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This Revision 25 updates the front matter, as well as Chapter 4, which incorporatesnew tailboom inspection requirements per ASB 407-08-84. In addition, Chapter 76

incorporates information on FADEC Software Version 5.358. General updates toChapters 7, 52, 53, 63, 65, 71, and 95 have also been included.

Please incorporate Revision 25 into the Maintenance Manual in accordance withthe Log of Pages attached.

Bell Helicopter would also like to thank its Customers for providing us withCustomer Feedback information. This information is very much appreciated and

allows us to improve the quality of our manuals with each revision.

REVISION ONLY BHT-407-MM

NOTICE

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NOTICE

The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or

MAINTENANCE MANUAL

VOLUME 1

GENERAL INFORMATION

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PROPRIETARY RIGHTS NOTICE

These data are proprietary to Bell Helicopter Textron Inc. Disclosure,

reproduction, or use of these data for any purpose other than helicopter

operation or maintenance is forbidden without prior written authorization from

Bell Helicopter Textron Inc.

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WARNING

THIS MANUAL APPLIES ONLY TO HELICOPTERS AND COMPONENTS

MAINTAINED IN ACCORDANCE WITH BELL HELICOPTER TEXTRON

(BELL) APPROVED PROCEDURES USING BELL APPROVED PARTS.

ALL INSPECTION, REPAIR AND OVERHAUL PROCEDURES PUBLISHED

BY BELL, INCLUDING PART RETIREMENT LIFE, ARE BASED SOLELY ON

THE USE OF BELL PARTS THAT HAVE BEEN MAINTAINED USING BELL

APPROVED DATA. THE DATA PUBLISHED HEREIN OR OTHERWISESUPPLIED BY BELL IS NOT APPLICABLE TO NON-BELL PARTS OR

PARTS THAT HAVE BEEN REPAIRED USING DATA AND/OR PROCESSES

NOT APPROVED BY BELL.

BELL IS NOT RESPONSIBLE FOR ANY PART OTHER THAN THOSE THAT

IT HAS APPROVED.

BEFORE PERFORMING ANY PROCEDURE CONTAINED IN THIS MANUAL

YOU MUST INSPECT THE AFFECTED PARTS AND RECORDS FOREVIDENCE OF ANY MANUFACTURE, REPAIR, REWORK OR USE OF A

PROCESS NOT APPROVED BY BELL.

IF YOU IDENTIFY OR SUSPECT THE USE OF PARTS NOT AUTHORIZED

BY BELL, EITHER REMOVE THE AFFECTED ITEM FROM THE AIRCRAFT

OR OBTAIN INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FROM

THE MANUFACTURER OR THE ORGANIZATION THAT APPROVED THE

REPAIR.

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CUSTOMER SUPPORT AND SERVICES

Flying smart means that no matter where you are, or what time it is, you can make a call

and get additional information, clarification, or advice on a technical or operational issue

concerning your helicopter or information contained in our Technical Publications.

Product Support Engineering (PSE) is just a phone call away and may be contacted as

follows:

For additional information on Customer Support and Services as well as Product Support

Engineering (PSE) and your local Customer Service Representative (CSR) network

MODEL 47, 206, OR 407

Phone: 450-437-2862 or 800-243-6407 (U.S./Canada)

Fax: 450-433-0272

E-mail: [email protected]

MODEL 222, 230, 427, 429, OR 430

Phone: 450-437-2077 or 800-463-3036 (U.S./Canada)

Fax: 450-433-0272


MODEL 204, 205, 212, OR 412

Phone: 450-437-6201 or 800-363-8028 (U.S./Canada)Fax: 450-433-0272


MODEL 210, 214, HUEY II, SURPLUS MILITARY

Phone: 817-280-3548

Fax: 817-280-2635


BHT-407-MM-1
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

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LOG OF REVISIONS

Insert latest revision pages and dispose of superseded ones.

On a revised page, the text and/or illustration affected by the latest revision is shown by a vertical line. A revised

page with only a vertical line next to the page number indicates that text has shifted or that non-technical

correction(s) were made on that page.

Page No. Rev No. Page No. Rev No. Page No. Rev No.

LOG OF PAGES

Original ........0 ............22 FEB 96

Revision....... 1 ............01 APR 96

Revision....... 2 ............01 JUN 96

Revision....... 3 ........... 28 OCT 96

Revision....... 4 ........... 16 DEC 96Revision....... 5 .............18 JUL 97

Revision....... 6 ............14 APR 98

Revision....... 7 ........... 01 MAY 98

Revision....... 8 ............01 SEP 98

Revision ...... 9............30 NOV 98

Revision ...... 10.......... 16 FEB 01

Revision ...... 11 ......... 23 MAR 01

Revision ...... 12..........08 MAY 01

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Revision .......22 .........28 NOV 05Revision .......23 .........07 NOV 06

Revision .......24 .........02 OCT 07

Revision .......25 ......... 29 SEP 08

VOLUME 1

Cover.......................................23

Title ..........................................25

PN............................................22

Warning ...................................25

CSS .........................................25

A D........................................25

HELP .......................................24Customer Feedback ................24

Helicopter Sale Notice .............24

Warranty ..................................25

BR............................................25

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Chapter 76

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Chapter 79

1 8...........................................4

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Chapter 96

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Chapter 98

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SPARE PARTS WARRANTY

ONE YEAR/1,000 HOURS PRORATED

WARRANTY AND REMEDY: Seller warrants each new helicopter part or helicopter part reconditioned by seller to be free from defectin material and workmanship under normal use and service and if installed on Bell model helicopters. Sellers sole obligation under thiswarranty is limited to replacement or repair of parts which are determined to Sellers reasonable satisfaction to have been defectivewith 1,000 hours of operation or one (1) year after installation, whichever occurs first and reimbursement of reasonable freight charges.After 200 hours of use, there will be a prorated charge to the Purchaser for replacement parts (prorating the hours of total use againstthe then applicable part life or 2,000 hours, whichever is the lesser). Defective parts must be reported in writing to the Sellers WarrantyAdministration within 90 days of being found defective. Replacement of parts may be with either new or reconditioned parts, at Sellerselection. Warranty adjustment is contingent upon the Purchaser complying with the Warranty Remedies as described in theCommercial Warranty Information brochure and the Sellers Warranty Administration disposition instructions for defective parts. Failure

to comply with all of the terms of this paragraph may, at Sellers sole option, void this warranty.

NOTE: Parts, components and assemblies of all new helicopters may have been restored or reworked due to mars, blemishes, dentsor other irregularities during the manufacturing process. Such restoration and/or rework is permitted under Sellers approvedmanufacturing and engineering processes and guidelines. The restoration and/or rework so completed does not render such itemsdefective in material or workmanship.

THIS WARRANTY IS GIVEN AND ACCEPTED IN PLACE OF (i) ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS ORIMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR CONDITIONS OF MERCHANT ABILITY ANDFITNESS FOR A PARTICULAR PURPOSE AND (ii) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACTORIN TORT (DELICT), INCLUDING PRODUCT LIABILITIES BASED UPON STRICT LIABILITY, NEGLIGENCE, OR IMPLIED

WARRANTY IN LAW.

