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BHT-222/222B-MM-1

NOTICE

The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or
other directions issued by Bell Helicopter Textron Inc. and Airworthiness Directives (AD) issued by the
applicable regulatory agencies, shall be strictly followed.

REISSUE — 12 FEBRUARY 1998

REVISION 7 — 9 SEPTEMBER 2011

COPYRIGHT NOTICE

COPYRIGHT

2011

BELL ® HELICOPTER TEXTRON INC.
AND BELL HELICOPTER TEXTRON
CANADA LTD.

ALL RIGHTS RESERVED

MAINTENANCE MANUAL

VOLUME 1

GENERAL INFORMATION

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Summary of Contents for 222

Page 1: ...by Bell Helicopter Textron Inc and Airworthiness Directives AD issued by the applicable regulatory agencies shall be strictly followed REISSUE 12 FEBRUARY 1998 REVISION 7 9 SEPTEMBER 2011 COPYRIGHT NOTICE COPYRIGHT 2011 BELL HELICOPTER TEXTRON INC AND BELL HELICOPTER TEXTRON CANADA LTD ALL RIGHTS RESERVED MAINTENANCE MANUAL VOLUME 1 GENERAL INFORMATION ...

Page 2: ...icopter 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 DESTINATION CONTROL STATEMENT These commodities technology or software were exported from the United States in accordance with the Export Administration Regulations EAR Diversion contrary to...

Page 3: ...E SUPPLIED 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 FOR EVIDENCE OF ANY MANUFACTURE REPAIR REWORK OR USE OF A PROCESS NOT APPROVED BY B...

Page 4: ...ative CSR network please access http www bellhelicopter com support Model 206 or 407 Phone 450 437 2862 or 800 243 6407 U S Canada Fax 450 433 0272 E mail pselight bellhelicopter textron com Model 222 230 427 429 or 430 Phone 450 437 2077 or 800 463 3036 U S Canada Fax 450 433 0272 E mail pseinter bellhelicopter textron com Model 204 205 212 or 412 Phone 450 437 6201 or 800 363 8028 U S Canada Fax...

Page 5: ... on occasion If we do and you discover it we would appreciate your telling us about it so that we can change whatever is incorrect or unclear Please be as specific as possible Your complaint or suggestion will be acknowledged and we will tell you what we intend to do You may use the enclosed Customer Feedback form as applicable to inform us where we have erred Your assistance is sincerely apprecia...

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Page 7: ...Manual Title Manual Number if assigned Date of Issue Date of Last Revision Section Chapter Paragraph Affected Your Feedback Now Reads Should Read Your Name Address Position Telephone No Company Fax No Reference No your initials and date If you choose to mail this form fold in thirds with address exposed tape and mail ...

Page 8: ...TAPE HERE TAPE HERE From POSTAGE NECESSARY PRODUCT SUPPORT ENGINEERING 12 800 rue de l Avenir Mirabel Québec Canada J7J 1R4 FOLD ON DOTTED LINES AND TAPE ...

Page 9: ... of New Operator _______________________________________________________ Future Publications to be mailed to this address Address ____________________________________________________________________ City _______________________________________________________________________ State Province _______________________________________________________________ Zip Postal Code _____________________________...

Page 10: ...O POSTAGE NECESSARY IF MAILED IN THE UNITED STATES COMMERCIAL PUBLICATION DISTRIBUTION CENTER P O BOX 482 FORT WORTH TEXAS 76101 0482 FOLD ON DOTTED LINES AND TAPE BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 1744 FORT WORTH TEXAS ...

Page 11: ...itation negligence and strict tort delictual liability with respect to work performed by third parties at Purchaser s request and with respect to engines engine accessories batteries radios and avionics except Seller assigns each manufacturer s warranty to Purchaser to the extent such manufacturer s warranty exists and is assignable This warranty shall not apply to any helicopter part which has be...

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Page 19: ... 00 43 5 20 Progressive Inspection Event 5 5 00 00 49 5 21 Progressive Inspection Event 6 5 00 00 53 5 22 Progressive Inspection Event 7 5 00 00 57 5 23 Progressive Inspection Event 8 5 00 00 63 5 24 Progressive Inspection Event 9 5 00 00 67 5 25 Progressive Inspection Event 10 5 00 00 71 5 26 Progressive Inspection Event 11 5 00 00 75 5 27 Progressive Inspection Event 12 5 00 00 79 5 28 Every 100...

