September 17, 2009

TRANSMITTAL SHEET

Subject: ALERT SERVICE BULLETIN NO. 76-66-49A, POWERTRAIN - Main Gear Box (MGB) - One-
Time Oil Analysis of

This page transmits Revision A to Alert Service Bulletin No. 76-66-49 dated September 09,
2009.

Alert Service Bulletin No. 76-66-49A supersedes basic Alert Service Bulletin No. 76-66-49.

The text changed by this revision is indicated by a vertical line in the outer margin of the page.
Illustration changes are indicated by a vertical line adjacent to the subject title.

REVISION INSTRUCTIONS:

Operators that have previously complied with the original released Alert Service Bulletin No. 76-
66-49 dated September 09, 2009 are not affected by Revision A.

Operators that have not complied with original released Alert Service Bulletin No. 76-66-49
dated September 09, 2009 must comply with Revision A in its entirety.

Revision Feature:

Reason for revision:

In paragraph 1., PLANNING INFORMATION - Effectivity - Section A., Added 9with the
following components installed in a helicopter that is in service9.

In paragraph 1., PLANNING INFORMATION - Effectivity - Section A., Component:, Added

76351-09000, 76351-09500, and 76351-09600 series main gearbox assemblies.

In paragraph 1., PLANNING INFORMATION - Compliance - Section D, Added Steps (1) and
(2).

In paragraph 1., PLANNING INFORMATION - Publications Affected - Section L, Added Steps

(1), (2) and (3).

In paragraph 3., ACCOMPLISHMENT INSTRUCTIONS - Record of Compliance - Section B,

Added suffix A to ASB No. 76-66-49.

In paragraph 3., ACCOMPLISHMENT INSTRUCTIONS - Record of Compliance - Section C,

Added telephone Nos.

SIKORSKY AIRCRAFT
Technical Directives Section

1 of 1
THIS ALERT SERVICE BULLETIN IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION AND IS PROTECTED UNDER THE COPYRIGHT LAWS OF THE UNITED
STATES AND OTHER COUNTRIES. THIS ALERT SERVICE BULLETIN IS DISTRIBUTED ONLY TO OWNERS/OPERATORS OF COMMERCIALLY-CERTIFIED SIKORSKY
S76 HELICOPTERS AND SIKORSKY-AUTHORIZED LOGISTIC AND SERVICE CENTERS FOR THE PURPOSE OF FOSTERING THE SAFE AND EFFICIENT OPERATION
OF SUCH HELICOPTERS AND UNDER THE EXPRESS CONDITION THAT THE CONTENTS OF THIS ALERT SERVICE BULLETIN ARE NOT TO BE DISCLOSED,
REPRODUCED, OR DISTRIBUTED, IN WHOLE OR IN PART, TO ANY THIRD PARTY, OR ADAPTED AS A DERIVATIVE WORK, WITHOUT THE EXPRESS DOCUMENTED
CONSENT OF SIKORSKY AIRCRAFT CORPORATION. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL AND/OR CRIMINAL PENALTIES.

LIMITED DISTRIBUTION R SIKORSKY AIRCRAFT CORPORATION 1999

ALL RIGHTS RESERVED

No. 76-66-49A

Subject: POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

1. PLANNING INFORMATION

A. Effectivity

All S-76 model helicopters delivered prior to the release date of this Alert Service Bulletin
(ASB) with the following components installed in a helicopter that is in service.

Component:

(1) 76351-09000 Series Main Gear Boxes.

(2) 76351-09500 Series Main Gear Boxes.

(3) 76351-09600 Series Main Gear Boxes.

B. Purpose

To perform and review a one-time Spectrographic Oil Analysis Program (SOAP) analysis of
MGB oil. A MGB was removed from service due to a high level of titanium in MGB oil.
MGB disassembly revealed the spur gear assembly to have a complete loss of nut pre-
load on the inner bottom web attachment hardware resulting in heavy wear and fretting on
the Titanium web plates.