This warranty is the only warranty made by Seller. The Purchasers sole remedy for a breach of this warranty or any defect in a part isthe repair or replacement of helicopter parts and reimbursement of reasonable freight charges as provided herein. Seller excludesliability, whether as a result of a breach of contract or warranty, negligence or strict product liability, for incidental or consequentialdamages, including without limitation, damage to the helicopter or other property, costs and expenses resulting from required changesor modifications to helicopter components and assemblies, changes in retirement lives and overhaul periods, local customs fees andtaxes, and costs or expenses for commercial losses or lost profits due to loss of use or grounding of helicopters or otherwise.

Seller makes no warranty and disclaims all liability in contract or in tort (delict), including, without limitation, negligence and strict tort(delictual) liability, with respect to work performed by third parties at Purchasers request and with respect to engines, engineaccessories, batteries, radios, and avionics, except Seller assigns each manufacturers warranty to Purchaser to the extent suchmanufacturers warranty exists and is assignable.

This warranty shall not apply to any helicopter part which has been repaired or altered outside Sellers factory in any way so as, inSellers judgment, to affect its stability, safety or reliability, or which has been subject to misuse, negligence or accident, or which hasbeen installed in any aircraft which has been destroyed unless that helicopter has been rebuilt by Bell. A list of destroyed aircraft isobtainable from Bell Product Support. Repairs and alterations which use or incorporate parts and components other than genuine Bellparts or parts approved by Bell for direct acquisit ion from sources other than Bell itself are not warranted by Bell, and this warranty shallbe void to the extent that such repairs and alterations, in Sellers sole judgment, affect the stability, safety or reliability of the helicopteror any part thereof, or damage genuine Bell or Bell-approved parts. No person, corporation or organization, including Bell CustomerService Facilities, is authorized by Seller to assume for it any other liability in connection with the sale of its helicopters and parts.

NO STATEMENT, WHETHER WRITTEN OR ORAL, MADE BY ANY PERSON, CORPORATION OR ORGANIZATION, INCLUDINGBELL CUSTOMER SERVICE FACILITIES MAY BE TAKEN AS A WARRANTY NOR WILL IT BIND SELLER.

Seller makes no warranty and disclaims all liability with respect to components or parts damaged by, or worn due to, corrosion. Sellermakes no warranty and disclaims all liability for consumables (wear items) which are defined as items required for normal and routinemaintenance or replaced at scheduled intervals shorter than the warranty period. Consumables include but are not limited to engineand hydraulic oil, oil filters, packings and o-rings, anti-corrosion and/or sealing compounds, brush plating material, nuts, bolts, washers,screws fluids compounds and standard aircraft hardware that is readily available to aircraft operators from sources other than Seller

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BULLETIN RECORD

All applicable Alert Service Bulletins and Technical Bulletins issued prior to and including the bulletins listed below

have been incorporated in this manual. Subsequent bulletins will be incorporated in future revisions/reissues.

ALERT SERVICE BULLETINS

ASB NUMBER SUBJECT DATE

1407-08-84 Tailboom Assembly 407-030-801-201, 407-030-801-203, and

407-030-801-205, New Inspection Requirements

18 AUG 2008

1With the exception of ASB 407-98-16, 407-98-18, 407-99-30, 407-00-36, 407-00-38, 407-01-39, 407-01-41,

407-01-42, and 407-02-50 all applicable bulletins issued prior to, and including 407-07-81, have been

incorporated.

TECHNICAL BULLETINS

TB NUMBER SUBJECT DATE

1

407-07-77 I mproved Caution/Warning Panel 407-375-015-111,

Introduction of

04 JUN 2007

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TEMPORARY REVISION RECORD

This Temporary Revision Record provides a current listing of active Temporary Revisions against the manual.

Temporary Revisions, which have been canceled/incorporated, will only be maintained on the record until the next

revision is issued. If there are no Temporary Revisions shown on the record, this is confirmation that there are no

Temporary Revisions issued against the manual.

TEMP. REV. NO. TITLE DATE ISSUED DATE CANCELED

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TC APPROVED BHT-407-MM-1

CONTENTS MAINTENANCE PROCEDURES

Paragraph Chapter/Section Page

Number Title Number Number

CHAPTER 4 AIRWORTHINESS LIMITATIONS SCHEDULE

AIRWORTHINESS LIMITATIONS SCHEDULE

4-1 Airworthiness Limitations Schedule ........................................... 4-00-00 5

FIGURES

Figure Page

Number Title Number

4-1 Disc Pack Coupling (P/N 406-040-340-101) Inspection............................. 11

4-2 Main Rotor Yoke (P/N 407-010-101-101) Inspection ................................. 12

4-3 Tail Rotor Hanger Bearing (P/N 406-040-339-ALL) Inspection.................. 13

4-4 Tail Rotor Blade (P/N 407-016-001-101) Inspection .................................. 15

4-5 Tailboom Assembly (P/N 407-030-801-201, 407-030-801-203, and

407-030-801-205) 300 Hour Inspection..................................................... 16

4-6 Tailboom Assembly (P/N 407-530-014-101, 407-530-014-103, or

407-030-801-107) Daily Inspection............................................................ 22

4-7 Tailboom Assembly (P/N 407-530-014-101, 407-530-014-103, and

407-030-801-107) 100 Hour Inspection ..................................................... 24

4-8 Inspection of Pylon Side Beams (P/N 407-010-201-105/407-010-203-105) .. 31

4-9 Horizontal Stabilizer (P/N 407-023-801-109) Recurring 600 Hour/AnnualInspection ...................................................................................................... 34

TABLES

Table Page

Number Title Number

4-1 Airworthiness Limitations Schedule................................................................ 6

4-2 Inspection Limitations Schedule ..................................................................... 9

The Airworthiness Limitations Schedule is approved by the Minister and specifies the maintenance required by

li bl i thi ti l l l lt ti h b d b th

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BHT-407-MM-1 TC APPROVED

REVISION NO. DATE OF SIGNATURE TC SIGNATURE

Revision 1 (01 Apr. 96) 29 March 1996

Revision 2 (01 Jun. 96) N/A Chapter 4 not affected

Revision 3 (26 Oct. 96) 26 October 1996

Revision 4 (16 Dec. 96) N/A Chapter 4 not affected

Revision 5 (18 Jul. 97) 18 July 1997

Revision 6 (14 Apr. 98) 14 April 1998

Revision 7 (01 May 98) N/A Chapter 4 not affected

Revision 8 (01 Sept. 98) N/A Chapter 4 not affected

Revision 9 (30 Nov. 98) 30 November 1998

Revision 10 (16 Feb. 01) N/A Chapter 4 not affected

Revision 11 (23 Mar. 01) N/A Chapter 4 not affected

Revision 12 (08 May 01) 8 May 2001

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Revision 13 (21 Sept. 01)

Revision 14 (21 Nov. 01)

21 September 2001

21 November 2001

Revision 15 (18 Jan. 02) N/A Chapter 4 not affected

Revision 16 (07 Jun. 02) N/A Chapter 4 not affected

Revision 17 (25 Oct. 02) N/A Chapter 4 not affected

Revision 18 (29 Aug. 03) 29 August 2003

Revision 19 (17 Dec. 03) N/A Chapter 4 not affected






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Revision 25 (29 Sept. 08) 29 September 2008

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AIRWORTHINESS LIMITATIONS SCHEDULE

4-1. AIRWORTHINESS LIMITATIONSSCHEDULE

WARNING

ALL REPAIR AND OVERHAUL

PROCEDURES LIVES PUBLISHED BY

BELL HELICOPTER TEXTRON,

INCLUDING COMPONENT RETIREMENT

LIFE, ARE BASED SOLELY ON THE USE

OF BELL APPROVED PARTS AND

PROCESSES. IF PARTS OR

PROCESSES DEVELOPED OR

APPROVED BY PARTIES OTHER THAN

BELL HELICOPTER ARE USED, THEN

THE DATA PUBLISHED OR OTHERWISE

SUPPLIED BY BELL HELICOPTER ARE

NOT APPLICABLE. THE USER IS

WARNED TO NOT RELY ON BELL

HELICOPTER DATA FOR PARTS AND

PROCESSES NOT APPROVED BY BELL

HELICOPTER. ALL APPLICABLE

INSPECTIONS AND REPAIR METHODS

MUST BE OBTAINED FROM THE

SUPPLIER OF THE PARTS OR

PROCESSES NOT APPROVED BY BELL

HELICOPTER. BELL HELICOPTER IS

NOT RESPONSIBLE FOR PARTS OR

PROCESSES OTHER THAN THOSE

WHICH IT HAS ITSELF DEVELOPED OR

APPROVED.

