AD 2013-20-15 Airworthiness Directives; Sikorsky Aircraft Corporation-Manufactured (Sikorsky) Model Helicopters (Type Certificate Currently Held by Erickson Air-Crane Incorporated)

This AD supersedes AD 97-19-10, Amendment 39-10130 (62 FR 47933, September 12, 1997).

(1) Before further flight, for each part listed in Table 1 to paragraph (f) of this AD: (i) Remove any part that has reached or exceeded its newly established or revised retirement life. (ii) Record the newly established or revised retirement life for each part on the component history card or equivalent record. (iii) Make pen and ink changes or insert a copy of this AD into the Airworthiness Limitations section of the maintenance manual to establish or revise the retirement life for each part that is listed in Table 1 to paragraph (f) of this AD. Table 1 to Paragraph (f) of This AD—Parts With New or Revised Life Limits Part name Part No. (P/N) Retirement life Rod and bushing assembly, main rotor (M/R) 6410-21090-012 5,700 hours time-in-service (TIS) or 60 months since the initial installation on any helicopter, whichever occurs first. Rod and bushing assembly, M/R 6410-21090-013 or -014 5,700 hours TIS. Lower plate, M/R hub 6410-23009-102 3,000 hours TIS. Upper plate, M/R hub 6410-23011-102 3,000 hours TIS. Swashplate, rotating, M/R 6410-24002-101 12,860 hours TIS. Piston rod 6410-26005-104 10,500 hours TIS. Cylinder, damper assembly 6410-26215-101 7,300 hours TIS. M/R blade 6415-20201-045 or -047 3,300 hours TIS. M/R blade 6415-20201-048, -049, -050, or -051 20,000 hours TIS. Truss assembly, stabilizer 6420-66250-041 4,720 hours TIS. M/R shaft assembly (includes shaft, P/N 6435-20078-104) 6435-20078-014 or -015 2,600 hours TIS. M/R shaft assembly (includes shaft, P/N 6435-20078-105) 6435-20078-016 5,000 hours TIS. Second stage planetary plate assembly, main gearbox assembly 6435-20231-012, -014, or -015 1,300 hours TIS. Second stage planetary plate assembly, main gearbox assembly 6435-20231-016 2,600 hours TIS. Oil cooler and support assembly 6435-60050-044 9,885 hours TIS. Tail rotor (T/R) blade 65160-00001-042, -045, or -048 23,300 hours TIS. T/R blade 65161-00001-042 23,300 hours TIS. Hub, M/R S1510-23001-005 3,000 hours TIS. Spindle assembly, M/R S1510-23027-5 5,675 hours TIS. Horn assembly, M/R S1510-23350-4, -6, or -8 9,710 hours TIS. Sleeve, M/R S1510-23351-2 12,930 hours TIS. Sleeve lockwasher, M/R S1510-23458-0 2,700 hours TIS. Cuff, M/R blade S1515-20320-0 6,410 hours TIS. Cuff, M/R blade S1515-20320-001 or -002 12,930 hours TIS. Piston assembly, M/R tandem servo S1565-20443-0 or S1565-20443-301 8,100 hours TIS. Fork assembly, M/R tandem servo S1565-20449 or S1565-20449-301 8,100 hours TIS. Bearing, T/R drive shaft SB1111-004 or -601 1,000 hours TIS or 12 months while installed on any helicopter, whichever occurs first. Note to Table 1 to paragraph (f) of this AD: The list of parts in Table 1 to paragraph (f) of this AD contains only a portion of the life-limited parts for this model helicopter and is not an all-inclusive list. (2) Before further flight, remove from service any part with a P/N listed in Table 2 to Paragraph (f) of this AD, regardless of the part's TIS. The part numbers listed in Table 2 to paragraph (f)(2) of this AD are not eligible for installation on any helicopter. Table 2 to Paragraph (f) of This AD—Parts To Be Removed From Service Part name P/N Rod and bushing assembly, M/R 6410-21090-011. M/R blade 6415-20001-013, -014, or -015. Pylon stabilizer 6420-66201-010, -014, or -015. M/R shaft assembly 6435-20078-013. Oil cooler and support assembly 6435-60050-043. Pitch change link, rotary rudder 65113-07100-046. Spindle, M/R blade S1510-23070-3. (3) Within 20 hours TIS, and thereafter at intervals not to exceed 20 hours TIS, visually inspect each M/R servo and control arm assembly, P/N S1565-20421-10, -11, -041, or -043, and determine if there is any oil leaking from the M/R tandem servo housing assembly (servo housing), P/N S1565-20252-2. If