Airworthiness Directives; Sikorsky Aircraft Corporation

[Federal Register Volume 81, Number 48 (Friday, March 11, 2016)]
[Rules and Regulations]
[Pages 12799-12802]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2016-05258]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2016-4280; Directorate Identifier 2016-SW-008-AD; 
Amendment 39-18429; AD 2016-05-11]
RIN 2120-AA64


Airworthiness Directives; Sikorsky Aircraft Corporation

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: We are adopting a new airworthiness directive (AD) for 
Sikorsky Aircraft Corporation (Sikorsky) Model S-92A helicopters. This 
AD requires certain inspections of the main rotor and tail rotor 
control pushrods (pushrods). This AD is prompted by a Sikorsky 
investigation that indicated that some pushrods may have incorrectly 
installed locking mechanisms. These AD actions are intended to detect 
an incorrectly installed locking mechanism, which if not corrected, 
could result in a loose jam nut, failure of the pushrod, loss of main 
rotor or tail rotor flight control, and consequent loss of helicopter 
control.

DATES: This AD becomes effective March 28, 2016.
    The Director of the Federal Register approved the incorporation by 
reference of a certain document listed in this AD as of March 28, 2016.
    We must receive comments on this AD by May 10, 2016.

ADDRESSES: You may send comments by any of the following methods:
    <bullet> Federal eRulemaking Docket: Go to http://www.regulations.gov. Follow the online instructions for sending your 
comments electronically.
    <bullet> Fax: 202-493-2251.
    <bullet> Mail: Send comments to the U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE., Washington, DC 20590-0001.
    <bullet> Hand Delivery: Deliver to the ``Mail'' address between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2016-
4280; or in person at the Docket Operations Office between 9 a.m. and 5 
p.m., Monday through Friday, except Federal holidays. The AD docket 
contains this AD, any incorporated by reference service information, 
the economic evaluation, any comments received, and other information. 
The street address for the Docket Operations Office (telephone 800-647-
5527) is in the ADDRESSES section. Comments will be available in the AD 
docket shortly after receipt.
    For service information identified in this final rule, contact 
Sikorsky Aircraft Corporation, Customer Service Engineering, 124 Quarry 
Road, Trumbull, CT 06611; telephone 1-800-Winged-S or 203-416-4299; 
email [email protected]. You may review the referenced service 
information at the FAA, Office of the Regional Counsel, Southwest 
Region, 10101 Hillwood Pkwy, Room 6N-321, Fort Worth, TX 76177. It is 
also available on the Internet at http://www.regulations.gov by 
searching for and locating Docket No. FAA-2016-4280.

FOR FURTHER INFORMATION CONTACT: Blaine Williams, Aerospace Engineer, 
Boston Aircraft Certification Office, Engine & Propeller Directorate, 
1200 District Avenue, Burlington, Massachusetts 01803; telephone (781) 
238-7161; email [email protected].

SUPPLEMENTARY INFORMATION: 

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety, and we did not provide you with notice and an opportunity to 
provide your comments prior to it becoming effective. However, we 
invite you to participate in this rulemaking by submitting written 
comments, data, or views. We also invite comments relating to the 
economic, environmental, energy, or federalism impacts that resulted 
from adopting this AD. The most helpful comments reference a specific 
portion of the AD, explain the reason for any recommended change, and 
include supporting data. To ensure the docket does not contain 
duplicate comments, commenters should send only one copy of written 
comments, or if comments are filed electronically, commenters should 
submit them only one time. We will file in the docket all comments that 
we receive, as well as a report summarizing each substantive public 
contact with FAA personnel concerning this rulemaking during the 
comment period. We will consider all the comments we receive and may 
conduct additional rulemaking based on those comments.