The mandatory airworthiness limitations schedule

(Table 4-1) summarizes the mandatory maximum life,

in hours, years or by Retirement Index Number (RIN)of components with a limited airworthiness life. Parts

that are not on the schedule have an unlimited

airworthiness life. The inspection limitations schedule

(Table 4-2) summarizes the mandatory inspection

interval in hours.

schedule applies to all the successive dashnumbers for that component unless it is

otherwise specified.

WARNING

SOME PARTS ARE INSTALLED AS

ORIGINAL EQUIPMENT ON BOTHMIL ITARY AND COMMERCIAL

HELICOPTERS AND MAY HAVE A

LOWER AIRWORTHINESS LIFE AND/OR

OVERHAUL SCHEDULE WHEN USED

ON A MIL ITARY HELICOPTER. IN

ADDIT ION, CIRCUMSTANCES

SURROUNDING THEIR USE MAY CALL

FOR OPERATION OF THE MILITARY

HELICOPTER OUTSIDE OF THEAPPROVED COMMERCIAL FLIGHT

ENVELOPE. CONSEQUENTLY, PARTS

THAT HAVE BEEN USED ON MILITARY

HELICOPTERS SHOULD NOT BE USED

ON COMMERCIAL HELICOPTERS.

CAUTION

AIRWORTHINESS LIFE OF SOME KIT

COMPONENTS MAY NOT BE COVERED

IN THIS SCHEDULE. REFER TO

APPLICABLE INSTALLATION

INSTRUCTION (II) OR MAINTENANCE

MANUAL SUPPLEMENT (MMS) FOR KIT

COMPONENTS SCHEDULE.

NOTE

The airworthiness life given or the failure to

give an airworthiness life to a component

does not constitute a warranty of any kind.

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airworthiness lives and inspection intervals cannot be

changed without the approval of the Minister of

Transport Canada.

Prior to disposing of unsalvageable helicopter parts

and materials, caution should be exercised to ensure

that the parts and materials are disposed of in a

manner that does not allow them to be returned for

service. Refer to FAA Advisory Circular 21-38 for

guidance on the disposal of unsalvageable helicopterparts and materials.

Table 4-1. Airworthiness Limitations Schedule

COMPONENT PART NUMBERRETIREMENT

YEARS/HOURS/RIN

MAIN ROTOR HUB AND BLADESYoke 407-010-101-101/-109

Grip 406-010-108-119/-121 1250 hrs

Grip 406-010-108-125/-131 5000 hrs

Pitch Horn 407-010-103-101/-107/-113 5000 hrs

Upper Plate 406-010-115-119/-127 2500 hrs

Lower Plate 406-010-117-115/-125 2500 hrs

Driving Ring Set 406-010-126-107/-113 48000 RINBlade Bolt, Expandable 406-310-103-101 5000 hrs

Lower Cone Seat 407-010-107-101 1250 hrs

Lower Cone Seat 407-010-107-103/-105 10000 hrs

MAIN ROTOR CONTROLS

Pitch Link Tube 406-010-413-119/-133/-139 5000 hrs

Clevis 406-010-416-101 5000 hrs

Bearing 406-310-405-101/-103 5000 hrsRod End Assembly 406-310-404-101 5000 hrs

Drive Link 406-010-426-101 5000 hrs

Drive Lever 406-010-425-107 5000 hrs

Gimbal Ring 406-010-427-109 5000 hrs

Drive Hub Set 406-010-428-109 5000 hrs

Swashplate Outer Ring 406-010-411-117 5000 hrs

Swashplate Inner Ring 406-010-410-121 5000 hrsAnti-Drive Link 406-010-432-101 5000 hrs

Anti-Drive Lever 406-010-431-109 5000 hrs

Collective Lever 406-010-408-101 5000 hrs

Collective Idler Link 406-010-407-101 5000 hrs

Cyclic Longitudinal Bellcrank 407 001 526 101/ 105 5000 hrs

12

8

3

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MAIN ROTOR CONTROLS (CONT)

Servo Actuator Support 407-001-500-101/-105 10000 hrs

Support Assembly 406-010-406-119 5000 hrs

Sleeve Assembly 406-010-409-107/-113 5000 hrs

Bellcrank Support 407-001-511-101 5000 hrs

TRANSMISSION

Transmission Top Case 406-040-052-105/-109

TAIL ROTOR

Blade 407-016-001-101 900 hrs

Blade 406-016-100-119 5000 hrs

Yoke 406-012-102-101/-109 5000 hrs

DRIVE SYSTEM

Main Rotor Mast 407-040-038-101/-105 5000 hrs or 18000 RINInput Drive Shaft 206-340-300-103

Input Drive Shaft 206-340-300-105

Input Drive Shaft 206-340-300-107 5000 hrs

Input Drive Shaft 407-340-310-101 5000 hrs

PYLON SUPPORT

L/H Pylon Side Beam 407-010-201-101 1000 hrs or 5500 RIN

L/H Pylon Side Beam 407-010-201-105 5000 hrs or 17000 RINR/H Pylon Side Beam 407-010-203-101 1000 hrs or 5500 RIN

R/H Pylon Side Beam 407-010-203-105 5000 hrs or 17000 RIN

Corner Mount 406-010-217-107 5000 RIN

Corner Mount 407-310-203-101

Pylon Restraint Spring 407-010-206-103 5000 hrs

TAILBOOM

Tailboom Assembly 407-030-801-107,407-530-014-101/-103

5000 hrs

LANDING GEAR

Fwd Crosstube Assembly

(Std. Gear)

407-050-101-101/-103 5000 RIN

Table 4-1. Airworthiness Limitations Schedule (Cont)


YEARS/HOURS/RIN1

2

8

3

7

10

9

15

3 6

3 11

3 6

3 11

8

12

4

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LANDING GEAR (CONT)


(High Gear/Lightweight Float)

407-050-201-101/-103 5000 RIN



407-724-101 5000 RIN

Aft Crosstube Assembly


407-050-202-101/-103 5000 RIN



407-725-104 5000 RIN



407-704-007-119 2500 Landings

5000 RIN

KITS

Reservoir 1271762 15 Years

NOTES:

Airworthiness limitation for the part number listed applies to all successive dash numbers for that component

unless otherwise specified.

