DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

1 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Background: Reference Drawings 76209-03001-041/042 through -057/-058, Fitting Assembly, Support Transmission - Center Section

Rev-1

A production condition was identified where one Hi-Lok fastener collar on each LHS/RHS beam (aft fastener hole) was found to fall in the radius of the beam fitting at Station 215, Water Line 121 and Butt Line 17. Further inspection of other airframes in process has showed the same issue (see Figure 1 through Figure 3). Root Cause investigation shows the blueprint for the machining of the beams indicates a 0.250 inch radius. The pilot hole position is adjacent the radius (Figure 3). The assessment indicates the fastener collar, when installed, is likely to interfere with the radius of the beam. The Corrective Action for new production is to have the pilot-hole position moved away from the radius while maintaining the proper fastener pitch and edge distance and the part becomes the 76209-03001059/060. For installed MGB support beams (76209-03001-041/042 through -057/058) identified with the Rev-1 interference condition, such that the maximum gap under the fastener collar exceeds 0.001 inches, then the corrective action is to have a radius block manufactured and installed, protecting the radius of the beam. The radius block will use the affected fastener hole and an adjacent fastener (as needed). This repair corrects installed MGB support beams identified to have the Hi-Lok fastener collar interfere with the LHS or RHS beam radius (Figure 1) by installing a radius block, protecting the beam radius, using the affected fastener hole and an adjacent fastener (Figure 6 and Figure 7) as needed.

Figure 1 Hi-Lok fastener found in aft radius of 76209-03001-057/058 (LHS/RHS) beam

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

2 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Figure 2 Fastener pilot hole found in aft radius of 76209-03001-057/058 (LHS/RHS) beam

Figure 3 Pilot hole location (circled) found with fastener in radius of 76209-03001 (LHS/RHS) beam

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

3 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Repair Procedure: This repair corrects installed MGB support beams identified to have the Hi-Lok fastener collar interfere with the LHS or RHS beam radius (Figure 1, Figure 2, and Figure 3). The repair data contained in this document is classified as Minor, 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 relevant EU registered helicopter or component to service. Note: This repair must be inspected and approved by FAA inspection personnel or their authorized representative as defined by CFR 43.7 and 43.17, or other requirements as defined by the applicable regulations in the nation of aircraft registry. 1. Prepare the ship for ground maintenance. 2. Gain access to the repair area and inspect visually the subject fastener (LHS & RHS) shown in Figure 1 Rev-1 and Figure 3 using adequate light and mirrors to look for the interference condition (see Figure 5). If the interference is observed between the collar and the radius of the beam (as seen in Figure 5) then the maximum gap dimension under the Hi-Lok collar must be measured. Measure the gap under the subject collar using a steel feeler gage (see below) with thickness 0.001 +/- 0.0001 inches thick that has been made to be at least 2 inches long and 0.5 inches wide with one half having a linear tapered width down to 3/32 max (about the fastener pin diameter). If the tapered end of the feeler gauge CANNOT be inserted any amount between the beam radius and the collar then the gap is acceptable and no further repair action is necessary. However, if the feeler gauge CAN be inserted any amount between the beam radius and the collar then the gap is un-acceptable and completion of this repair is needed.
2.0 min. 1.0 min.

~ 0.5 3/32 max.

Figure 4 Steel Feeler Gauge 0.0010 inches thick made from High Carbon Steel or Stainless Steel (302/304) Flat Shim Stock. PREFERRED Option Radius block that incorporates two fasteners 3. Remove the fastener causing interference with radius from the repair area as shown in Figure 1 and Figure 3. Also remove the adjacent fastener (illustrated in Figure 6 and Figure 7) because two fasteners

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

4 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

are needed to attach the radius block. Take care not to damage the fastener holes or neighboring structure. 4. Remove paint and sealant material in the repair area as needed per the Maintenance Manual, using paint stripper (CeeBee R-256, MIL-R-81294, or equivalent) and non-metallic scraper to expose a smooth and continuous surface. Vacuum the area to remove any loose particles. Inspect the repair area for corrosion or damage. If any corrosion or damage is found, contact Sikorsky for additional repair instructions. 5. Clean the repair area per the Maintenance Manual in preparation for Fluorescent Penetrant Inspection (FPI) of the beam radius and fastener hole found with fastener collar interference. Perform FPI per the Maintenance Manual instructions. If any cracks are identified and are confirmed by a second FPI inspection then, contact Sikorsky Aircraft to report findings and request instructions for a replacement beam that will be required before further flight. 6. Degrease the repair area by wiping with a low-lint cleaning cloth (conforming to A-A-59323, Type II) using acetone (conforming to ASTM D329) or ethyl alcohol (conforming to A-A-51693). Wash with clean water to a water-break free condition and blow dry with compressed air. 7. Fabricate the radius block(s) using Al 7075-T6 per AMS-QQ-A-250 AlClad sheet 0.040 inch thick. Next thickness sheet may be used as needed to provide better edge distance and fastener support against the radius of the beam. Measure the beam flange width, length, and radii that will accommodate the radius block illustrated in Figure 6. The width of the radius block is the same as the beam flange. The length is as required to provide proper edge distance for the two fasteners (the discrepant fastener plus the adjacent fastener). The edges that nest into the radii of the beam (aft and in-board) should be matched with those measured for the beam as required to provide a smooth and continuous contact with the radii of the beam. Break all sharp edges 0.005 0.015R (inches). Bruch Alodine per SS8693. Prime with 2 coats Primer MIL-PRF-85582 per SS8555. 8. Inspect radius block per the instructions above. 9. Measure fastener hole diameters in the beam to assure proper hole diameters exists to provide interference fit with replacement Hi-Lok fasteners. Single oversize fasteners may be used as needed to provide interference fit. Locate radius block to pick-up the two fasteners and to assure a proper fit exists (as illustrated in Figure 6) that assures a smooth and continuous contact with the radii of the beam. Mark fastener hole locations on the radius block then drill and finish ream holes as needed to accommodate the Hi-Lok fasteners with interference fit. 10. Select same type Hi-Lok fasteners and collars (with captivated washer) with the proper grip length to accommodate the radius block. Seal mating surfaces on install using AMS-3265. Wet install fasteners using AMS-3265. 11. Touch-up radius block as required. 12. Apply two coats of MIL-P-23377 epoxy primer to the repair area