C. Description

Helicopter is prepared for maintenance. Overhead access panel in baggage compartment is

removed or right MGB fairing is removed. MGB magnetic drain plug is removed or oil filler
with strainer is removed. Oil sample is taken from MGB. Magnetic drain plug is installed
and lockwired, or oil filler and strainer is installed and lockwired. Oil sample is sent to a
certified laboratory for SOAP analysis. MGB is serviced, overhead access panel in baggage
compartment is installed, or right MGB fairing is installed. Helicopter is returned to service.

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 No. 76-66-49A

POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

1. PLANNING INFORMATION (Continued)

D. Compliance

Compliance is essential.

(1) For a MGB installed in a helicopter and the helicopter is in service the following is
required:

(a) One-time SOAP analysis outlined herein, which includes oil sample taken, report
returned from lab, and a review of the titanium level in the MGB is to be accomplished
no later than 100 flight hours or 60 calendar days from the issue date of this ASB, or
before a scheduled MGB oil change, whichever occurs first.

(b) If MGB oil has been changed, allow up to 50 hours to accumulate on new oil before
taking oil sample for analysis, but do not exceed the 60 calendar day limit.

(c) If results of oil analysis show presence of titanium at 15 ppm or greater, MGB must be
removed from service before next flight.

(d) Recurring inspection shall be performed every 100 flight hours if oil analysis results
show a titanium count greater than 1.0 ppm but less than 15 ppm.

(2) For a MGB not in service and a MGB in a helicopter that is in storage or long-term
maintenance; will be covered by a future temporary revision against Chapters 5, 10 and
66 of the applicable Maintenance Manual.

E. Approval

Inspection Item.

F. Manpower (Estimated)

No. of Men No. of Hours *Man-Hours

Take MGB Oil Sample 1 2.0 2.0

*Estimate does not include time required to prepare helicopter or return it to flight status.

G. Material

None.

H. Tooling

(1) Drain Attachment, D734 (Technical Development Corp.), or equivalent.

(2) 10 Gallon container (minimum), or equivalent.

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POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

1. PLANNING INFORMATION (Continued)

(3) Plastic tube, or equivalent.

(4) Screw-top oil sample jar, typical 60 ml (approximately 2 oz.), or equivalent.

I. Weight and Balance

None.

J. Electrical Load Data

Not Affected.

K. References

Applicable Maintenance Manual.

L. Publications Affected

(1) Temporary Revisions will be issued against applicable Maintenance Manual, Chapter 5, at
a later date.

(2) Temporary Revisions will be issued against applicable Maintenance Manual, Chapter 10,
at a later date.

(3) Temporary Revisions will be issued against applicable Maintenance Manual, Chapter 66,
at a later date.

M. Attachments

None.

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 No. 76-66-49A

POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

2. MATERIAL INFORMATION

A. Basis for Material Data

Per helicopter.

B. Bill of Material

None.

C. Consumable Material

OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN

WARNING
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.

INSTRUCTIONS/
QTY KEY WORD NOMENCLATURE DISPOSITION
AS REQ’D LUBRICATING OIL DOD-L-85734 (1)
OR EQUIVALENT

(1) Locally procure.

3. ACCOMPLISHMENT INSTRUCTIONS

A. Perform a one-time SOAP analysis of MGB oil as follows:

NOTE: Oil sample must be drawn from MGB between 30 minutes and 1 hour after shutdown.

(1) Prepare helicopter for maintenance.

NOTE: There are two methods for taking oil samples from the MGB; one method is by
accessing MGB oil from the MGB drain plug as shown in step (2), and the
alternate method is by accessing MGB oil from the MGB oil filler as shown in
step (3).

(2) Take oil sample from MGB drain plug as follows:

(a) Open baggage compartment and remove overhead access panel. Refer to applicable
Maintenance Manual.

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POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

3. ACCOMPLISHMENT INSTRUCTIONS (Continued)

(b) Place 10 gallon (minimum) container, or equivalent under MGB magnetic drain plug.

NOTE: The intent of this procedure is not to drain the oil from the MGB, only take as
much oil as needed to submit for SOAP analysis.