Page 20: ...llowing Each Installation 5 00 00 133 5 49 After 25 Hours of Operation Following Each Installation 5 00 00 135 5 50 After 100 Hours of Operation Following Each Installation 5 00 00 137 CONDITIONAL INSPECTIONS 5 51 Conditional Inspections 5 00 00 139 5 52 Hard Landing 5 00 00 141 5 53 Sudden Stoppage Power ON or OFF 5 00 00 149 5 54 Overtorque 5 00 00 157 5 55 Overtorque One Engine Inoperative 5 00...

Page 21: ...ll Helicopter Textron engineers They are subject to change only by Bell Helicopter Textron or an approved airworthiness authority Changes to TBO will be introduced by either revision to the Maintenance Manual Chapter 5 or a Technical Bulletin Every calendar and hourly inspection is a thorough visual inspection to determine the airworthiness of the helicopter and the components Qualified persons mu...

Page 22: ...at specified operating intervals The intervals may be in operating time hours cycles torque events RIN calendar days months years or other assigned units This makes sure that the helicopter is airworthy b Special inspections are of a temporary nature or of a special interval that is not consistent with the scheduled inspections c Conditional inspections do not occur at a specified time A condition...

Page 23: ...g time Actual flight or calendar time that must be recorded in the Historical Service Records or in the helicopter logs The operating time is specified as Time in service flight time The measured time which starts the moment the helicopter leaves the ground and continues until it touches the ground at the next point of landing The time when the helicopter is on the ground with the engine and the r...

Page 24: ...BHT 222 222B MM 1 5 00 00 Page 6 Rev 7 9 SEP 2011 ECCN EAR99 Figure 5 1 Maintenance Zones ...

Page 25: ...duling convenience only Scheduled inspections special inspections interim inspections or overhaul intervals required beyond the stated tolerances must be approved by Product Support Engineering NOTE The following is only applicable for those operators whose governing aviation authority requires to specifically approve the inspection and overhaul tolerance If approval of the inspection and overhaul...

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Page 27: ...done at 50 hour intervals The events must be accomplished in the sequence shown in Table 5 1 After Event 12 is completed the progressive cycle begins again with Event 1 A minimum of one complete cycle 12 events must be accomplished within 12 months 5 11 Inspection Program Selection You must establish the airframe periodic or the airframe progressive program to maintain the helicopter from new To c...

Page 28: ...BHT 222 222B MM 1 5 00 00 Page 10 Rev 7 9 SEP 2011 ECCN EAR99 Every 600 hours Every 1200 hours Every 2500 hours Every 6 months Every 2 years Every 3 years Every 5 years Every 10 years ...

Page 29: ...nimum of once every 12 months whichever comes first GENERAL 1 Log book Review for recorded discrepancies Correct discrepancies on installed equipment 2 Make sure all applicable and required special instructions Alert Service Bulletins ASB and Airworthiness Directives AD are accomplished Chapter 99 Applicable Service Instruction 3 Comply with Scheduled Inspections Special Inspections and required t...

Page 30: ...t nose landing gear for condition extend retract and downlock actuators for leakage and tire for proper inflation and serviceability Inspect wheel for cracks and serviceability Chapter 32 BHT 222 CR O V 1 5 Inspect main landing gear for condition brake assemblies for hydraulic leaks and excessive lining wear brake disc and torque keys for condition and tire for proper inflation and serviceability ...

Page 31: ...d without movement of the nut torque the bolt nut to 125 foot pounds 169 Nm If any nut moves before 100 foot pounds 135 Nm of torque is reached remove flapping bearing from main rotor hub assembly Inspect repair flapping bearing and main rotor yoke assemblies R1 Chapter 65 11 Model 222 Inspect main rotor blade 222 015 500 101 105 upper and lower center spar doublers for debonding Chapter 71 12 If ...

Page 32: ...Chapter 65 16 Clean main and tail rotor blades R1 R2 CAUTION ON BLADES THAT HAVE EROSION PROTECTION TAPE INSTALLED CARE MUST BE TAKEN TO PREVENT PRESERVATIVE OIL FROM CONTACTING THE TAPE CORROSION PREVENTIVE COMPOUND C 125 WILL DETERIORATE THE TAPE ADHESION NOTE It is not necessary to apply preservative oil to the blade fiberglass skin One inch of the fiberglass skin adjacent to the metal componen...