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

5 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Figure 5 Transmission Beam Visual Using Adequate Light and Mirrors to See the Interference Condition on the Beam.

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

6 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Figure 6 Transmission Beam Radius Block to Eliminate Interference between Fastener Collar and the Radius of Beam (LHS/RHS) Beam Fitting

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

7 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Figure 7 Fastener locations, indicated by triangle and circle, to be used to attach radius block for 76209-03001 (LHS/RHS) beams

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

8 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

2nd Option Radius block that incorporates one fastener Rev-1 3. Remove the fastener collar causing interference with radius from the repair area as shown in Figure 3. Take care not to damage the fastener or neighboring structure. If the fastener is un-damaged do not remove the fastener. A reduce height collar (see step 9) will be used to accommodate the radius block with the existing fastener. If the fastener is damaged then a replacement Hi-Lok fastener is required. 4. Remove paint and sealant material in the repair area as needed per the Maintenance Manual, using paint stripper (CeeBee R-256, MIL-R-81294, or equivalent) and non-metallic scraper to expose a smooth and continuous surface. Vacuum the area to remove any loose particles. Inspect the repair area for corrosion or damage. If any corrosion or damage is found, contact Sikorsky for additional repair instructions. 5. Clean the repair area per the Maintenance Manual in preparation for Fluorescent Penetrant Inspection (FPI) of the beam radius and fastener hole found with fastener collar interference. Perform FPI per the Maintenance Manual instructions. If any cracks are identified and are confirmed by a second FPI inspection then, contact Sikorsky Aircraft to report findings and request instructions for a replacement beam that will be required before further flight. 6. Degrease the repair area by wiping with a low-lint cleaning cloth (conforming to A-A-59323, Type II) using acetone (conforming to ASTM D329) or ethyl alcohol (conforming to A-A-51693). Wash with clean water to a water-break free condition and blow dry with compressed air. 7. Fabricate the radius block(s) using Al 7075-T6 per AMS-QQ-A-250 AlClad 0.040 inch minimum thickness as needed to accommodate the final required grip length. Measure the beam flange radius, width, and length that will accommodate the radius block illustrated in Figure 9 and Figure 10. The width of the radius block is no wider than the beam flange. The length is as required to provide proper edge distance for the one fastener (the discrepant fastener). The edges that nest into the radii of the beam (aft and in-board) should be very carefully matched with those measured for the beam as required to provide a smooth and continuous contact with the radii of the beam. Break all sharp edges 0.005 0.015R (inches). Bruch Alodine per SS8693. Prime with 2 coats Primer MIL-PRF-85582 per SS8555. 8. Inspect radius block per the instructions above. 9. Measure fastener grip length required to select the radius block thickness that will provide proper thread engagement using a NASM21043 collar. No washer is needed since the radius block acts as a washer required for a Hi-Lok fastener. Locate radius block to pick-up the fastener and to assure a proper fit exists (as illustrated in Figure 11) that assures a smooth and continuous contact with the radii of the beam. Mark fastener hole locations on the radius block then drill and finish ream holes as needed to accommodate the Hi-Lok fasteners with interference fit. 10. Select NASM21043 fastener collar that will accommodate the existing fastener and the radius block. Seal mating surfaces on install using AMS-3265. Wet install collar using AMS-3265. Torque the NASM21043 collar to 30-40 inch-pounds. 11. Touch-up radius block as required. 12. Apply two coats of MIL-P-23377 epoxy primer to the repair area

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

9 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Figure 8 Transmission Beam shown with one fastener collar removed

Figure 9 Single Fastener Radius Block options.

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

10 PAGE

DRB 2010-SA-76-010 Rev-1 Repair of Interference Hi-Lok fastener with beam radius on S-76 MGB Support Beam attachment

Figure 10 Single Fastener Radius Block options (side view).

Figure 11 Single Fastener Radius Block installed.

PREPARED BY D. Tritsch

CHECKED BY D. Tritsch

DATE Sept. 17, 2010 Rev-1

11 PAGE