Discussion

    We propose to adopt a new AD for Sikorsky Model S-92A helicopters 
with certain main rotor or tail rotor control pushrods installed. After 
a review of a failed pushrod, Sikorsky investigated the airworthiness 
of pushrods installed on its helicopters. The investigation indicates 
that the pushrods installed on Model S-92A helicopters may have 
incorrect safety cable routing, incorrect jam nut torque, and/or 
incorrect locking device serrations and key engagement. This AD 
consequently requires inspecting the pushrods for safety cable routing, 
engagement of serrations of the locking device, engagement of keys on 
the locking device, thread engagement, and jam nut torque. This AD 
requires either repairing or replacing the pushrod assembly, depending 
on the inspection's outcome. These AD actions are intended to detect 
and correct an incorrectly installed locking mechanism resulting in a 
loose jam nut, failure of the pushrods, loss of main rotor or tail 
rotor flight control, and consequent loss of helicopter control.

FAA's Determination

    We are issuing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of these same type 
designs.

[[Page 12800]]

Related Service Information Under 1 CFR Part 51

    We reviewed Sikorsky S-92 Helicopter Alert Service Bulletin ASB 92-
67-006, Revision A, dated February 19, 2016 (ASB), which specifies a 
one-time inspection of the pushrod assemblies for safety cable routing, 
engagement of serrations of the locking device, engagement of keys on 
the locking device, thread engagement, and torque of the jam nuts. The 
ASB also specifies documenting any non-compliant inspection results 
and, if any discrepancies are found during the inspection, removing, 
reworking, and reinstalling or replacing the pushrod. The ASB specifies 
performing a rig check as required.
    This service information is reasonably available because the 
interested parties have access to it through their normal course of 
business or by the means identified in the ADDRESSES section.

AD Requirements

    This AD requires within 5 hours time-in-service (TIS):
    <bullet> For each pushrod adjustable end, except for the upper deck 
quadrant pushrod, removing the safety cable and using finger pressure, 
inspecting each jam nut for movement. If a jam nut moves with finger 
pressure, removing the pushrod assembly from service.
    [cir] Inspecting to determine whether a 0.02 inch diameter safety 
wire can pass through the inspection hole. If the safety wire passes 
through the inspection hole, repairing the pushrod, which is 
terminating action for that adjustable end.
    [cir] Inspecting for correct engagement of serrations and keys of 
the locking device. If a locking device is not correctly engaged, 
repairing the locking device, which is terminating action for that 
adjustable end.
    [cir] Torqueing each jam nut and installing the safety cable, 
making sure the right-hand threads have safety cable correctly routed, 
and the left-hand threads have safety cable correctly routed.
    <bullet> For the upper deck quadrant pushrod, this AD requires 
determining whether there is any gap between the jam nut, locking 
device, and the adjustable end. It also requires:
    [cir] If there is a gap, gaining access to the pushrod, removing 
the safety cable and using finger pressure, inspecting the jam nut for 
movement. If the jam nut moves with finger pressure, removing the 
pushrod assembly from service. If the jam nut does not move, performing 
corrective actions.
    [cir] If there is no gap, visually inspecting the adjustable end 
for correct safety cable routing, correct engagement of serrations and 
keys of the locking device, and determining whether any thread is 
visible in the inspection hole. If the safety cable is routed 
incorrectly, if the locking device is not correctly engaged, or if 
there is no thread in the inspection hole, gaining access to the 
pushrod. Using finger pressure, inspecting the jam nut for movement. If 
the jam nut moves with finger pressure, removing the pushrod assembly 
from service. If the jam nut does not move with finger pressure, 
performing corrective actions.

Differences Between This AD and the Service Information

    Sikorsky specifies compliance by May 16, 2016. We require 
compliance within 5 hours TIS. We also do not require you to contact 
Sikorsky or record information on the Pushrod Data Sheet.

Costs of Compliance

    We estimate that this AD will affect 80 helicopters of U.S. 
Registry and labor costs average $85 per work-hour. Based on these 
estimates, we expect the following costs:
    <bullet> Inspecting all pushrod assemblies requires 2 work-hours 
for a labor cost of $170. No parts are needed for a total fleet cost of 
$13,600.
    <bullet> Replacing a pushrod requires 2 work-hours for a labor cost 
$170. Parts cost an average of $2,500 for a total cost of $2,670 per 
pushrod.
    <bullet> Repairing a pushrod requires an average 2 work-hours per 
helicopter for a labor cost of $170 and minimal part costs.