Page 33: ...inimum of once every 12 months whichever comes first GENERAL 1 Log book Review for recorded discrepancies Correct discrepancies on installed equipment 2 Make sure all applicable and required special inspections Alert Service Bulletins ASB and Airworthiness Directives AD are accomplished Chapter 99 Applicable Service Instructions 3 Comply with Scheduled Inspections Special Inspections and required ...

Page 34: ...y of attachment F1 F2 F3 F4 Chapter 26 5 lnspect cabin fire extinguisher for security and condition damage corrosion and quick opening clamp for operation and security F1 F2 Chapter 11 Chapter 95 Applicable Flight Manual 6 lnspect placards and instrument panel decals and all instrument markings for appearance and legibility F1 F2 Chapter 96 7 Remove battery lnspect vent lines for obstructions or d...

Page 35: ...y inspect the outboard and inboard collective lever idler link attachment points for condition in area of lugs in transmission top case R1 BHT 222 CR O 2 13 Inspect hydraulic actuator support attaching nuts for proper torque R1 Chapter 65 14 lnspect cyclic and collective control levers swashplate assembly drive assembly and links for evidence of damage security and corrosion lnspect walking beam p...

Page 36: ...g and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Chapter 66 19 lnspect transmission for evidence of oil leakage and correct fluid level F5 F6 Chapter 66 20 Remove transmission chip detectors lnspect and clean detectors and test electrical circuits Install chip detectors R1 Chapter 66 BHT 222 CR O 3 21 lnsp...

Page 37: ...aring for evidence of grease loss overheating and grease seal condition F5 F6 c Weight and cam arms for indications of misalignment and chafing F5 F6 d Restraint arms and lift links for security damage and elastomeric bearings for obvious damage F5 F6 e Visually inspect the outside surfaces of station 270 bulkhead at and around the area of attachment fittings 222 031 592 101 to the bulkhead for cr...

Page 38: ...ush rod and lever for wear or lost motion and for security of attachment E1 33 Inspect left engine ejector for security of attachment at plenum and support link E1 Chapter 71 34 Remove left engine air inlet duct assembly Inspect duct assembly for delamination Inspect reverse flow baffle door for security of attachment and general condition E1 Chapter 66 35 Remove the left aft fairing assembly and ...

Page 39: ...curity of attachment cracks at mounting ears and corrosion or mechanical damage Check bearings for evidence of grease seal leakage and discoloration caused by overheating T1 T2 Chapter 66 40 lnspect driveshaft hanger coupling discs and the disc at the tail rotor gearbox input quill for cracks radiating from bolt holes corrosion wrinkles or other evidence of overstress T1 T2 Chapter 53 41 Visually ...

Page 40: ... 130 inch pounds 14 5 Nm of torque is reached without nut movement increase torque to 160 inch pounds 18 Nm of torque If the nut moves below 130 inch pounds 14 5 Nm proceed with 2 year Inspection NOTE Examine inspection window s and or glass es for cracking and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Ch...

Page 41: ...for unbonded bearing in the upper leg of tail rotor input lever assembly g Check for worn bearings in the tail rotor pitch links Chapter 65 50 Inspect tail rotor hub and blades for cleanliness visible damage to blades evidence of wear or excessive play in pitch change bearings and trunnion bearings and pitch horn for security R2 Chapter 65 51 Inspect tail rotor hub and blades assembly retaining nu...

Page 42: ...l leaks flexible and rigid fuel and oil lines for wear chafing damage and security of attachment E2 Chapter 71 54 Inspect right engine mounts and accessories for damage and security of attachment E2 Chapter 76 55 Inspect right engine throttle control push rod lever and bellcrank for lost motion and security of attachment E2 56 Inspect right engine ejector for security of attachment at plenum and s...

Page 43: ...r 32 1 Inspect landing gear as follows a Jack helicopter clear of ground and cycle landing gear Check for binding excessive cycle time proper light operation and proximity switch operation and adjustment Check nose gear centering actuator for correct pressure b Perform emergency drop check c Remove oleo inflation valve and check for indication of hydraulic fluid 2 lnspect first aid kit contents Re...

Page 44: ...pilot station lnspect the lower and upper cyclic and collective pitch control bellcranks for bearing security of attachment corrosion or mechanical damage to clevises and security of attachment to supports and control tube bearings F5 F6 Chapter 25 7 On helicopters equipped with emergency exit windows in the passenger doors and or aft window position inspect as follows after removing interior trim...