RIN: Retirement Index Number. Components sensitive to operational events, such as torque events or run-on

landings, are assigned a maximum RIN number. This number is based on the fatigue damage that results from

normal helicopter lifts and take-offs (torque events) or from run-on landings, whichever applies.

New components will begin with an accumulated RIN of zero, which will increase as the helicopter is subjected to

torque events or run-on landings. The operator must record the number of torque events or run-on landings, and

increase the accumulated RIN as directed. When a component reaches the maximum RIN or retirement flight

hours, whichever occurs first, the component must be retired from service.

For every one (1) torque event, you add one (1) RIN to the previous total. A torque event occurs for every

takeoff (one takeoff plus the subsequent landing equals one RIN) and every load lift.

A load lift (internal or external) may be defined as a sling load, a rescue hoist load or any load that is added to the

helicopter while airborne. For example: if an operator performs one (1) takeoff, picks up and drops ten (10) sling

loads, and then lands, he must record eleven (11) torque events.

For every one (1) run-on landing, you add one (1) RIN to the previous total. A run-on landing is defined asone where there is forward ground travel of the helicopter greater than three (3) feet with the weight on the skids.

Refer to ASB 407-03-59.

This crosstube is modified from crosstube assembly P/N 407-050-202-101 per ASB 407-02-50. Depending

on status of part determined per Table 1 of ASB 407-02-50, crosstube may be subject to retirement upon

reaching 2500 landings.



YEARS/HOURS/RIN1

2

4

4 14

4

4 14

5

4

13

1

2

3

4

5

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NOTES (CONT):

These components were identified as life-limited items in Revision 6 of the airworthiness limitation schedule.

They are now on condition items. They will be removed from Table 4-1at a subsequent revision if their status

stays unchanged.

Input drive shaft 206-340-300-107 must be overhauled every 1,250 hours of operation. The overhaul is to be

done by Kamatics Corp. only.The input drive shaft 206-340-300-105 must be removed from service upon reaching 1250 hours in service.

Refer to ASB 407-01-45 for details.

Pylon side beams 407-010-201-105 and 407-010-203-105 are to be subjected to an airworthiness inspection.

See Table 4-2for details.

Tailboom assemblies 407-030-801-107, 407-530-014-101 and 407-530-014-103 are also subjected to an

airworthiness inspection. Refer to Table 4-2and ASB 407-07-80 for details. Tailboom assemblies

407-030-801-201, -203 and -205 are only subjected to an airworthiness inspection. See Table 4-2for details.

Reservoir per DOT-3HT and DOT exemption letter DOT-E-8162. This reservoir is part of reservoir assembly

P/N 407-073-848-101.

Aeronautical Accessories Incorporated (AAI) crosstube assemblies listed are BHT-approved production and

spare alternates.

Input drive shaft 407-340-310-101 must be overhauled every 2,500 hours of operation. The overhaul is to be

done by Kamatics Corp. only.



YEARS/HOURS/RIN1

2

8

9

10

11

12

13

14

15

Table 4-2. Inspection Limitations Schedule

COMPONENT PART NUMBERINSPECTION INTERVAL

(HRS OPERATING TIME)

Thomas Coupling Disks 406-040-340-101 25 hours

Pylon Side Beam 407-010-201-105, 407-010-203-105 300 hoursBearing, Tail Rotor Hanger 406-040-339-ALL 25 hours

Bearing, Tail Rotor Hanger 407-340-339-101/-103

Swashplate Bearing 406-310-402-101 50/150 hours

Tail Rotor Blade 407-016-001-101 300 hours

12

3

106

12

5

7

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NOTES:

Inspection limitation for the part number listed applies to all successive dash numbers for that component

unless otherwise specified.

Refer to Chapter 5 for inspection requirements.

Inspect couplings 406-040-340-101 every 25 hours of operation. Refer to ASB 407-97-13, TransportCanada Aviation Airworthiness Directive CF-97-20R1 and Federal Aviation Authority Airworthiness Directive

97-24-17. Refer to Figure 4-1for inspection details.

Refer to Figure 4-2for inspection details.

The swashplate bearing 406-310-402-101 must be removed from service not later than December 31,

1998 and replaced by bearing 406-310-402-103. Refer to ASB 407-97-11 and Transport Canada Aviation

Airworthiness Directive CF-97-22 Bell.



You must do an inspection of tailbooms 407-030-801-201/-203, and -205 every 300 hours of operation.

Additional inspection requirements are applicable for tailbooms that have accumulated 6900 hours in service and

8600 hours in service. Refer to Figure 4-5for inspection details.

You must do an inspection of tailbooms 407-030-801-107 and 407-530-014-101/-103 daily and every 100

hours of operation. Refer to Figure 4-6and Figure 4-7for inspection details.You must do a 10X inspection of pylon side beams 407-010-201-105 and 407-010-203-105 that have

accumulated 1000 hours or more in service every 300 hours of operation. Do a fluorescent penetrant inspection

upon reaching 2500 hours in service. Refer to Figure 4-8for inspection details.

Contact Bell Helicopter Textron Product Support Engineering for changes or modifications to the structure

in area where a mandatory airworthiness inspection is specified.

The oil cooler blower and tail rotor segmented driveshaft bearings 407-340-339-101 and -103 must be

removed from service not later than May 31, 2004 and replaced by bearing 407-340-339-107. Refer to ASB407-04-63 Revision A, dated March 3, 2004 (or subsequent) and Transport Canada Aviation Airworthiness

Directive CF-2002-18R3.

Selected serial numbers of horizontal stabilizer 407-023-801-109 must be removed from service no later

than 30 September 2008. Refer to BHT ASB 407-06-72 for listing of serial numbers affected. Applicable

horizontal stabilizers must be inspected every 600 hours or annually until replaced Refer to Figure 4-9 for

Table 4-2. Inspection Limitations Schedule (Cont)

COMPONENT PART NUMBERINSPECTION INTERVAL

(HRS OPERATING TIME)1

2

1

2

3

4

5

6

7

8

9

10

11

12

13

C O

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BHT 407 MM 1 TC APPROVED

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TC APPROVED BHT 407 MM 1

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TC APPROVED BHT 407 MM 1

12.0 IN.

NO REPAIR

TO SKIN PERMITTED

STA14.50

This inspection applies to the tail rotor blade 407-016-001 only.

Do this inspection every 300 hours of component operation.

Remove the tail rotor blade.

Crazing will look like a series of minute cracks on the surface of the skin and

will make the surface of the skin look cloudy.

Using a coin or heavy washer, lightly tap the outer surface of the blade in the

blade root area to detect delamination in the skin. An area of delamination will

sound hollow when gently tapped. If delamination is detected, remove the blade

from service.

If no crazing or delamination is detected, return the blade to service.

Install the tail rotor blade.

Balance the tail rotor (Chapter 18).

NOTES

1.

(304.8 mm)

4

2.

3.

5.

6.

7.

8.

Inspect the blade roots inboard of blade station 14.50 for signs of damage.

Examine the inside of the blade root pocket (where the tail rotor yoke is

inserted) for signs of crazing on the surface of the blade skins. If crazing is

detected, remove the blade from service.

