[Federal Register Volume 77, Number 126 (Friday, June 29, 2012)]
[Proposed Rules]
[Pages 38744-38747]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2012-15978]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2012-0689; Directorate Identifier 2009-SW-065-AD]
RIN 2120-AA64


Airworthiness Directives; Sikorsky Aircraft-Manufactured Model S-
64F Helicopters

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to supersede an existing airworthiness directive 
(AD) for the Sikorsky Aircraft Corporation-manufactured Model S-64F 
helicopters, now under the Erickson Air-Crane Incorporated (Erickson) 
Model S-64F type certificate. That AD currently requires inspections, 
rework, and replacement, if necessary, of the main gearbox (MGB) second 
stage lower planetary plate (plate). Since we issued that AD, the 
manufacturer has conducted a configuration review and analysis, and a 
review of the service history of certain components. The proposed 
actions are intended to establish life limits for certain components, 
remove various parts from service, and require consistency in the part 
numbers of certain four bladed tail rotor (T/R) assemblies to prevent 
fatigue cracking, failure from static overload, and subsequent loss of 
control of the helicopter.

DATES: We must receive comments on this proposed AD by August 28, 2012.

ADDRESSES: You may send comments by any of the following methods:
     Federal eRulemaking Docket: Go to http://www.regulations.gov. Follow the online instructions for sending your 
comments electronically.
     Fax: 202-493-2251.
     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.
     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 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 proposed AD, 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 proposed AD, contact 
Erickson Air-Crane Incorporated, ATTN: Chris Erickson/Compliance 
Officer, 3100 Willow Springs Rd, P.O. Box 3247, Central Point, OR 
97502, telephone (541) 664-5544, fax (541) 664-2312, email address 
[email protected]. You may review a copy of this service 
information at the FAA, Office of the Regional Counsel, Southwest 
Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas 76137.

FOR FURTHER INFORMATION CONTACT: Michael Kohner, Aviation Safety 
Engineer, FAA, Rotorcraft Directorate, Rotorcraft Certification Office, 
Fort Worth, Texas 76137, telephone (817) 222-5170, email [email protected].

SUPPLEMENTARY INFORMATION:

Comments Invited

    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 might 
result from adopting the proposals in this document. The most helpful 
comments reference a specific portion of the proposal, 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 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 proposed rulemaking. Before acting on this proposal, we 
will consider all comments we receive on or before the closing date for 
comments. We will consider comments filed after the comment period has 
closed if it is possible to do so without incurring expense or delay. 
We may change this proposal in light of the comments we receive.

Discussion

    On May 9, 1997, we issued AD 97-10-15, Amendment 39-10028 (62 FR 
28321, May 23, 1997), for the Sikorsky Aircraft-manufactured Model S-
64F helicopters (now under the Erickson Model S-64F helicopter type 
certificate) with a plate, P/N 6435-20516-101, with 2,000 or more hours 
time-in-service (TIS). That AD requires, before the first flight of 
each day, inspecting the MGB main oil filter for magnesium 
contamination, and if magnesium contamination is present, replacing the 
MGB assembly. That AD also requires inspecting the MGB assembly within 
100 hours TIS, and thereafter at intervals not to exceed 500 hours TIS, 
and if necessary, replacing the MGB assembly. Finally, that AD 
requires, at the next overhaul of the MGB assembly, inspecting and 
reworking the plate. That action was prompted by two incidents in which 
the plate was found cracked. The requirements of that AD are intended 
to prevent failure of the plate due to fatigue cracking, which could 
lead to failure of the MGB and subsequent loss of control of the 
helicopter.

Actions Since Existing AD Was Issued

    Since we issued AD 97-10-15, Erickson has performed additional 
analysis as a part of a configuration review and has also reviewed the 
service history of certain components. Erickson determined that certain 
life-limits and other maintenance requirements need to be revised, and 
released Erickson Service Bulletin (SB) No. 64F General-1, Revision 17, 
dated August 17, 2010 (SB No. 64F General-1, Rev. 17). We have reviewed 
this SB and have determined that the retirement lives of certain parts 
need to be revised. We have also determined that certain parts, 
including the plate, P/N 6435-20516-101, which is the subject of the 
existing AD, should be removed from service and should no longer be 
eligible for installation on these helicopters.

FAA's Determination

    We are proposing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or

[[Page 38745]]

develop in other products of the same type design.

Related Service Information

    SB No. 64F General-1, Rev. 17, contains the Airworthiness 
Limitations Schedule for the Model S-64F helicopter and lists the parts 
and assemblies with their specified retirement lives.