Page 45: ...ts are located install support assembly Chapter 27 9 Remove aft right fuselage access panel and inspect control tube bellcrank and support assembly for security of attachment corrosion or mechanical damage and excessively worn bearings and clevises F4 Chapter 27 BHT 222 CR O 4 10 Remove and inspect tail rotor control tube nylatron sleeves and heat shrink if installed at four areas where tube conta...

Page 46: ... 270 bulkhead b Remove transmission drain pan from aft cabin c Remove screws retaining the door 222 031 506 043 to the bottom side of the station 270 bulkhead Remove the access door d Using a bright light inspect the outside and inside surfaces of the bulkhead assembly for cracks and damage paying particular attention to the area around the rivets Hi Locks attaching the aft nodal beam fittings 222...

Page 47: ... is correctly attached Examine bleed air tubing connection for leakage Make sure all tubes and connectors are securely attached d If installed examine auxiliary fuel system components wiring and tubing for corrosion chafing and correct attachment SCHEDULED INSPECTIONS 5 15 600 HOUR INSPECTION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 9 SEP 2011 Rev 7 Page 29 30 ...

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Page 49: ... es for cracking and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Chapter 26 1 Inspect right and left engine fire bottles for proper pressure indication F3 F4 Chapter 27 Chapter 29 2 Remove access panel from bottom of aft fuselage and inspect bellcrank and directional control hydraulic actuator supports for ...

Page 50: ...urity of attachment T1 T2 Chapter 53 8 Visually inspect upper and lower surface of stabilizer for indications of cracks immediately adjacent to stabilizer support attaching stabilizer to tailboom T1 T2 Chapter 53 9 lnspect tail skid for obvious damage and security of attachment T1 T2 Chapter 53 10 lnspect vertical fin assembly for damage T1 T2 CAUTION HARDWARE AND TORQUE REQUIREMENTS OF THE VERTIC...

Page 51: ...or proper oil level T1 T2 Chapter 66 13 Remove tail rotor gearbox chip detector Inspect and clean detector and test electrical circuit Install chip detector R2 14 Inspect tail rotor gearbox retaining nuts for proper torque 15 Inspect tail rotor pitch control assembly as follows a Check for excessive radial play between the pitch control assembly and the tail rotor gearbox output shaft due to a wor...

Page 52: ...bly prior to upgrade per TB 222 06 174 Part II 18 Inspect tail rotor blades pitch change bearings as follows a Without removing the blade clean exposed areas of pitch change bearings BHT 222 CR O 3 b With the blade bolts torqued to the highest value of torque range visually inspect each bearing inner member neck area full 360 for cracks If cracks are found replace both bearings in blade BHT 222 CR...

Page 53: ...__________________ GENERAL Paragraph 5 13 1 Perform a complete 50 hour inspection DETAIL Chapter 66 1 Inspect right and left nodal beam assembly as follows a Flexure assembly for cracks in fiberglass shear pad debond delamination and security F5 F6 b Cam bearing for evidence of grease loss overheating and grease seal condition F5 F6 c Weight and cam arms for indications of misalignment and chafing...

Page 54: ...c leakage security of attachment and excessive wear of brake linings Check brake disc for damage Check reservoir for fluid level and discoloration R1 F6 Chapter 66 BHT 222 CR O 3 7 lnspect tail rotor driveshaft coupling overtemperature indicators TEMP PLATES for evidence of overheating discoloration and grease leakage R1 Chapter 66 BHT 222 CR O 3 8 lnspect main driveshafts overtemperature indicato...

Page 55: ...s for freedom of movement R1 BHT 222 CR O 2 14 Visually inspect the accessible portion of the main rotor elastomeric pitch axis bearings trunnion bearings and flapping springs for evidence of delamination or loss of elastomer R1 Chapter 65 15 lnspect main rotor blades for obvious damage and for cleanliness R1 Chapter 27 BHT ALL SPM 16 lnspect roof mounted cyclic and collective shaft assemblies and...

Page 56: ...ck for binding excessive cycle time proper light operation and proximity switch operation and adjustment Check nose gear centering actuator for correct pressure b Perform emergency drop check c Remove oleo inflation valve and check for indication of hydraulic fluid SCHEDULED INSPECTIONS 5 17 PROGRESSIVE INSPECTION EVENT 2 CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 57: ...e and clean battery mounting area prior to installing a serviceable battery F1 F2 Chapter 52 Chapter 96 2 lnspect nose compartment electrical components for condition and security of mounting all electrical harnesses and cables for frayed wires loose or broken clamps and fasteners lnspect nose door for obvious damage and security of latching F1 F2 Chapter 95 3 lnspect pitot tube s for security of ...

