070-20115-119) with rivets (NAS1097AD4-9) wet with sealing compound (AMS 3265 or equivalent) (Sheet 2, View C- C). (f) Perform electrical bonding check using milliohmmeter (R1L-E2 or equivalent) between points A and B. Resistance shall not exceed 2.5 milliohms (Sheet 1, Section B-B). (17) Install RH hinge (92070-20115-118) as follows: (a) Clean area using a low-lint cloth (A-A-59323 or equivalent) dampened with isopropyl alcohol (TT-I-735 or equivalent). October 26, 2017 5 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 NOTE: Do not prime or paint hatched area. (Refer to Figure 1, Note 4). (b) Apply chemical conversion coating (MIL-DTL-5541 Class 3 or equivalent) to surfaces that will mate with hinge. (c) Install RH hinge (92070-20115-118) on overhead support installation (92207-01101), overhead panel (92070-20017), or overhead panel relay mount (92CEO-37609) with screws (MS27039-0807) and flat washers (NAS1149FN832P). (d) Perform electrical bonding check using milliohmmeter (R1L-E2 or equivalent) between points G and H. Resistance shall not exceed 2.5 milliohms (Sheet 2, View C-C). (e) Install RH hinge (92070-20115-118) on RH circuit panel assembly (92070-20115-051) using rivets (NAS1097AD4-9) wet with sealing compound (AMS 3265 or equivalent) (Sheet 2, View C-C). (f) Perform electrical bonding check using milliohmmeter (R1L-E2 or equivalent) between points C and D. Resistance shall not exceed 2.5 milliohms (Sheet 1, Section B-B). (18) Secure RH circuit panel assembly (92070-20115-051) using captive screws (SS5301-0808) and flat washer (NAS1149FN832P). (19) Secure panel (92070-20115-119) using captive screws (SS5301-0808) and flat washer (NAS1149FN832P). C. Install portion of Modification Kit Auxiliary Circuit Breaker Panel Provision (M/K, PROV, AUX CB PNL) (92070-55075-011) as follows (Refer to Figure 2, Sheet 1): NOTE: Finished length of wire (P5335G14), part of LH W/G CKPT APU (92552-55096-041), shall be 10.50 - 10.75 inches. (1) Install button plugs (SFHP5006L01BK) and circuit breaker (MS3320-1) on AUX CB PNL. (2) Install cover assembly (MS18029-2S-3), terminal (MS27212-2-3), screws (MS35206-217), nuts (MS35650-304), lock washers (MS35338-138), flat washers (NAS1149C0332R), washers (MS14151-2), MTG strip (MS3373-B2), and MTG strip (MS3373-A2), using existing nutplate onto AUX CB PNL (Sheet 2). D. Install Modification Kit Left Hand Cockpit Auxiliary Power Unit (M/K LH CKPT APU) (92070-55096- 012) as follows: NOTE: Wiring group cockpit auxiliary power unit (W/G CKPT APU) (92552-55096-041) is a loose wire group. (1) Install W/G LH CKPT APU (92552-55096-041). (2) Route new wire (P5335F10) along existing wiring harness, from terminal board TB108 to terminal board TB122 (Figure 3). (3) Install terminal (M7928/1-67) on end of wire (P5335F10) near terminal board TB108 on OVHD CNSL CB PNL. (4) Install terminal (M7928/1-65) on end of wire (P5335F10) near terminal board TB122 on AUX CB PNL. (5) Install new wire (P5335F10) on terminal board TB108-1 and terminal board TB122-3. October 26, 2017 6 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 (6) Tie new wire (P5335F10) to existing wiring harness using lacing tape (SS7057-2). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 20-20-02-910-002). (7) Route new wire (P5335G14) along existing wiring harness, from terminal board TB122 to M XMSN PRESS SWITCH circuit breaker (CB4004). (8) Install terminal (M7928/1-51) on end of wire (P5335G14) near terminal board TB122 on AUX CB PNL. (9) Install terminal (M7928/1-50) on end of wire (P5335G14) near M XMSN PRESS SWITCH circuit breaker (CB4004) on AUX CB PNL. (10) Install new wire (P5335G14) on terminal board TB122-3 and terminal 2 of M XMSN PRESS SWITCH circuit breaker (CB4004). (11) Tie new wire (P5335G14) to existing wiring harness using lacing tape (SS7057-2). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 20-20-02-910-002). (12) Route new wire (W4422D24) along existing wiring harness LH cockpit main (92552-01101- 046), from M XMSN PRESS SWITCH circuit breaker (CB4004) near station (STA) 180.00, Right Buttline (RBL) 10.00, Water Line (WL) 257.00, to electrical connector (J111) near STA 221.50, Left Butt Line (LBL) 28.35, WL 251.00 (Figure 4, Sheets 1 and 2). (13) Install terminal (M7928/1-9) on end of wire (W4422D24) near M XMSN PRESS SWITCH on AUX CB PNL (Figure 3). (14) Crimp contact (M39029/56-348) on end of wire (W4422D24) near electrical connector (J111). (15) Install new wire (W4422D24) to terminal 1 of M XMSN PRESS SWITCH circuit breaker (CB4004). (16) Using contact insertion tool (294-40 or equivalent), install new wire (W4422D24) on M XMSN PRESS SWITCH and electrical connector pin (J111-61). (17) Install sleeve marker (SS7094-S3-175-9) on wire (W4422D24) near electrical connector (J111). (18) Using a fine point permanent marker (commercially available or equivalent), print identification number (92552-55096-041) clearly on sleeve marker (SS7094-S3-175-9). (19) Tie new wire (W4422D24) to existing wiring harness LH cockpit main (92552-01101-046) using lacing tape (SS7057-2). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 20- 20-02-910-002). E. Install Modification Kit Left Hand Cabin Auxiliary Power Unit (M/K LH CBN APU) (92070-55096- 013) as follows: NOTE: Wiring group left hand cabin auxiliary power unit (W/G LH CBN APU) (92552-55096- 042) is a loose wire group. (1) Install W/G LH cabin APU (92552-55096-042). (2) Route new wire (W4422C24) along existing wiring harness LH cabin main (92552-02101-045), from electrical connector (P111) near STA 237.50, WL 251.00, LBL 35.00, to electrical connector (P449) near STA 237.50, WL 265.00, LBL 16.50 (Figure 5, Sheets 1 and 2). October 26, 2017 7 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 (3) Install insulating sleeve (SS7072A0063Z010) on wire (W4422C24) near electrical connector (P111) (Figure 3). (4) Crimp contact (M39029/58-360) on end of wire (W4422C24) near electrical connector (P111). (5) Crimp contact (M39029/56-351) on end of wire (W4422C24) near electrical connector (P449). (6) Using contact insertion tool (294-40 or equivalent), install new wire (W4422C24) in electrical connector pin (P449-A) and electrical connector pin (P111-61). (7) Install sleeve marker (SS7094-S3-175-9) on wire (W4422C24) near electrical connector (P111). (8) Using a fine point permanent marker (commercially available or equivalent), legibly print identification number (92552-55096-042) on sleeve marker (SS7094-S3-175-9). (9) Tie new wire (W4422C24) to existing wiring harness LH cabin main (92552-02101-045) using lacing tape (SS7057-2). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 20-20-02- 910-002). F. Install Modification Kit Left Hand Top Deck FLD (92070-55096-016) as follows: NOTE: • Wiring group XMSN (W/G XMSN) (92552-55096-043) is a loose wire group. • Some clamp set ups will require two people for removal/installation. (1) Install W/G LH top deck (92552-55096-043). (2) Route new wire (W4422B24) along existing wiring harness LH T/D main (92552-04101-046), from electrical connector (J449) near STA 250.60, WL 268.00, LBL 16.50, then along existing wiring harness top deck hums (92602-04103-043) to electrical connector (J453R), STA 364.00, WL 360.00, LBL 12.40. Cover wire with HR ½ sleeving (625300413 or equivalent) and wire braid (AA59569R36T0203 or equivalent. Terminate braid at braid terminator at rear of electrical connector J449. (Refer to Figure 6, Sheets 1 and 2). (3) Install solder sleeves (S03-02-R-100), insulating sleeves (SS7072B0093S010), and precoiled bands (600-052-1) on wire (W4422B24) (Figure 3). (4) Crimp contact (M39029/58-363) on end of wire (W4422B24) near electrical connector (J449). (5) Crimp contact (M39029/56-348) on end of wire (W4422B24) near electrical connector (J453R). (6) Using contact insertion tool (294-40 or equivalent), install new wire (W4422B24) in electrical connector pin (J449-A) and electrical connector pin (J453R-1). (7) Terminate solder sleeves (S03-02-R-100) to rings of electrical connectors (J449 and J453R). (8) Install sleeve marker (SS7094-S3-175-9) on wire (W4422B24) near electrical connector (J453R). (9) Using a fine point permanent marker (commercially available or equivalent), print identification number (92552-55096-043) clearly on sleeve marker (SS7094-S3-175-9). October 26, 2017 8 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 (10) Tie new wire (W4422B24) to existing wiring harnesses LH T/D main (92552-04101-046) and top deck hums (92602-04103-043) using lacing tape (SS7057-2). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 20-20-02-910-002). G. Install Modification Kit MGB XMSN (92070-55096-017) as follows: NOTE: • Wiring group transmission FLD (W/G XMSN FLD) (92552-55096-045) is a loose wire group. • Some clamp set ups will require two people for removal/installation. (1) Install W/G XMSN FLD (92552-55096-045). (2) Cover wire (W4422A20) with shrink tubing (SS7072E0250ZXXX) (Figure 3). (3) Route new wire (W4422A20) along existing wiring harness HUMS sensor, MGB (92602- 15100-044), from electrical connector (P453R) near STA 354.00, WL 264.00, LBL 10.80, then breakout from HUMs sensor, MGB (92602-15100-044) to route along existing wiring harness H/A transmission (92552-15101-043/-044/-045/-046 or -047) near STA 340.00, WL 269.00, LBL 16.00. (Refer to Figure 7, Sheets 1 and 2). (4) Route new wire (W4422A20) along existing wiring harness H/A transmission (92552-15101- 043/-044/-045/-046 or -047) to electrical connector (P417) near STA 309.00, WL 270.00, LBL 22.00 (Sheet 3). (5) Install solder sleeves (S03-02-R-100) on wire (W4422A20) (Figure 3). (6) Install insulated sleeves (SS7072B0093S010) on wire (W4422A20). (7) Install precoiled band (600-052-1) near electrical connector (P453R). (8) Install new splice (M81824/1-1) between jumper wire (JMPRP453R-1-22) and wire (W4422A20) at splice group (SGP453R-1). (9) Crimp contact (M39029/58-360) on end of jumper wire (JMPRP453R-1-22) near electrical connector (P453R). (10) Crimp socket contact (M39029/5-115) on end of wire (W4422A20) near electrical connector (P417). (11) Remove splice (M81824/1-2) at splice group (SGP401) from wires (W4400F20, W4400E20, and JMPRP401-U-20) (Figure 3). (12) Using contact insertion tool (294-40 or equivalent), disconnect wire (W4400E20) from electrical connector pin (P417-2). (13) Remove existing solder sleeve from shield (CGP417). (14) Install caps (324693) on wire (W4400E20) (two places). (15) Install new splice (M81824/1-1) between jumper wire (JMPRP401-U-20) and wire (W4400F20) at splice group (SGP401-1). (16) Terminate solder sleeves (S03-02-R-100) to rings of electrical connectors (P453R and P417). October 26, 2017 9 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 (17) Using contact insertion tool (294-40 or equivalent), install new jumper wire (JMPRP453R-1- 22) in electrical connector pin (P453R-1). (18) Using contact insertion tool (294-40 or equivalent), install wire (W4422A20) in electrical connector pin (P417-2). (19) Install sleeve marker (SS7094-S3-175-9) on wire (W4422A20) near electrical connector (P453R). (20) Using a fine point permanent marker (commercially available or equivalent), print identification number (92552-55096-045) clearly on sleeve marker (SS7094-S3-175-9). (21) Tie new wire (W4422A20) to existing wiring harnesses HUMS sensor, MGB (92602-15100- 044) and H/A transmission (92552-15101-043/-044/-045/-046 or -047) using lacing tape (SS7057-2). (Refer to Figure 7, Sheets 1-3, and Maintenance Manual, SA S92A-AMM-000, Task 20-20-02-910-002). H. Continue installation of M/K, PROV, AUX CB PNL (92070-55075-011) as follows (Refer to Figure 2): NOTE: • All wires routed across hinge shall be routed with minimum slack achievable while allowing for full relative motion of hinged panel. • All wires shall be routed with existing electrical mains. • Make sure sufficient slack is added to the wire routed along the hinge, between wire tie and terminal lug. This is to make sure the lug is not loaded when cover is opened. It is permissible to route wire around terminal block and tie off to surrounding wire or clamp. (1) Cut insulation tubing (SS7114FT02-0050) lengthwise and install on W/G LH CKPT APU (92552-55096-041), and tie to wire bundle using lacing tape (SS7057-2). (Refer to Sheet 1, and Maintenance Manual, SA S92A-AMM-000, Task 20-20-02-910-002). NOTE: Insulation tubing (SS7114FT02-0050) and spiral wrap (SW-31 BK005) may be trimmed as required. (2) Install spiral wrap (SW-31 BK005) over insulation tubing (SS7114FT02-0050), and install on wire bundle using lacing tape (SS7057-2). (Refer to Maintenance Manual, SA S92A-AMM- 000, Task 20-20-02-910-002). (3) Install tie down straps (MS3387-1-9) on W/G LH CKPT APU (92552-55096-041). (Refer to Maintenance Manual, SA S92A-AMM-000, Task 20-20-02-910-002). (4) Bond identification tape (SS9084-122 and SS9031-1) to AUX CB PNL as follows: (a) Thoroughly clean surface where identification tape (SS9084-122 and SS9031-1) will be bonded by wiping with a clean cheesecloth (CCC-C-440 or equivalent) moist with isopropyl alcohol (TT-I-735 or equivalent). (b) Dry surface using a clean dry cheesecloth (CCC-C-440 or equivalent). (c) Remove backing paper from adhesive and install identification tape (SS9084-122 and SS9031-1). October 26, 2017 10 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 (d) Using a roller (commercially available or equivalent), apply firm pressure to identification tape (SS9084-122 and SS9031-1) to obtain intimate contact of adhesive to the bonding surface. (5) Install clamp (AS21919DG1), flat washer (NAS1149D0363K), screw (MS27039-1-15), and spacer (NAS43DD3-32FC), using existing nutplate onto AUX CB PNL. (6) Remove screw (MS27039-1-09), nut (MS21044N3), and flat washer (NAS1149D0332K) securing clamp (MS21919WDG8) to electrical mains. (7) Install screw (MS27039-1-24), nut (MS21044N3), flat washer (NAS1149D0332K), and spacer (NAS43DD3-60FC) securing clamp (MS21919WDG9) to electrical mains. (8) Proceed to step J. I. For helicopters with S/Ns 920297 through 920304 and 920311 through 920314, perform the following modifications to enable functionality for MGB indications (Refer to Figure 8): (1) Modify auxiliary circuit breaker panel as follows: (a) Remove button plug from DC essential bus. (b) Install circuit breaker (MS3320-1) at CB4004 location on DC essential bus. (c) Remove shrink tubing from terminal lugs. (d) Reroute wire (P5335G14) from terminal bus TB122 to circuit breaker (CB4004) location on DC essential bus. (e) Install wire (P5335G14) at circuit breaker (MS3320-1) on DC essential bus. (f) Secure wire (P5335G14) to existing wiring harness bundle using lacing tape (SS7057-2). (g) Remove identification tag labeled 92070-55108-012 from circuit breaker CB4004. (2) Modify transmission harness as follows: (a) Remove splice (M81824/1-2) from jumper (JMPRP401-U-20) and wires (W4400F20 and W55108-1A-20). (b) Using contact insertion tool (294-40 or equivalent), de-pin wire (W55108-1A-20) from electrical connector P417-2. (c) Remove and discard wire (W55108-1A-20). (d) Install splice (M81824/1-1) on jumper (JMPRP401-U-20) and wire (W4400F20). (e) Remove shrink tubing from wire (W4422A20) and contact. (f) Reroute wire (W4422A20) from electrical connector P401 to electrical connector P417. (g) Terminate contact at electrical connector P417-2. (h) Install wire (W4422A20) in electrical connector P417-2. (i) Secure wire (W4422A20) to existing wiring harness bundle using lacing tape (SS7057-2). October 26, 2017 11 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 (j) Remove identification tag labeled 92070-55108-013 from electrical connector P417. J. Install Modification Kit Auxiliary Cabin Panel Faceplate (M/K, FACEPLATE, AUX CB PNL) (92070- 55075-012) as follows (Refer to Figure 2, Sheet 1): (1) Install auxiliary circuit breaker panel information plate (92550-01372-101) using screws (NAS601-6B). K. Re-identify the following components: TABLE 1 - RE-IDENTIFICATION OF REWORKED COMPONENTS Old Part Number Nomenclature New Part Number Effectivity 92207-01101-043 OVHD Panel SPRT ASSY 92080-20432-041 0031-TBD 92207-01101-137 Frame-Front 92070-20115-114 0006-0009 92207-01101-156 Frame-Front 92080-20432-102 0010-TBD 92207-01101-151 Ceiling 92080-20432-101 0006-TBD 92070-20017-041 OVHD Panel 92070-20115-041 0006-0007 92CEO-37609-041 ELEC Relay MNT ASSY 92070-20115-053 0008-0030 L. Reinstall OVHD CNSL CB PNL. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 31-10- 06-900-002). M. If removed, install duct on top LH cabin rack, top deck LHS horse collar fairing, and top deck LHS cabin heater bleed air tube. N. Perform operational check as follows: (1) Verify 28VDC power to MGB Last Jet Pressure switch electrical connector (P417) is applied to pin 2 when M XMSN PRESS SWITCH circuit breaker is pushed in. (2) Verify 28VDC power to MGB Last Jet Pressure switch electrical connector (P417) is removed when M XMSN PRESS SWITCH circuit breaker is pulled out. O. Install the following access panels: (1) Left hand air inlet cover plate. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 71- 62-05-900-002). (2) Left hand and right hand oil cooler access doors. (Refer to Maintenance Manual, SA S92A- AMM-000, Task 52-43-02-900-002). (3) Oil cooler platform. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 63-25-01-900- 004). (4) Rear cover. (Refer to Maintenance Manual, SA S92A-AMM-000, Task 54-40-01-900-004). P. Return helicopter to service. October 26, 2017 12 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 CLIPS AND BRACKETS MODIFICATIONS FIGURE 1 (SHEET 1 OF 2) October 26, 2017 13 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 CLIPS AND BRACKETS MODIFICATIONS FIGURE 1 (SHEET 2) October 26, 2017 14 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 AUX CB PANEL MODIFICATION FIGURE 2 (SHEET 1 OF 2) October 26, 2017 15 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 AUX CB PANEL MODIFICATION FIGURE 2 (SHEET 2) October 26, 2017 16 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 MGB INDICATIONS WIRING MODIFICATION FIGURE 3 October 26, 2017 17 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K LH COCKPIT AUXILIARY POWER UNIT (92070-55096-012) BEGINNING OF ROUTE FIGURE 4 (SHEET 1 OF 2) October 26, 2017 18 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K LH COCKPIT AUXILIARY POWER UNIT (92070-55096-012) END OF ROUTE FIGURE 4 (SHEET 2) October 26, 2017 19 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K LH CABIN AUXILIARY POWER UNIT (92070-55096-013) BEGINNING OF ROUTE FIGURE 5 (SHEET 1 OF 2) October 26, 2017 20 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K LH CABIN AUXILIARY POWER UNIT (92070-55096-013) END OF ROUTE FIGURE 5 (SHEET 2) October 26, 2017 21 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K LH TOP DECK FLD (92070-55096-016) BEGINNING OF ROUTE FIGURE 6 (SHEET 1 OF 2) October 26, 2017 22 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K LH TOP DECK FLD (92070-55096-016) END OF ROUTE FIGURE 6 (SHEET 2) October 26, 2017 23 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K MGB XMSN (92070-55096-017) BEGINNING OF ROUTE FIGURE 7 (SHEET 1 OF 3) October 26, 2017 24 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K MGB XMSN (92070-55096-017) BREAKOUT FROM H/A HUMS SNSR MGB IN H/A TRANSMISSION FIGURE 7 (SHEET 2) October 26, 2017 25 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 WIRE ROUTING FOR M/K MGB XMSN (92070-55096-017) END OF ROUTE FIGURE 7 (SHEET 3) October 26, 2017 26 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 MODIFICATION KIT - MGB INDICATIONS WIRING RECONNECTION FIGURE 8 October 26, 2017 27 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 Electrical Load Data: Not affected. Software Load Data: Not changed. Weight and Balance: Change resulting from these instructions is as follows: (1) Modification Kit (92070-20115-012): +0.81 lb at STA 207.3. (a) RH Circuit Breaker Panel Assembly (92070-20115-051): + 0.39 lb at STA 207.3. (b) LH Hinge (92070-20115-117): +0.08 lb at STA 207.3. (c) RH Hinge (92070-20115-118): +0.08 lb at STA 207.3. (d) Panel (92070-20115-119): +0.26 lb at STA 207.3. (2) Modification Kit (92070-55096-011): +0.39 lb at STA 232.2. (a) W/G LH CKPT APU (92552-55096-041): +0.25 lb at STA 232.2. (b) W/G LH CBN APU (92552-55096-042): +0.02 lb at STA 232.2. (c) W/G LH Top Deck (92552-55096-043): +0.05 lb at STA 232.2. (d) W/G XMSN (92552-55096-044): +0.07 lb at STA 232.2. Manpower (Estimated): Task No. of Men No. of Hours Man-hours* Prepare Documentation 1 0.25 0.25 Installation of Modification Kit 92070- 20115 Clips and Brackets 1 12.00 12.00 Installation of Modification Kit 92070- 55096 MGB Indications Wiring 2 12.00 24.00 Installation of Modification Kit 92070- 55075 Aux CB 1 10.00 10.00 Modification of Aux CB Panel 1 1.00 1.00 Modification of Transmission Harness 1 1.00 1.00 Total 48.25 *Estimate does not include time required to prepare helicopter or return it to flight status. October 26, 2017 28 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 Material Information: Q. Modification Kit Required: Qty Nomenclature Part Number Source 1 M/K Collector, MGB Indications 92070-55095-011 (1)(2) Consisting of: 1 M/K Clips and Brackets 92070-20115-015 Made up of: 1 M/K OVHD Support 92070-20115-012 Made up of: 27 Rivet CCR244CS-3-02 3 Cherry Rivet CR3214-4-03 Alternate: AF3214-4-03 3 Nutplate MS21061L08 3 Nutplate MS21076L04N 7 Nutplate MS21076L08N 3 Nutplate MS21076L3N 9 Screw MS27039-0807 14 Rivet NAS1097AD4-9 22 Washer, Flat NAS1149FN832P 14 Screw, Captive SS5301-0808 REF OVHD SPRT ASSY 92070-20115-041 REF Circuit Panel ASSY RH 92070-20115-042 1 Circuit PNL ASSY RH 92070-20115-051 REF ELEC Relay MNT ASSY 92070-20115-053 REF Hinge LH 92070-20115-101 REF Hinge RH 92070-20115-102 REF Panel 92070-20115-103 REF Frame - Front 92070-20115-114 1 Hinge LH 92070-20115-117 1 Hinge RH 92070-20115-118 1 Panel 92070-20115-119 REF OVHD SPRT INSTL 92080-20432-012 REF OVHD SPRT ASSY 92080-20432-041 REF Ceiling 92080-20432-101 REF Frame - Front 92080-20432-102 October 26, 2017 29 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 Qty Nomenclature Part Number Source 1 M/K, PROV, AUX CB PNL 92070-55075-011 Made up of: 1 Clamp AS21919DG1 3 Washer MS14151-2 1 Cover ASSY MS18029-2S-3 1 Nut MS21044N3 1 Clamp MS21919WDG9 1 Screw MS27039-1-15 1 Screw MS27039-1-24 1 Terminal MS27212-2-3 1 Circuit Breaker MS3320-1 3 