Proposed AD Requirements

    This AD proposes to reduce or establish the life limits for certain 
flight-critical components, remove other parts with service 
difficulties from service, and require that T/R blade assembly P/N 
65160-00001-048 be installed only as a set of four and not be installed 
with another part-numbered blade. The requirements in current AD 97-10-
15 would be superseded and the part-numbered planetary plate, which is 
the subject of that AD, would be removed from service. This proposed AD 
would require, before further flight, a change in the life-limit for 
the following components:
     Main Rotor (M/R) Blade Assembly, P/N 6415-20601-045;
     Main Transmission Support Beam Assembly, LH, P/N 6420-
62363-045;
     Main Transmission Support Beam Assembly, RH, P/N 6420-
62363-046;
     Left Splice Fitting (Transition Fitting), Rotary, Rudder 
Boom, P/N 6420-66341-101;
     Right Splice Fitting (Transition Fitting), Rotary, Rudder 
Boom, P/N 6420-66341 102;
     M/R Drive Shaft, P/N 6435-20536-101;
     Pressure Plate Assembly, Rotary Wing Head, P/N 65101-
11016-042;
     Horn and Liner Assembly, P/N 65102-11047-041;
     Lower Hub Plate Assembly, P/N 65103-11009-041;
     Horizontal Hinge Pin, Rotary Wing Head, P/N 65103-11020-
103;
     Damper Bracket Assembly, Rotary Wing Head, P/N 65103-
11032-043;
     Hub Subassembly, Rotary Wing, P/N 65103-11310-043;
     Shaft Assembly, Pitch Control Tail Gearbox, P/N 65358-
07035-043; and
     Rod End Assembly, Primary Servo Assembly, P/N 65652-11212-
041.
    In addition to proposing new or revised life limits for certain 
flight-critical components, this AD also proposes to remove the 
following components from service due to service difficulties:
     Spindle Assembly, Rotary Rudder, P/N 6410-30302-041;
     MGB Second Stage Lower Planetary Plate, P/N 6435-20516-101 
or 6435-20516-102;
     Bracket Assembly, Main Servo, P/N 6435-20527-041 or 6435-
20527-042;
     Primary Servo Link Assembly, Tandem Servo, M/R, P/N 6465-
62161-042;
     Shoulder Bolt, T/R, P/N 65111-07001-102; and
     T/R Blade Assembly, P/N 65161-00001-041.
    This proposed AD contains only a portion of the life-limited parts 
for this model helicopter, and is not an all-inclusive list.

Costs of Compliance

    We estimate that this proposed AD would affect 7 helicopters of 
U.S. Registry and estimate, at an average labor rate of $85 per hour, 
the following costs for removing from service the parts listed in Table 
2 of this proposed AD action:
     Reviewing helicopter records to determine if an affected 
part is installed will require approximately 2 work-hours, for a cost 
per helicopter of $170 and a fleet cost of $1,190.
     Replacing the rotary rudder spindle assembly will require 
10 work-hours and a parts cost of $2,787, for a cost per helicopter of 
$3,637 and a fleet cost of $25,459.
     Replacing the plate will require 40 work-hours and a parts 
cost of $43,750, for a cost per helicopter of $47,150 and a fleet cost 
of $330,050.
     Replacing the main servo bracket assembly will require 2 
work-hours and a parts cost of $5,223, for a cost per helicopter of 
$5,393 and a fleet cost of $37,751.
     Replacing the primary servo link assembly of the M/R 
tandem servo will require 10 work-hours and a parts cost of $14,533, 
for a cost per helicopter of $15,383 and a fleet cost of $107,681.
     Replacing the T/R shoulder bolt will require 10 work-hours 
and a parts cost of $571, for a cost per helicopter of $1,421 and a 
fleet cost of $9,947.
     Replacing the T/R Blade Assembly will require 8 work-hours 
and a parts cost of $125,765 for a cost per helicopter of $126,445 and 
a fleet cost of $885,115.
     The total cost to replace the parts that are proposed to 
be removed from service is estimated to be $199,599 per helicopter and 
a fleet cost of $1,397,193.

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 proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would 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 this proposed regulation:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under the 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 proposed 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.

The Proposed Amendment

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

PART 39--AIRWORTHINESS DIRECTIVES

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

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


Sec.  39.13  [Amended]

    2. The FAA amends Sec.  39.13 by removing Amendment 39-10028 (62 FR 
28321, May 23, 1997), and adding the following new AD:


[[Page 38746]]


ERICKSON AIR-CRANE INCORPORATED: Docket No. FAA-2012-0689; 
Directorate Identifier 2009-SW-065-AD.

(a) Applicability

    This AD applies to Sikorsky Aircraft Corporation-manufactured 
Model S-64F helicopters, now under the Erickson Air-Crane 
Incorporated Model S-64F type certificate, certificated in any 
category.

(b) Unsafe Condition

    This AD defines the unsafe condition as a fatigue crack in a 
flight critical component. This condition could result in component 
failure from static overload and subsequent loss of control of the 
helicopter.

(c) Other Affected ADs

    This AD supersedes AD 97-10-15, Amendment 39-10028 (62 FR 28321, 
May 23, 1997).

(d) Compliance

    You are responsible for performing each action required by this 
AD within the specified compliance time unless accomplished 
previously.