4


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BS157.00

BS140.428

TAILBOOM IDENTIFICATION PLATE

AREA D

BS107.397

BS72.370

BS

39.00

AREA A

AREA C

AREA B

AREA I

AREA H

300-HOUR VISUAL INSPECTION

CRITICAL INSPECTION AREAS (SEE DETAILS)


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GENERAL VISUAL INSPECTION (300 HOURS)

AREA C AND AREA D(HORIZONTAL STABILIZER NOT SHOWN FOR CLARITY)

2.0 IN.(50.8 mm)

(139.7 mm)5.5 IN.

AREA D73

36

2.0 IN.

BS

98.89

BS

120.75

(50.8 mm)

4.25 IN.

(108.0 mm)

3 6 7

1

AREA C2 4


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1.

2.

3.

Upper tailboom skin

Horizontal stabilizer

Left upper stabilizer attachment support

1.

2.

3

4

5

6

7

8.

9.

AT EVERY 300-HOUR INTERVAL:

Inspect the complete tailboom assembly for general condition.

On the left side of the tailboom only, do a detailed inspection of all areas shown

for cracks in the tailboom skin and loose rivets. Do not remove the paint or primer. If a loose rivet is found,

remove rivet and inspect hole for cracks using a 10X magnifying glass. If no cracks are found, install

correct diameter rivet. Do not exceed maximum diameter prescribed.

Use a 10X magnifying glass to inspect for cracks in tailboom skin and around fastener heads as

indicated in area shown in Details E, F, G, Areas C, D, H and I.

Do not remove horizontal stabilizer.

FOR TAILBOOMS IN SERVICE FOR 6900 FLIGHT-HOURS OR MORE, OR WITH TOTAL TIME UNKNOWN:

Inspect Area H and Area I at every 150-hour interval using 10X magnifying glass inspection method,

or at every 500-hour interval using Eddy current inspection method.

FOR TAILBOOMS IN SERVICE FOR 8600 FLIGHT-HOURS OR MORE, OR WITH TOTAL TIME UNKNOWN:

Visually check Area C and Area D daily or at every 50-hour interval using 10X magnifying glass inspection

method. Do not exceed a distance of 12 inches (30.48 cm) from the tailboom surface when conducting the

daily visual inspection.

Pay close attention to skin just above edge of upper support.

Some tailboom components not shown for clarity.

If a crack is found on the tailboom skin, replace the tailboom before the next flight and contact Product

Support Engineering using the following information:

Bell Helicopter Textron Product Support Engineering

Light Helicopters

Tel: 1-800-243-6407 (Continental USA and Canada)

Tel: 1-800-363-8023 (Continental USA)

Tel: 1-800-361-9305 (Within Canada)

NOTES


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Tailboom

assem

bly(Re

f)

Ho

rizon

tals

tabilizer

(Re

f)

Up

persupport

(Re

f)

Lowersupport

(407-0

23-8

00-1

21)

1.

2.

3.

4.

NO

TES

Paintan

dprimer

toberemove

dfrom

theseareas

(ASB407-0

7-8

0).

Exam

ine

theseareas

forcra

ckson

lefts

ideo

ftailboom

on

ly.

Ho

rizon

tals

tabilizerno

ts

ho

wn

forc

lari

ty.

Dailyc

hec

karea

4

2

3

1

1 21

2

1

2

BS

120

.75

1.5

IN

(3

8.1

mm

)

2.0

IN

(50

.8mm

)

3.


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DAILY INSPECTION

NOTES

1. Before the first flight of the day, do a check of the left side of the tailboom assembly in the areas where

paint was removed for cracks, as follows:

a) If required, use a clean cloth moistened with cleaning compound (C-318) prepared in accordance with

manufacturers recommendations to remove any exhaust residues or dirt, from both areas that require

checking, as shown.

b) Make sure that the tailboom skin is clean and that adequate lighting exists. Visually inspect the two

areas where original paint and primer was removed and protected with clear paint coating. Look for

cracks from a distance not exceeding 12 inches (30.48 cm).

c) Pay close attention near the edge of the stabilizer upper support.

d) If a crack is found on the tailboom skin, replace the tailboom before the next flight and contact

Product Support Engineering at the following numbers:

Bell Helicopter Textron

Product Support Engineering

Light Helicopters




Tel: 1-450-437-2682 (All other areas - call collect)

Fax: 450-433-0272 Internet: [email protected]

e) If no crack is found, the intent of the daily inspection is complete.

2. Make an entry in the helicopter records to show that the daily inspection is completed.

3. Comply with subsequent 100 hour inspection requirements described in Figure 4-7 when time is reached.


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BS140.428

BS107.397

BS39.00

BS72.370

BS90.00

AREA B

AREA C

AREA D

AREA A

100 HOUR VISUAL INSPECTION

CRITICAL INSPECTION AREAS (SEE DETAILS)


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AREA B

SEEDETAILE SEE

DETAIL FSEEDETAIL G

SEE

DETAIL I

SEEDETAIL G

SEEDETAIL H

AREAB

DETAIL E

FWD

BL

0.00

BS

39.000

LBL

7.50

BS

45.515

BL

0.00

0.50 IN.

(12.7 mm)0.50 IN.

(12.7 mm)

9 FASTENERS(LEFT SIDE ONLY)

BS

45.515

BS

52.600

BS

58.995

BS

72.475

BS

77.000

BS

85.955

LBL7.50

BS

90.00

BS

74.370BS

31.920

3


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3.00 IN.

BL0.00

LBL7.00

BS107.397

AREA C

SEEVIEW J

3

4

3

FWD

4.0 IN.

(101.6 mm) 4.0 IN.

(101.6 mm)

2.0 IN.

(50.8 mm)

2.0 IN.

(50.8 mm)

HORIZONTAL

STABILIZER

(REF)

BS

97.89

BS

98.89

BS

107.397BS

120.75

BS

121.75

8 RIVETS

(LEFT SIDE ONLY)

8 RIVETS

(LEFT SIDE ONLY)


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D

AREA D

BS

140.428

BS

140.428

6.00 IN.

(152.4 mm)

BL

0.00

LBL

5.00

LEFT SIDE ONLY

6 RIVETS

(LEFT SIDE ONLY)

SEEVIEW D

3

FWD


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100 HOURS OF OPERATION

1.

2.

3

4

5.

6.

7.

Inspect the complete tailboom assembly for general condition.

On the left side of the tailboom only, do a detailed inspection of all areas shown, for cracks in the tailboom

skin and loose rivets. Do not remove the paint or primer. If a loose rivet is found, remove rivet and inspect

hole for cracks using a 10X magnifying glass. If no cracks are found, install correct diameter rivet. Do not

exceed maximum diameter prescribed.

Use a 10X magnifying glass to inspect for cracks in tailboom skin and around fastener heads as

indicated in area shown in Detail E, F, G, H, I, View J, View D and Area C .

Do not remove horizontal stabilizer.

Some tailboom components not shown for clarity.

If a crack is found on the tailboom skin, replace the tailboom before the next flight and contact

Product Support Engineering at the following numbers:


Product Support EngineeringLight Helicopters






Contact Bell Helicopter Textron Product Support Engineering for changes or modifications to thestructure in areas where a mandatory airworthiness inspection is specified.

NOTES


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NOTES

Inspect the upper outboard flange and flange/web area for cracks. Inspect the area

between 1.25 inches (31.7 mm) and 2.0 inches (50.8 mm) above the mounting pad.

If a crack is found in a pylon side beam, replace before the next flight and contact Product Support

Engineering at the following numbers:


Product Support Engineering

Light Helicopters






2

3.

1


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NOTES

SEALANT MIL-PRF-81733 (C-392)

Washer12.

