AIRWORTHINESS DIRECTIVE
For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (AD) under subregulation 39.1 (1) of CASR 1998. The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.
Sikorsky S-76 Series Helicopters
AD/S-76/72 Main Landing Gear Brake Discs - Replacement 10/2003
DM
Applicability: Model S-76A, B and C series helicopters, with main landing gear brake (MLG) assembly part number (P/N) 5007555, 5007555-1, or 5007555-2 installed.
Requirement: 1. Determine if a MLG brake disc P/N 5014067 is installed in the braking assembly in accordance with:
(a) For brake assembly P/N 5007555 and P/N 5007555-1:
Section 111-Acommplishment Instructions, paragraph 1.A. to 1.D., of Aircraft Braking Systems Corporation Alert Service Bulletin (ASB) S76-32-A24, dated 10 April 2002; and
(b) For brake assembly P/N 5007555-2:
Section 111-Acommplishment Instructions, paragraph 1.A. and 1.B., of Aircraft Braking Systems Corporation ASB S76-32-A25, dated 15 May 2002.
2. If it is determined, in compliance with Requirement 1, that a disc P/N 5014067 is installed, remove that disc and replace with disc P/N 5007672 and re-identify brake assembly:
(a) P/N 5007555 and P/N 5007555-1 as brake assembly P/N 5007555-3, in accordance with the conversion of brake assembly instructions on page 6 of ASB S76-32-A24, dated 10 April 2002; and
(b) P/N 5007555-2 as brake assembly P/N 5007555-4, in accordance with the conversion of brake assembly instructions on page 6 of ASB S76-32-A25, dated 15 May 2002.
3. Increase the Category A - Rejected Takeoff Distance, the Category A-Landing Distance, and the Category B - Landing Distance, as stated in the current Rotorcraft Flight Manual (RFM) for the helicopter, by multiplying these rejected takeoff and landing distances by a factor of 1.67. This can be accomplished by inserting into the helicopter flight manual a copy of this Directive, or the helicopter manufacturers temporary revision to the RFM reflecting increased rejected takeoff and landing distances.
Sikorsky S-76 Series Helicopters
AD/S-76/72 (continued)
4. MLG brake discs having P/N 5014067 shall not be installed on any aircraft.
Note 1: Temporary revisions to the RFM reflecting increased rejected takeoff and landing distances can be obtained from the helicopter manufacturer.
Note 2: Sikorsky Aircraft Corporation ASB 76-32-27 dated 30 April 2002 contains Aircraft Braking Systems Corporation ASB S76-32-A24, dated 10 April 2002, and Sikorsky Aircraft Corporation ASB 76-32-28 dated 17 May 2002 contains Aircraft Braking Systems Corporation ASB S76-32-A25, dated 15 May 2002.
Note 3: FAA AD 2003-14-18 Amdt 39-13237 refers.
Compliance: For Requirement 1: Within 60 days from the effective date of this Directive.
For Requirement 2: Within 90 days from compliance with Requirement 1 of this Directive.
For Requirement 3: Before further flight after the effective date of this Directive, until all installed discs P/N 5014067 on the helicopter are replaced with disc P/N 5007672, and all brake assemblies are re-identified in accordance with Requirement 2 of this Directive.
For Requirement 4: Following compliance with Requirement 1 of this Directive. This Airworthiness Directive becomes effective on 25 August 2003.
Background: This Directive is issued after it was been found that some MLG brake discs have been manufactured using inferior materials. To rectify this condition, it is required to replace any non-conforming discs with different part-numbered airworthy discs, and to revise the helicopter flight manual to adjust the rejected takeoff and landing distances until the discs are replaced.
Jim Coyne
Delegate of the Civil Aviation Safety Authority 6 August 2003
The above AD is notified in the Commonwealth of Australia Gazette on 13 August 2003.