(e) Required Actions

    (1) Before further flight:
    (i) Remove from service any part with a number of hours time-in-
service (TIS) equal to or greater than the part's retirement life as 
stated in following Table 1 of this AD.

             Table 1--Parts With New or Revised Life Limits
------------------------------------------------------------------------
            Part name               Part No. (P/N)     Retirement life
------------------------------------------------------------------------
Main Rotor (M/R) Blade Assembly..    6415-20601-045  13,280 hours TIS.
Main Transmission Support Beam       6420-62363-045  9,300 hours TIS.
 Assembly, LH.
Main Transmission Support Beam       6420-62363-046  9,300 hours TIS.
 Assembly, RH.
Left Splice Fitting (Transition      6420-66341-101  8,300 hours TIS.
 Fitting), Rotary, Rudder Boom.
Right Splice Fitting (Transition     6420-66341-102  8,300 hours TIS.
 Fitting), Rotary, Rudder Boom.
M/R Drive Shaft..................    6435-20536-101  2,200 hours TIS.
Pressure Plate Assembly, Rotary     65101-11016-042  8,800 hours TIS.
 Wing Head.
Horn and Liner Assembly..........   65102-11047-041  1,140 hours TIS.
Lower Hub Plate Assembly.........   65103-11009-041  15,500 hours TIS.
Horizontal Hinge Pin, Rotary Wing   65103-11020-103  5,100 hours TIS.
 Head.
Damper Bracket Assembly, Rotary     65103-11032-043  20,000 hours TIS.
 Wing Head.
Hub Subassembly, Rotary Wing.....   65103-11310-043  21,600 hours TIS.
Shaft Assembly, Pitch Control       65358-07035-043  9,400 hours TIS.
 Tail Gearbox.
Rod End Assembly, Primary Servo     65652-11212-041  20,800 hours TIS.
 Assembly.
------------------------------------------------------------------------


    Note to Table 1: The list of parts in Table 1 of this AD 
contains only a portion of the life-limited parts for this model 
helicopter and is not an all-inclusive list.

    (ii) Revise the retirement life of each part as shown in Table 1 
of this AD by making pen and ink changes or by inserting a copy of 
this AD into the Airworthiness Limitations section of the 
maintenance manual.
    (iii) Record on the component history card or equivalent record 
the retirement life for each part as shown in Table 1 of this AD.
    (2) Before further flight, remove from service any part with a 
P/N listed in the following Table 2 of this AD, regardless of the 
part's TIS. The P/Ns listed in Table 2 of this AD are not eligible 
for installation on any helicopter.

                Table 2--Parts To Be Removed From Service
------------------------------------------------------------------------
               Part name                               P/N
------------------------------------------------------------------------
Spindle Assembly, Rotary Rudder........  6410-30302-041.
Main Gearbox Second Stage Lower          6435-20516-101 or 6435-20516-
 Planetary Plate.                         102.
Bracket Assembly, Main Servo...........  6435-20527-041 or 6435-20527-
                                          042.
Primary Servo Link, Tandem Servo, M/R..  6465-62161-042.
Shoulder Bolt, Tail Rotor (T/R)........  65111-07001-102.
T/R Blade Assembly.....................  65161-00001-041.
------------------------------------------------------------------------

     (3) Before further flight, if a T/R blade assembly, P/N 65160-
00001-048, is installed, remove any of the other three T/R blade 
assemblies that have a different P/N and replace it with a T/R blade 
assembly, P/N 65160-00001-048. The T/R blade assembly, P/N 65160-
00001-048, must be installed in sets of four only.

(f) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Rotorcraft Certification Office, FAA, may 
approve AMOCs for this AD. Send your proposal to: Michael Kohner, 
Aviation Safety Engineer, FAA, Rotorcraft Directorate, Rotorcraft 
Certification Office, Fort Worth, Texas, 76137, telephone (817) 222-
5170, 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) Additional Information

    Erickson Service Bulletin No. 64F General-1, Revision 17, dated 
August 17, 2010, which is not incorporated by reference, contains 
additional information about the subject of this AD. For service 
information identified in this AD, contact Erickson Air-Crane 
Incorporated, ATTN: Chris Erickson/Compliance Officer, 3100 Willow 
Springs Rd, PO Box 3247, Central Point, OR 97502, telephone (541) 
664-5544, fax (541) 664-2312, email address 
[email protected]. You may review a copy of this 
information at the FAA,

[[Page 38747]]

Office of the Regional Counsel, Southwest Region, 2601 Meacham 
Blvd., Room 663, Fort Worth, Texas 76137.

(h) Subject

    Joint Aircraft Service Component (JASC) Code: 6300: Main Rotor 
Drive System and 6400: Tail Rotor System.

    Issued in Fort Worth, Texas, on June 21, 2012.
M. Monica Merritt,
Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 2012-15978 Filed 6-28-12; 8:45 am]
BILLING CODE 4910-13-P