Screw11.

Support bracket10.

Screw9.Rivet8.

Horizontal stabilizer7.Tailboom6.

Lower attachment support5.

Upper attachment support4.

Rivet3.

Slat assembly2.

Finlet1.

InsertsNut

23.

Washer

22.

Screw21.

Spacer (left side only)

20.

Flap

19.

Casting supports

18.17.

Upper and lower doubler16.

Screw15.

Washer14.

Washer13.

20 TO 25 IN-LBS(2.26 TO 2.83 Nm)

2

5

12

9

SEE DETAILA

DETAILA

22

21

201

7

18

16

1

2

17

13

11

1514

19 26

8

4

12

9

173

10

SEE DETAILB

DETAILB

INSPECTION AREA

Inspect stabilizer on upper and lower surfaces

FWD

23

1.5 IN.(38.1 mm)

SECTIONC-CC C

24

Identification tag24.


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Inspect the horizontal stabilizer (7) as follows:

Horizontal stabilizer does not require to be removed from tailboom.

1.

PROCEDURE

CAUTION

PROTECTION UNDERNEATH STABILIZER IS REQUIRED TO NOT DAMAGE

STABILIZER OR TAILBOOM WHEN STABILIZER IS DETACHED FROM UPPER

SUPPORTS. SLAT MAY REMAIN INSTALLED HOWEVER SIDE MOVEMENT WILL BELIMITED. ENSURE NO DAMAGE TO SLATS AND/OR TAILBOOM SURFACES.

NOTE

Do not damage liquid shim compound between upper and lower supports (4 and 5)

and stabilizer (7). If liquid shim is damaged during removal of the parts, the

shimming procedure shall be repeated as described in BHT-407-MM, Chapter 53.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remove the screws (9) and the washers (12) from the L/H and R/H lower supports (5). Remove the nuts (22),

washers (21) and screws (20).

Remove L/H and R/H lower supports (5).

Protect tailboom (6) underneath stabilizer (7) with padding or equivalent.

Hold the stabilizer (7). Remove the screws (9) and the washers (12) that attach the L/H and R/H upper

supports (4) to stabilizer (7).

Carefully lower stabilizer (7) and move to left side.

Refer to Figure Detail B. Clean and prepare surface of the stabilizer for inspection using cheesecloth (C-486)

moistened with acetone (C-316).

Inspect stabilizer in area of the inserts (23), on upper and lower surfaces for cracks and deformation using a

10X power magnifying glass. Inspect the area around each insert and between inserts for debonding using

tap test method.

If any damage is found, the stabilizer is not repairable. Replace the stabilizer.

If no damage is found, continue with the inspection.

Carefully move stabilizer (7) to the right side.

Repeat step 7 to 9 for the R/H side of stabilizer in area of inserts (23).

NOTE

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BHT-407-MM-2

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NOTICE


MAINTENANCE MANUAL

VOLUME 2

HANDLING AND SERVICING

BHT-407-MM-2

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BHT-407-MM-2

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BHT-407-MM-2

7-3. LIFTING THE COMPLETE HELICOPTERNOTE

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WITH THE MAST NUT

WARNING

DO NOT GO INTO OR CLIMB ONTO THE

HELICOPTER WHILE IT IS SUPPORTED

ON THE JACKS OR BEING RAISED. IF

YOU DO NOT OBEY, INJURY TO

PERSONNEL CAN OCCUR.

CAUTION

ALL OF THE LIFT EQUIPMENT MUST BE

RATED FOR A MINIMUM CAPACITY OF

7500 POUNDS (3400 KG). IF YOU USEEQUIPMENT THAT IS NOT RATED FOR

THIS CAPACITY, DAMAGE TO THE

HELICOPTER CAN OCCUR.

1. Make the area around the helicopter safe. Put

ropes around the area. Put warning signs up that have

the message, "THIS HELICOPTER IS ON A HOIST".

2. Remove the main rotor fairing and the Frahmdamper (if installed) (Chapter 62).

3. If applicable, use the tail rotor strap and safety

the tail rotor (Chapter 10).

NOTE

If you lift the helicopter higher than you can

hold it, attach a rope to the tail skid. Make a

person hold the rope.

7. Put a person at the tail skid. Tell the person to

keep the helicopter in a level position when you lift the

helicopter.

8. Operate the hoist (1). Apply a constant force and

slowly lift the helicopter from the ground.

7-4. LIFTING THE HELICOPTER WITH THE

MAIN ROTOR AND THE MAST ASSEMBLY

REMOVED

WARNING

DO NOT GO INTO OR CLIMB ONTO THEHELICOPTER WHILE IT IS SUPPORTED

ON THE JACKS OR BEING RAISED. IF

YOU DO NOT OBEY, INJURY TO

PERSONNEL CAN OCCUR.

CAUTION

ALL OF THE LIFT EQUIPMENT MUST BE

RATED FOR A MINIMUM CAPACITY OF

7500 POUNDS (3400 KG). IF YOU USE

EQUIPMENT THAT IS NOT RATED FOR

THIS CAPACITY DAMAGE TO THE

SPECIAL TOOLS REQUIRED

NUMBER NOMENCLATURE

T102137-101 Lifting Eye Clevis

206-070-469-001 Tail Rotor Strap

SPECIAL TOOLS REQUIRED

NUMBER NOMENCLATURE

T103314-101 Lift Plate

BHT-407-MM-5

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NOTICE


MAINTENANCE MANUAL

VOLUME 5

AIRFRAME

BHT-407-MM-5

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BHT-407-MM-5

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VIEW C

SECTION A-A

1

2

B-BSECTION

CSEE VIEW

SEE VIEW D

2

3

1

1

32

23

1

1.

2.3.

Lower windowScrew

Washer

6.0 IN. (152.4 mm)

LONG. APPLY TO

FILL DIMPLED ZONE

TO FILL ALONG

LOWER WINDOW

TO FILL ALONG

LOWER WINDOW

VIEW D

A

A B

B

1

2

2

1

2

1

1

2 2

BHT-407-MM-5

b. Examine the lower windows (1) for abrasions,

scratches cracks holes and other defects that can

6. Install 33 screws (2) and washers (3) to attach the

lower window (1) to the nose skin floor panel and

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scratches, cracks, holes, and other defects that can

decrease visibility. Repair the lower windows, as

specified in Figure 52-12.

c. You can temporarily repair cracks, holes, or

other damage by stop drilling, with repair patches, or

by following other standard practices for acrylic plastic.

d. Examine the lower windows (1, Figure 52-14)

for loose screws (2).

e. Make sure the sealant (C-392) has no cracks,holes, or deterioration that permit water leakage.

f. To stop water leaks, apply sealant (C-392) to

the area of the leak.

52-67. Lower Windows Installation

1. Clean the fiberglass area of the window (1,

Figure 52-14) with aliphatic naphtha (C-305).

2. Apply a layer of sealant (C-328) to the faying

surfaces of the lower window (1).

3. Clean the excess sealant (C-328) from the

window.

4 Apply sealant (C 392) at the locations shown on

lower window (1) to the nose skin, floor panel, and

console structure.

7. Seal the window edges with sealant (C-308).

8. Clean the lower window (Chapter 12).

52-68. SKYLIGHT DESCRIPTION

The two skylights are made of light grey tinted acrylic

plastic. The skylights are flush mounted on the forward

cabin roof and part of the sidebody fairings. Theskylights are installed with double-sided self-adhesive

tape and four screws. The skylights are sealed for

water tightness.