Overview
The Civil Aviation Safety Authority Airworthiness Directive (AD/S-76/72) was enacted in 2003 in response to a safety issue identified in certain Sikorsky S-76 Series Helicopters. This legislation was introduced to address the problem of main landing gear (MLG) brake discs that had been manufactured using inferior materials, thereby posing a risk to the airworthiness of the aircraft. The directive was issued by the Civil Aviation Safety Authority (CASA) as a delegate, under subregulation 39.1 (1) of the Civil Aviation Safety Regulations 1998 (CASR 1998). The primary objective of this directive is to ensure the safety of the aircraft by requiring the replacement of non-conforming brake discs with specified airworthy parts and to adjust the relevant flight manual parameters to reflect the increased safety margins.
Scope and Application
This Airworthiness Directive applies specifically to Sikorsky S-76 series helicopters, namely S-76A, B, and C models, equipped with main landing gear (MLG) brake assemblies bearing specific part numbers: 5007555, 5007555-1, or 5007555-2. The directive mandates a series of actions to address an unsafe condition identified in certain MLG brake discs. These actions include determining whether a particular brake disc (P/N 5014067) is installed, replacing it with a specified airworthy disc (P/N 5007672), and updating the helicopter's flight manual to reflect increased rejected takeoff and landing distances. The directive applies nationally across the Commonwealth of Australia, and compliance with its provisions is required within stipulated timeframes. Notably, the directive also prohibits the installation of MLG brake discs with the part number 5014067 on any aircraft. The directive was issued under the authority of the Civil Aviation Safety Authority (CASA) and became effective on 25 August 2003.
Key Provisions
The Airworthiness Directive (AD) AD/S-76/72, issued under subregulation 39.1 (1) of the Civil Aviation Safety Regulations (CASR) 1998, mandates specific actions to address a safety concern with the main landing gear (MLG) brake discs in certain Sikorsky S-76 series helicopters. This AD applies to Model S-76A, B, and C series helicopters equipped with MLG brake assemblies having part numbers 5007555, 5007555-1, or 5007555-2 (paragraph 1). Firstly, the directive requires operators to determine whether a particular MLG brake disc part number 5014067 is installed (Requirement 1). Secondly, if such a disc is found, it must be removed and replaced with a disc part number 5007672, and the brake assembly must be re-identified according to the instructions provided in the Aircraft Braking Systems Corporation Alert Service Bulletins (ASB) S76-32-A24 and S76-32-A25 (Requirement 2). Thirdly, operators must increase the rejected takeoff and landing distances in the helicopter's flight manual by a factor of 1.67 (Requirement 3). Lastly, MLG brake discs part number 5014067 must not be installed on any aircraft (Requirement 4).
Operators of the affected helicopters must comply with these requirements within specified timeframes. Specifically, Requirement 1 must be completed within 60 days of the AD's effective date, Requirement 2 within 90 days of completing Requirement 1, Requirement 3 before further flight after the AD's effective date, and Requirement 4 must follow completion of Requirement 1 (paragraph 2). Failure to comply with the AD may result in civil or criminal penalties. The AD was issued due to the discovery of MLG brake discs made from inferior materials, and its aim is to ensure the safety of the aircraft by rectifying this issue (paragraph 3).
The AD imposes several obligations on the parties it governs. Primarily, operators of the affected helicopters must inspect their MLG brake assemblies to determine if a specific disc part number is installed, and if so, replace it with a specified part number and re-identify the brake assembly. Additionally, operators must adjust the rejected takeoff and landing distances in their flight manuals, and ensure that no non-conforming discs are installed in their helicopters. These requirements must be completed within the specified timeframes, and failure to do so can have serious legal consequences. The AD also mandates that temporary revisions to the flight manual, reflecting the increased distances, must be obtained from the helicopter manufacturer.
Failure to comply with the AD may result in both civil and criminal penalties. Civil penalties can include fines and enforcement actions by the Civil Aviation Safety Authority (CASA). Criminal penalties may be applicable in cases of gross negligence or willful disregard of the AD, leading to prosecution under the Civil Aviation Act 1988. The exact penalties for non-compliance are not specified in the AD itself but would be determined by CASA and the courts in the event of a breach. The AD serves to ensure the airworthiness and safety of the affected helicopters by addressing a critical issue with the MLG brake discs.