FAA's Justification and Determination of the Effective Date

    Providing an opportunity for public comments prior to adopting 
these AD requirements would delay implementing the safety actions 
needed to correct this known unsafe condition. Therefore, we find that 
the risk to the flying public justifies waiving notice and comment 
prior to the adoption of this rule because the required corrective 
actions must be accomplished within 5 hours TIS.
    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we determined that notice and opportunity for 
prior public comment before issuing this AD are impracticable and 
contrary to the public interest and that good cause exists to make this 
AD effective in less than 30 days.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority of the FAA Administrator. ``Subtitle VII: Aviation 
Programs,'' describes in more detail the scope of the Agency's 
authority.
    We are issuing this rulemaking under the authority described in 
``Subtitle VII, Part A, Subpart III, Section 44701: General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

Regulatory Findings

    We determined that this AD will not have federalism implications 
under Executive Order 13132. This AD will not have a substantial direct 
effect on the States, on the relationship between the national 
Government and the States, or on the distribution of power and 
responsibilities among the various levels of government.
    For the reasons discussed, I certify that this AD:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979);
    3. Will not affect intrastate aviation in Alaska to the extent that 
it justifies making a regulatory distinction; and
    4. Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared an economic evaluation of the estimated costs to comply 
with this AD and placed it in the AD docket.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

    Authority:  49 U.S.C. 106(g), 40113, 44701.

[[Page 12801]]

Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive (AD):

2016-05-11 Sikorsky Aircraft Corporation (Sikorsky): Amendment 39-
18429; Docket No. FAA-2016-4280; Directorate Identifier 2016-SW-008-
AD.

(a) Applicability

    This AD applies to Sikorsky Model S-92A helicopters, serial 
numbers 920006 through 920291, with a main rotor or tail rotor servo 
input pushrod with a part number (P/N) listed in Table 1 to 
paragraph (a) of this AD, certificated in any category.

                                            Table 1 to Paragraph (a)
----------------------------------------------------------------------------------------------------------------
                      Name                              P/N                         Torque value
----------------------------------------------------------------------------------------------------------------
Yaw Boost Input Pushrod........................    92400-04801-108  60-100 inch pounds.
Pitch Boost Input Pushrod......................    92400-04801-107  43 inch pounds.
Collective Boost Input Pushrod.................    92400-04801-107  350 inch pounds.
Roll Boost Input Pushrod.......................    92400-04801-109  43 inch pounds.
Yaw Boost Out Pushrod..........................    92400-04802-109  40-46 inch pounds.
Roll Boost Out Pushrod.........................    92400-04803-103  40-46 inch pounds.
Pitch Boost Out Pushrod........................    92400-04803-102  40-46 inch pounds.
Collective Boost Out Pushrod...................    92400-04802-108  40-46 inch pounds.
Limiter Pushrod................................    92400-04803-106  40-46 inch pounds.
Pitch to Roll Pushrod..........................    92400-04803-107  40-46 inch pounds.
Left Hand Main Rotor Servo Pushrod.............    92400-04801-110  350 inch pounds.
Forward Main Rotor Servo Pushrod...............    92400-04801-111  350 inch pounds.
Right Hand Main Rotor Servo Pushrod............    92400-04801-112  350 inch pounds.
Upper Deck Quadrant Pushrod....................    92400-04802-105  60-100 inch pounds.
Tail Rotor Servo Input Pushrod.................    92400-04802-107  40-46 inch pounds.
----------------------------------------------------------------------------------------------------------------

(b) Unsafe Condition

    This AD defines the unsafe condition as an incorrectly installed 
locking mechanism resulting in a loose jam nut. This condition, if 
not detected and corrected, could result in failure of the main 
rotor or tail rotor control pushrod, loss of main rotor or tail 
rotor flight control and consequent loss of helicopter control.

(c) Effective Date

    This AD becomes effective March 28, 2016.

 (d) Compliance

    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.