52-69. Skylight Removal

1. Remove the nuts (2, Figure 52-15), washers (3),

spacers (4), and screws (5).

2. Lubricate a wire 0.025 inch (0.635 mm) in

diameter with a soap/detergent and water solution.

3. Push the wire in between the window and frame.

4. Attach a wooden dowel at each end of the wire.

Safety the wire with lockwire (C-405).

Refer to BHT-ALL-SPM for specifications.

MATERIALS REQUIRED

NUMBER NOMENCLATURE

C-305 Aliphatic Naphtha

C-328 Sealant

C-392 Sealant


MATERIALS REQUIRED

NUMBER NOMENCLATURE

C-305 Aliphatic Naphtha

C-392 Sealant

C-405 Lockwire

C-407 Abrasive Pad

BHT-407-MM-5

VERTICAL FIN
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53-53. VERTICAL FIN

The vertical fin (3, Figure 53-26) is an aerodynamic

surface that gives stability to the helicopter while it is in

flight. The vertical fin is installed with the leading edge

at a 9 angle (with reference to the helicopter

longitudinal axis) outboard. This helps unload the tail

rotor while the helicopter is in forward flight. The

vertical fin is made of an aluminum honeycomb core

with aluminum outer skins. The forward and the aft

edge caps are made of formed aluminum alloy. The

anti-collision light (1) is installed on the top fairing (2)

of the vertical fin. The rubber bumper and the tail skid

(9) are installed on the lower edge of the vertical fin.

The tail skid absorbs shocks in a tail low landing.

(Refer to Chapter 32.)

On helicopters S/N 53057 and subsequent, and on

helicopters S/N 53000 through 53056 Post TB

407-96-2, a flap is installed along the trailing edge of

the vertical fin.

53-54. VERTICAL FIN REMOVAL

1. Remove the tail rotor gearbox fairing (paragraph53-83).

2. Disconnect the wires of the anti-collision light (1,

Figure 53-26) at the quick disconnects or at the

terminal board on the tail rotor gearbox support

casting (Chapter 96).

3. Put insulation on the wire ends and stow wires to

prevent damage.

4. Hold the vertical fin (3). Remove the bolts (5) and

53-55. VERTICAL FIN INSPECTION AND

REPAIR

WARNING

CORROSION AT THE FAYING EDGES

OF THE VERTICAL FIN FITTINGS CAN

CAUSE THE BOLTS (5, FIGURE 53-26)TO LOOSEN. THIS CAN RESULT IN

DAMAGE TO THE FITTINGS AND THE

BOLTS AND THE LOSS OF THE

VERTICAL FIN.

NOTE

For information on damage and repair

procedures not contained in this chapter,please contact Product Support

Engineering for assistance.

1. Examine the attachment area of the vertical fin (3,

Figure 53-26) for cracks, extended bolt holes, loose

bolts, distortion, and corrosion.

NOTE

Step 2 applies if the vertical fin has been

removed.

2. Examine the bolts (5), the barrel nuts (13), and

the nut retainers (12) for wear or thread damage.

3. On helicopters S/N 53057 and subsequent, andon helicopters S/N 53000 through 53056 Post TB

407-96-2, examine the flap (4) for cracks, dents,

damage, and loose rivets.

BHT-407-MM-5
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Helicopter S/N 53000 through 53056 Post TB 407-96-2 and

helicopter S/N 53057 and subsequent.

Apply a coating of corrosion preventive compound (C 104) to

NOTES

1

Anticollision light

FairingVertical fin

Flap

Bolt

Thin aluminium washer

Sleeve and plug

Former tail rotor gearbox fairing

Tail skid assembly

Tail rotor gearbox support casting

and fin support

TailboomNut retainer

Barrel nut

1.

2.3.

4.

5.

6.

7.

8.

9.

10.

11.12.

13.

12

75 TO 95 IN-LBS(8.5 TO 10.7 Nm)

13

SEE DETAIL A

DETAIL A

5

6

12

3

4 1

8

7

9

11

10

SEE DETAIL B

CORROSION PREVENTIVE COMPOUND (C-104)

2

2

103

3 (4 PLACES)

3

(4 PLACES)

BHT-407-MM-6

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NOTICE


MAINTENANCE MANUAL

VOLUME 6

MAIN ROTOR/MAIN ROTOR DRIVE SYSTEM

BHT-407-MM-6

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BHT-407-MM-6

CHAPTER 63 MAIN ROTOR DRIVE SYSTEM

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TABLE OF CONTENTS



MAIN ROTOR DRIVE SYSTEM

63-1 Main Rotor Drive System............................................................... 63-00-00 9

63-2 Main Rotor Drive System Operational Check ...................... 63-00-00 9

63-3 Main Rotor Drive System Scheduled Inspection.................. 63-00-00 21

63-4 Main Rotor Drive System Condition and Security Inspection 63-00-00 2463-5 Transmission Top Case Torque Check Special

Instructions........................................................................ 63-00-00 25

63-6 Mast 12 Month Inspection ............................... ...... ....... 63-00-00 25

63-7 Mast 60 Month Inspection ............................... ...... ....... 63-00-00 25

63-8 Transmission 60 Month Inspection............................... 63-00-00 26

63-9 Freewheel 60 Month Inspection ................................... 63-00-00 26

63-10 Main Rotor Drive System Permitted Leakage Rate ............. 63-00-00 26

63-11 Serviceability Check....................................................................... 63-00-00 27

63-12 Transmission and Freewheel Assemblies ServiceabilityCheck........................................................................................ 63-00-00 27

63-13 Unwanted Particles ........................................................................ 63-00-00 28

63-14 Unwanted Particles Visual Identification .............................. 63-00-00 28

63-15 Unwanted Particles Chemical Identification ......................... 63-00-00 31

MAST ASSEMBLY

63-16 Mast Assembly............................................................................... 63-00-00 33

63-17 Mast Assembly Removal...................................................... 63-00-00 3363-18 Mast Assembly Cleaning...................................................... 63-00-00 36

63-19 Mast Assembly Inspection and Repair................................. 63-00-00 37

63-20 Mast Assembly Installation................................................... 63-00-00 37

TRANSMISSION ASSEMBLY

63-21 Transmission Assembly................................................................. 63-00-00 39

63-22 Transmission Removal......................................................... 63-00-00 39

63-23 Transmission Cleaning......................................................... 63-00-00 4363-24 Transmission Inspection and Repair.................................... 63-00-00 43

63-25 Transmission Installation...................................................... 63-00-00 44

63-26 Transmission Input Seal....................................................... 63-00-00 47

63-27 Transmission Input Magnetic Carbon Seal Removal ... 63-00-00 47

63 28 Transmission Input Magnetic Carbon Seal Cleaning 63 00 00 49

BHT-407-MM-6

TABLE OF CONTENTS (CONT)
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PYLON ASSEMBLY

63-35 Pylon Assembly ............................................................................. 63-00-00 69

63-36 Pylon Beam Assembly.............................................................. 63-00-00 69

63-37 Pylon Beam Assembly Removal .. ............. ...... ............. 63-00-00 69

63-38 Pylon Beam Assembly Cleaning .................................. 63-00-00 70