(c) Remove magnetic drain plug and install Drain Attachment (D734, or equivalent).

(d) Place screw-top oil sample jar, or equivalent into oil stream until oil sample jar is
nearly full.

(e) Remove Drain Attachment (D734, or equivalent) and install magnetic drain plug into
MGB and lockwire.

(3) Alternate method of taking oil sample from MGB oil filler is as follows:

(a) Remove right MGB fairing. Refer to applicable Maintenance Manual.

CAUTION MAKE SURE FOD DOES NOT ENTER MGB WHEN REMOVING
OIL FILLER AND STRAINER AND TAKING OIL SAMPLE FROM
MGB.

(b) Remove oil filler with strainer. Refer to applicable Maintenance Manual.

(c) Extract oil sample using plastic tube, or equivalent and transfer to oil sample jar.

CAUTION MAKE SURE FOD DOES NOT ENTER MGB WHEN

INSTALLING OIL FILLER AND STRAINER.

(d) Install oil filler with strainer and lockwire fitting. Refer to applicable Maintenance Manual.

(4) Secure top onto oil sample jar and identify oil sample with information: MGB Oil Analysis
Data Sheet

NOTE: • A laboratory capable of providing an oil analysis of less than one parts-per-
million (PPM) of titanium is to be used. Sikorsky Aircraft recommends Jet-Care,
located in the USA and Spectro located in the United Kingdom and Switzerland
as labs that meet this requirement.
• Presence of titanium shall be the primary focus of certified laboratory’s oil
analysis and shall be expressed in parts per million (ppm).
• Operator shall request immediate notification from certified laboratory when oil
analysis shows presence of titanium at 1.0 ppm or greater.

(5) Forward oil sample jar to a certified laboratory for oil analysis, once results are received
back from the lab proceed as follows:

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POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

3. ACCOMPLISHMENT INSTRUCTIONS (Continued)

(a) If results of oil analysis show presence of titanium at less than 1.0 ppm, no further
action is required, proceed to step 6.

NOTE: Operator shall notify Customer Service Engineering at 1-800-Winged-S or 1-

203-416-4299 upon receiving notification from certified laboratory that oil
analysis has shown presence of titanium at 1.0 ppm or greater.

(b) If results of oil analysis show presence of titanium greater than 1.0 ppm but less than
15 ppm, MGB oil must be monitored by taking MGB oil sample every 100 flight hours.

(c) If results of oil analysis show presence of titanium at 15 ppm or greater, MGB must be
removed from service. Proceed to section B.

(6) Service MGB with lubricating oil (DOD-L-85734, or equivalent), refer to applicable
Maintenance Manual.

(7) Install overhead access panel in baggage compartment, or install right MGB fairing. Refer
to applicable Maintenance Manual.

(8) Return helicopter to service.

B. Record of Compliance

(1) Make an appropriate logbook entry to show compliance with this ASB No. 76-66-49A.

Upon compliance with this Alert Service Bulletin, complete attached ALERT SERVICE BULLETIN
COMPLIANCE RECORD CARD and return it to Sikorsky Aircraft Corporation.

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 No. 76-66-49A

POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

3. ACCOMPLISHMENT INSTRUCTIONS (Continued)

C. MGB Oil Analysis Data Sheet.

Record the following information for all inspected MGB assemblies and forward to Customer
Service Engineering at:
1-800-Winged-S or 1-203-416-4299.

Make copy of MGB Oil Analysis Data Sheet for each MGB inspected.

Customer/Operator Name: ____________________________________________________

Oil Analysis Performed by:_____________________________Date:_____________________

Helicopter Serial Number:_____________________________________________________

MGB Serial Number:________________________________________________________
Oil Specification: ___________________________________________________________

Date of Oil Sample: _________________________________________________________

Flight Hours on Oil: _________________________________________________________

Calendar Date of Last Oil Change: ______________________________________________

September 09/09 Page 7 66-10-00

Revision A - September 17/09

9

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POWERTRAIN - Main Gear Box (MGB) - One-Time Oil Analysis of

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