Strap, Tiedown MS3367-1-9 1 Strip, MTG MS3373-A2 1 Strip, MTG MS3373-B2 2 Screw MS35206-217 3 Washer, Lock MS35338-138 3 Nut MS35650-304 3 Washer, Flat NAS1149C0332R 1 Washer, Flat NAS1149D0332K 1 Washer, Flat NAS1149D0363K 1 Spacer NAS43DD3-32FC 1 Spacer NAS43DD3-60FC 7 Plug, Button SFHP5006L01BK 2 FT Tape, Lacing SS7057-2 1 Tubing, INSUL SS7114FT02-0050 1 Tape, IDENT SS9031-1 1 Tape, IDENT SS9084-122 0.5 FT Spiral Wrap SW-31 BK005 1 M/K, Faceplate, AUX CB PNL 92070-55075-012 Made up of: 4 Screw NAS601-6B 1 INFO Plate, AUX CB PNL 92550-01372-101 1 M/K MGB INDICS 92070-55096-011 Consisting of: October 26, 2017 30 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 Qty Nomenclature Part Number Source 1 M/K LH CKPT APU 92070-55096-012 Made up of: 2 Contact M39029/56-348 1 Terminal M7928/1-50 1 Terminal M7928/1-51 1 Terminal M7928/1-65 1 Terminal M7928/1-67 1 Terminal M7928/1-9 16 FT Tape, Lacing SS7057-2 1 Sleeve Marker SS7094-S3-175-9 1 W/G LH CKPT APU 92552-55096-041 1 M/K LH CBN APU 92070-55096-013 Made up of: 2 Contact M39029/56-351 2 Contact M39029/58-360 7 FT Tape, Lacing SS7057-2 2 Sleeve, INSUL SS7072A0063Z010 1 Sleeve Marker SS7094-S3-175-9 1 W/G LH CBN APU 92552-55096-042 1 M/K LH Top Deck FLD 92070-55096-016 Made up of: 2 Contact M39029/56-348 2 Contact M39029/58-363 2 Solder Sleeve #2, With Braid S03-02-R-100 20 FT Tape, Lacing SS7057-2 2 Sleeve, INSUL SS7072A0063Z010 1 Sleeve, INSUL SS7072A0125Z030 2 Sleeve, INSUL SS7072B0093S010 1 Sleeve Marker SS7094-S3-175-9 2 Band, Precoiled 600-052-1 1 W/G LH Top Deck 92552-55096-043 1 M/K MGB XMSN FLD 92070-55096-017 Made up of: October 26, 2017 31 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 Qty Nomenclature Part Number Source 2 Contact, Socket M39029/5-115 2 Contact M39029/58-360 2 Splice M81824/1-1 2 Solder Sleeve #2, With Braid S03-02-R-100 20 FT Tape, Lacing SS7057-2 2 Sleeve, INSUL SS7072B0093S010 10 FT Sleeve, INSUL SS7072E0250ZXXX 1 Sleeve Marker SS7094-S3-175-9 3 Cap 324693 1 Band, Precoiled 600-052-1 1 W/G XMSN 92552-55096-045 1 Circuit Breaker MS3320-1 (2)(3) 1 Splice M81824/1-1 (2)(3) R. Consumable Materials: Qty Nomenclature Part Number Source A/R Tape, PTFE Film 3M-60 or equivalent (4) A/R HR ½ Sleeving 625300413 or equivalent (4) A/R Tape A-A-59163 or equivalent (4) A/R Low Lint Cloth A-A-59323 or equivalent (4) A/R Wire Braid AA59569R36T0203 or equivalent (4) A/R Sealing Compound AMS 3265 or equivalent (4) A/R Cheesecloth CCC-C-440 or equivalent (4) A/R Tape DMYNO-6A669-001 or equivalent (4) A/R Chemical Conversion Coating MIL-DTL-5541 Class 3 or equivalent (4) 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 DEPARTMENT OR THE MANUFACTURER OF THE CONSUMABLE. October 26, 2017 32 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 Qty Nomenclature Part Number Source A/R Epoxy Primer MIL-PRF-23377 or equivalent (4) A/R Black Paint MIL-PRF-85285, FED-STD-595 color no. 37038 or equivalent (4) 2 FT Tape, Lacing SS7057-2 (4) A/R Isopropyl Alcohol TT-I-735 or equivalent (4) A/R Epoxy Primer Alternate: Axalta (Formerly DuPont) Corlar 13580S or equivalent (5) S. Support Equipment: Qty Nomenclature Part Number Source 1 Milliohmmeter R1L-E2 or equivalent (4) T. Tooling Required: Qty Nomenclature Part Number Source 1 Contact Insertion Tool 294-40 or equivalent (4) 1 Fine Point Permanent Marker Commercially available or equivalent (4) 1 Roller Commercially available or equivalent (4) U. Source: (1) Modification kit collector, MGB indications (92070-55095-011) contains: (a) Modification kit auxiliary circuit breaker panel provision (92070-55075-011). (b) Modification kit auxiliary cabin panel faceplate (92070-55075-012). (c) Modification kit MGB indications (92070-55096-011). (d) Modification kit MGB XMSN FLD (92070-55096-017). (e) Modification kit clips and brackets (92070-20115-015). (f) Modification kit MGB indications wiring (92070-55107-011). (2) For parts availability and lead time requirements, contact your Customer Service Representative at Sikorsky Commercial Inc. (SCI). Submit a no-cost purchase order referencing this SSI number and the helicopter serial number(s) on which these parts will be used. This will allow SCI and the operator to track shipment and receipt of parts. Orders will be accepted by letter, telephone, facsimile (FAX) or through the SCI website: October 26, 2017 33 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. SPECIAL SERVICE INSTRUCTIONS NO. 92-121 https://customerportal.sikorsky.com. For prompt shipment, reference address of each shipping destination. Direct your order to: Sikorsky Aircraft Corporation Commercial Systems and Services Mailstop K100 124 Quarry Road Trumbull, CT 06611 U.S.A. Attn: Account Service Manager FAX: (203) 416-4291, Telephone: (203) 416-4000 3 3 T U 3 3 T U 3 3 T U https://customerportal.sikorsky.comU U U 3 3 T 3 3 T 3 3 (3) For helicopters with S/Ns 920297 through 920304 and 920311 through 920314. (4) Available through normal supply channels. (5) Available through: Merritt Marine Supply Website: http://www.merrittsupply.com V. Record of compliance: (1) Make helicopter logbook entries to show compliance with this SSI as follows: (a) When SSI modifies a component that can be removed from this helicopter: 1 Make component log card entries on forms SA7343-22 (Aircraft Component Log Cards) & SA7343-21 (Component Log Cards), as applicable. 2 If a component modified by this SSI does not have a log card and the SSI does not create one, then annotate compliance on the next higher assembly that the component belongs to which does have a log card. (2) Upon compliance with this SSI, complete attached SPECIAL SERVICE INSTRUCTIONS COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation. October 26, 2017 34 This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. (Fold over and tape closed) SIKORSKY AIRCRAFT CORPORATION FACSIMILE NUMBER (817) 762-6715 EMAIL ADDRESS: product_safety.gr-sik@lmco.com ATTENTION: Gr-SIK, Product_Safety SIKORSKY AIRCRAFT CORPORATION (Fold Up to Arrows) IMPORTANT NOTICE Upon COMPLIANCE with the attached SSI, Sikorsky requests your cooperation in completing and returning this ENTIRE PAGE by MAIL, FAX, or scan & EMAIL. 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. SPECIAL SERVICE INSTRUCTION: ________________ Compliance Record Card TITLE: ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ OWNER/OPERATOR: _____________________________________________________ SUBMITTED BY: ___________________________ DATE: ____________________ FOLLOWING SERIAL NUMBERS ARE NOT AFFECTED BY THIS SSI SSI HAS BEEN COMPLIED WITH ON HELICOPTER SERIAL NUMBERS: ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ ___________ No. 92-121 ROTOR DRIVES – Main Gearbox (MGB) Oil Pressure, Temperature, and Pump Warning – Installation of Auxiliary Circuit Breaker Panel and M XMSN PRESS SWITCH Circuit Breaker Modification Kits This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page. No Postage Necessary BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT NO. 432 BRIDGEPORT CT POSTAGE WILL BE PAID BY ADDRESSEE SIKORSKY AIRCRAFT CORPORATION Commercial Systems and Services Mailstop K100 124 QUARRY ROAD TRUMBULL, CT 06611 U.S.A. ATTENTION: Gr-SIK, Product_Safety Please complete the form on the reverse side and FAX to FACSIMILE NUMBER (817) 762-6715 Or scan and email to: EMAIL ADDRESS: product_safety.gr-sik@lmco.com or fold and return ENTIRE form to Sikorsky Aircraft Corporation This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.