63-39 Pylon Beam Assembly Inspection................................ 63-00-00 70

63-40 Pylon Beam Assembly Repair...................................... 63-00-00 8063-41 Pylon Beam Assembly Installation .................. ...... ....... 63-00-00 80

63-42 Pylon Stop Transmission Fitting ............................................... 63-00-00 83

63-43 Pylon Stop Transmission Fitting Removal.................... 63-00-00 83

63-44 Pylon Stop Transmission Fitting Cleaning.................... 63-00-00 83

63-45 Pylon Stop Transmission Fitting Stripping....... ............. 63-00-00 84

63-46 Pylon Stop Transmission Fitting Inspection .................. 63-00-00 84

63-47 Pylon Stop Transmission Fitting Painting..................... 63-00-00 84

63-48 Pylon Stop Transmission Fitting Installation................. 63-00-00 84

63-49 Pylon Stop Deck Fitting ............................................................ 63-00-00 8663-50 Pylon Stop Deck Fitting Removal................................. 63-00-00 86

63-51 Pylon Stop Deck Fitting Cleaning................................. 63-00-00 86

63-52 Pylon Stop Deck Fitting Inspection............................... 63-00-00 86

63-53 Pylon Stop Deck Fitting Installation.............................. 63-00-00 86

63-54 Restraint Spring Assembly ....................................................... 63-00-00 88

63-55 Restraint Spring Assembly Removal............................ 63-00-00 88

63-56 Restraint Spring Assembly Disassembly...................... 63-00-00 90

63-57 Restraint Spring Assembly Cleaning............................ 63-00-00 90

63-58 Restraint Spring Assembly Inspection.......................... 63-00-00 9063-59 Restraint Spring Assembly Repair ..... ............. ...... ....... 63-00-00 90

63-60 Restraint Spring Assembly Assembly .......................... 63-00-00 93

63-61 Restraint Spring Assembly Installation......................... 63-00-00 93

ENGINE TO TRANSMISSION DRIVESHAFT

63-62 Engine to Transmission Driveshaft ................................................ 63-00-00 97

63-63 Engine to Transmission Driveshaft Removal ....................... 63-00-00 97

63-64 Engine to Transmission Driveshaft Cleaning ....................... 63-00-00 10563-65 Engine to Transmission Driveshaft Inspection..................... 63-00-00 105

63-66 Engine to Transmission Driveshaft Repair........................... 63-00-00 110

63-67 Engine to Transmission Driveshaft Installation.................... 63-00-00 110

BHT-407-MM-6

5. Examine the engine to transmission driveshaft

(paragraph 63-65).

4. Use a bright light and examine the mast (1) inside

diameter for corrosion and condition of the protective

coating
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63-5. Transmission Top Case Torque Check

Special Instructions

1. Apply the minimum torque required for the nut

(11, Figure 63-14). If the fastener does not move, the

test is completed.

2. If the fastener moved, examine the split line at the

top case, the ring gear gearshaft support case, and

the lower case to make sure that there are no cracks

in the sealant. If there is a crack in the sealant, clean

the old sealant and apply sealant (C-308).

3. If the fastener moved, do the transmission top

case torque check again at the same scheduled

interval (Chapter 5) until the fastener does not move.

63-6. Mast 12 Month Inspection

1. Remove the Frahm assembly (Chapter 62).

coating.

5. If there is corrosion, the mast (1) must beremoved, inspected, and repaired as per the

BHT-407-CR&O.

6. If the protective coating is removed, scratched, or

cracked, remove the mast (1) and refer to the

BHT-407-CR&O for protective coating application.

7. Install the plastic cap plug (10).

CAUTION

DO NOT APPLY THIXOGREASE TO THE

THREADS OF THE MAST OR MAST NUT.

8. Apply a thin layer of Thixogrease (C-561) to thesurface of the upper cone that contacts the mast nut

(Chapter 62).

NOTE

Do not disturb the lower cone hardware.

9. Install the mast nut (Chapter 62).

10. If applicable, install the Frahm assembly

(Chapter 62).

11. Do a mast nut torque check (Chapter 5).

63-7. Mast 60 Month Inspection

1. Do this inspection if an overhaul inspection has

not been done in the last 60 months. Do not do a non

destructive inspection.

2. If the primer protective coating of the mast inside

is damaged, refer to the BHT-407-CR&O for primer


MATERIALS REQUIRED

NUMBER NOMENCLATURE

C-308 Sealant


MATERIALS REQUIRED

NUMBER NOMENCLATURE

C-561 Thixogrease

BHT-407-MM-6

6. Assemble the mast assembly (BHT-407-CR&O).

f f

63-9. Freewheel 60 Month Inspection
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7. Apply paint on the outer surface of the mast

where damaged (BHT-407-CR&O).

8. Install the mast assembly (paragraph 63-20).

63-8. Transmission 60 Month Inspection

1. Do this inspection if an overhaul inspection has

not been done in the last 60 months. Do not do a non

destructive inspection. It is not necessary to paint strip

the parts.

2. Remove the transmission assembly (paragraph

63-22).

3. Remove the transmission top case, the planetary

assembly, and the sungear (BHT-407-CR&O).

4. Do not disassemble the planetary assembly.

5. Examine all of the visible parts and assembled

components for condition (BHT-407-CR&O).

6. Insert a mirror between the spiral bevel gear edge

and the lower case and use a bright light to examine

the input pinion gear and surrounding areas for

condition.

7. Remove the transmission lower chip detector and

chip detector housing and screen (paragraph 63-195).

Use a bright light and a mirror to examine the spiral

bevel gear, the gearshaft, the accessory drive gear

and the surrounding areas for condition.

8. Install the transmission chip detector housing and

screen and the lower chip detector (paragraph63-197).

9. Install the sungear, the planetary and the top

case (BHT-407-CR&O).

1. Do this inspection if an Overhaul Inspection has

not been done in the last 60 months. Do not do a Non

Destructive Inspection. It is not necessary to paint stripthe parts.

2. Remove the freewheel assembly (paragraph

63-69).

3. Disassemble the freewheel assembly

(BHT-407-CR&O).

4. Inspect the freewheel parts for condition

(BHT-407-CR&O).

5. Assemble the freewheel assembly

(BHT-407-CR&O).

6. Apply paint where damaged (BHT-407-CR&O).

7. Install the freewheel assembly (paragraph 63-72).

63-10. MAIN ROTOR DRIVE SYSTEM

PERMITTED LEAKAGE RATE

Table 63-1. Maximum Permitted Leakage Rates for

the Transmission and Freewheel Assembly

COMPONENT TYPE LEAKAGE RATE

Transmission

and

Freewheel

Assembly

Static The input quill

leakage must not be

more than 5 drops

per minute.

The total

transmission

leakage at all

sources with the

BHT-407-MM-6

63-11. SERVICEABILITY CHECK

63 12 TRANSMISSION AND FREEWHEEL

g. Remove the jet assemblies No. 1, No. 2, No. 3

and No. 4.
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63-12. TRANSMISSION AND FREEWHEEL

ASSEMBLIES SERVICEABILITY

CHECK

1. Drain the transmission and freewheel oil system

(Chapter 12) through a paper filter and save the paper

filter for the inspection. Flush the transmission with

clean oil.

2. Examine the electrical magnetic element of the

transmission top chip detector for unwanted particles.

3. Examine the electrical magnetic element of the

transmission lower chip detector and the screen of the

chip

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407-MM Rev 25 29-Sep-2008

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