 (e) Required Actions

    Within 5 hours time-in-service:
    (1) For each control input pushrod (pushrod) adjustable end, 
except for the upper deck quadrant pushrod:
    (i) Remove the safety cable and using finger pressure, inspect 
each jam nut for movement. If a jam nut moves with finger pressure, 
remove the pushrod assembly from service.
    (ii) Inspect to determine whether a 0.02 inch diameter safety 
wire can pass through the inspection hole. If the safety wire passes 
through the inspection hole, repair the pushrod in accordance with 
the Accomplishment Instructions, paragraphs C.(2)(b) through 
C.(2)(l) of Sikorsky S-92 Helicopter Alert Service Bulletin ASB 92-
67-006, Revision A, dated February 19, 2016 (ASB), which is 
terminating action for that adjustable end.
    (iii) Where locking devices are used, inspect for correct 
engagement of serrations and keys of the locking device as shown in 
Figure 4 of the ASB. If a locking device is not correctly engaged, 
repair the locking device in accordance with the Accomplishment 
Instructions, paragraphs C.(3)(c) through C.(3)(f) of the ASB, which 
is terminating action for that adjustable end.
    (iv) Torque each jam nut using the torque values listed in Table 
1 to paragraph (a) of this AD. Install the safety cable, making sure 
the right-hand threads have safety cable routed as shown in Figure 2 
of the ASB, and the left-hand threads have safety cable routed as 
shown in Figure 3 of the ASB.
    (2) For the upper deck quadrant pushrod, determine whether there 
is any gap between the jam nut, locking device, and adjustable end.
    (i) If there is a gap, gain access to the pushrod, remove the 
safety cable, and using finger pressure, inspect the jam nut for 
movement. If the jam nut moves with finger pressure, remove the 
pushrod assembly from service. If the jam nut does not move, perform 
the actions in paragraphs (e)(1)(ii) through (e)(1)(iv) of this AD.
    (ii) If there is no gap, visually inspect the adjustable end for 
correct safety cable routing as shown in Figure 2 of the ASB, 
correct engagement of serrations and keys of the locking device as 
shown in Figure 4 of the ASB, and to determine whether any thread is 
visible in the inspection hole. If the safety cable is routed 
incorrectly, if the locking device is not correctly engaged, or if 
there is no thread in the inspection hole, gain access to the 
pushrod. Using finger pressure, inspect the jam nut for movement. If 
the jam nut moves with finger pressure, remove the pushrod assembly 
from service. If the jam nut does not move with finger pressure, 
perform the actions in paragraphs (e)(1)(ii) through (e)(1)(iv) of 
this AD.

 (f) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Boston Aircraft Certification Office, FAA, may 
approve AMOCs for this AD. Send your proposal to: Blaine Williams, 
Aerospace Engineer, Boston Aircraft Certification Office, Engine & 
Propeller Directorate, 1200 District Avenue, Burlington, 
Massachusetts 01803; telephone (781) 238-7161; email 
[email protected].
    (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.

 (g) Subject

    Joint Aircraft Service Component (JASC) Code: 6700, Rotorcraft 
Flight Control.

 (h) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference of the service information listed in this 
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Sikorsky S-92 Helicopter Alert Service Bulletin ASB 92-67-
006, Revision A, dated February 19, 2016.
    (ii) Reserved.
    (3) For Sikorsky service information identified in this final 
rule, contact Sikorsky Aircraft Corporation, Customer Service 
Engineering, 124 Quarry Road, Trumbull, CT 06611; telephone 1-800-
Winged-S or 203-416-4299; email [email protected].
    (4) You may view this service information at FAA, Office of the 
Regional Counsel, Southwest Region, 10101 Hillwood Pkwy., Room 6N-
321, Fort Worth, TX 76177. For information on the availability of 
this material at the FAA, call (817) 222-5110.
    (5) You may view this service information that is incorporated 
by reference at the National Archives and Records Administration 
(NARA). For information on the availability of this material at 
NARA, call

[[Page 12802]]

(202) 741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued in Fort Worth, Texas, on March 2, 2016.
Scott A. Horn,
Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 2016-05258 Filed 3-10-16; 8:45 am]
 BILLING CODE 4910-13-P

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