there is any oil leaking from the servo housing, before further flight, replace the M/R servo and control arm assembly. (4) Within 20 hours TIS or before reaching 1,120 hours TIS, whichever occurs later, and thereafter at intervals not to exceed 200 hours TIS or 12 months, whichever occurs first, ultrasonic (UT) inspect each M/R hub horizontal hinge pin (hinge pin), P/N S1510-23099-1 or P/N S1510-23099-001, for a crack in accordance with the Accomplishment Instructions, paragraphs 2.A through 2.C, of Erickson Service Bulletin No. 64B10-3, Revision D, dated October 15, 2007, except you are not required to contact Erickson nor send hinge pins to them. A non-destructive testing (NDT) UT Level I Special, Level II, or Level III inspector who is qualified under the guidelines established by ASNT SNT-TC-1A, ISO 9712, or an FAA-accepted equivalent qualification standard for NDT inspection and evaluation, must perform the UT inspection. (5) Within 150 hours TIS or before reaching 1,450 hours TIS, whichever occurs later, perform a fluorescent-magnetic particle inspection (MPI) of each second stage planetary plate assembly, P/N 6435-20231-016, for a crack. (6) Within 150 hours TIS or before reaching 1,450 hours TIS, whichever occurs later, and thereafter at intervals not to exceed 650 hours TIS, perform an MPI of each M/R shaft, P/N 6435-20078-104, for a crack, paying particular attention to the lower spline area. (7) Within 150 hours TIS or before reaching 1,450 hours TIS, whichever occurs later, and thereafter at intervals not to exceed 1,450 hours TIS, perform an MPI of each M/R shaft, P/N 6435-20078-105, for a crack, paying particular attention to the lower spline area. (8) Within 150 hours TIS or before reaching 3,375 hours TIS, whichever occurs later, and thereafter at intervals not to exceed 3,375 hours TIS, perform a fluorescent penetrant inspection of each housing lug on each servo housing, P/N S1565-20252-2, for a crack. (9) At each overhaul of the main gearbox assembly, P/N 6435-20400-053, -054, -058, -060, -062, -063, -064, -065, or -066, perform an MPI of the entire shaft of each M/R shaft assembly, P/N 6435-20078-014, -015, or -016, for a crack, paying particular attention to the rotating swashplate spherical bearing ball travel area, which is located approximately ten inches above the upper roller bearing journal shoulder. (10) If there is a crack in any part, before further flight, replace the cracked part. (11) At each overhaul of the damper assembly, P/N 6410-26200-042, replace the following parts with airworthy parts that have zero (0) hours TIS: (i) All Air Force-Navy Aeronautical Standard (AN), Aerospace Standard (AS), Military Standard (MS), and National Aerospace Standard (NAS) nuts, bolts, washers, and packings, except packing, P/N MS28775-011, installed on stud, P/N SHF111-11SN-12A; (ii) Lock washer, P/N SS5073-2; (iii) Nut, P/N SS5081-05; (iv) Felt seal, P/N S1510-26017; (v) Retaining ring, P/N UR106L; and (vi) Nut, P/N 6410-26214-101.

(1) The Manager, Rotorcraft Certification Office, FAA, may approve AMOCs for this AD. Send your proposal to: Michael Kohner, Aerospace Engineer, Rotorcraft Certification Office, Rotorcraft Directorate, FAA, 2601 Meacham Blvd., Fort Worth, TX 76137; telephone (817) 222-5170; email 7-avs-asw-170@faa.gov. (2) For operations conducted under a 14 CFR part 119 operating certificate or under 14 CFR part 91, subpart K, we suggest that you notify your principal inspector, or lacking a principal inspector, the manager of the local flight standards district office or certificate holding district office before operating any aircraft complying with this AD through an AMOC.

You are responsible for performing each action required by this AD within the specified compliance time unless it has already been accomplished prior to that time.

This AD defines the unsafe condition as fatigue cracking in a flight critical component, failure of the component, and subsequent loss of control of the helicopter.