Page 58: ...shields for cracks distortion loose or missing rivets broken spot welds deteriorating seals and sealant E1 E2 Chapter 71 12 lnspect left power plant area for evidence of fuel and oil leaks flexible and rigid fuel and oil lines for wear chafing damage and security of attachment E1 Chapter 71 13 lnspect left engine mounts and accessories for damage and security of attachment E1 Chapter 76 14 lnspect...

Page 59: ...uct assembly Inspect duct assembly for delamination Inspect reverse flow baffle door for security of attachment and general condition Chapter 65 BHT 222 CR O 2 22 For all main rotor hub assemblies verify torque of main rotor grip s retaining bolts nuts Apply 100 foot pounds 135 Nm of torque to the nut in the tightening direction Provided 100 foot pounds 135 Nm of torque is reached without movement...

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Page 61: ... es for cracking and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Chapter 26 1 lnspect right and left engine fire bottles for proper pressure indication F3 F4 Chapter 27 Chapter 29 2 Remove access panel from bottom of aft fuselage and inspect bellcrank and directional control hydraulic actuator supports for ...

Page 62: ...rstress T1 T2 Chapter 53 7 Visually inspect horizontal stabilizer auxiliary fins for obvious damage and security of attachment T1 T2 Chapter 53 8 lnspect horizontal stabilizer center area as follows T1 T2 a Remove upper support assembly Save attaching hardware b Clean upper surface of stabilizer NOTE Surface must be free of all dirt and residue c With bright light inspect upper surface for any cra...

Page 63: ...ters after TB 222 98 156 torque the nut in the tightening direction while restraining the bolt head If 130 inch pounds 14 5 Nm of torque is reached without nut movement increase torque to 160 inch pounds 18 Nm of torque If the nut moves below 130 inch pounds 14 5 Nm proceed with 2 year Inspection NOTE Examine inspection window s and or glass es for cracking and discoloration If either of these con...

Page 64: ...h or worn counterweight bellcrank bearings e Check for worn inner race in the tail rotor idler assembly f Check for unbonded bearing in the upper leg of tail rotor input lever assembly g Check for worn bearings in the tail rotor pitch links Chapter 65 16 Inspect tail rotor hub and blades for cleanliness visible damage to blades evidence of wear or excessive play in pitch change bearings and trunni...

Page 65: ...3 b With the blade bolts torqued to the highest value of torque range visually inspect each bearing inner member neck area full 360 for cracks If cracks are found replace both bearings in blade BHT 222 CR O 3 c Visually inspect chamfered washers installed in direct contact with the outboard surface of the yoke for deformation Deformed washers must be replaced SCHEDULED INSPECTIONS 5 19 PROGRESSIVE...

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Page 67: ...__________________ GENERAL Paragraph 5 13 1 Perform a complete 50 hour inspection DETAIL Chapter 66 1 Inspect right and left nodal beam assembly as follows a Flexure assembly for cracks in fiberglass shear pad debond delamination and security F5 F6 b Cam bearing for evidence of grease loss overheating and grease seal condition F5 F6 c Weight and cam arms for indications of misalignment and chafing...

Page 68: ...leakage security of attachment and excessive wear of brake linings Check brake disc for damage Check reservoir for fluid level and discoloration R1 F6 Chapter 66 BHT 222 CR O 3 7 lnspect tail rotor driveshaft coupling overtemperature indicators TEMP PLATES for evidence of overheating discoloration and grease leakage R1 Chapter 66 BHT 222 CR O 3 8 lnspect main driveshafts overtemperature indicators...

Page 69: ...R1 BHT 222 CR O 2 14 Visually inspect the accessible portion of the main rotor elastomeric pitch axis bearings trunnion bearings and flapping springs for evidence of delamination or loss of elastomer R1 Chapter 65 15 lnspect main rotor blades for obvious damage and for cleanliness R1 Chapter 27 BHT ALL SPM 16 lnspect roof mounted cyclic and collective shaft assemblies and control tubes for bearing...

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Page 71: ...e and clean battery mounting area prior to installing a serviceable battery F1 F2 Chapter 52 Chapter 96 2 lnspect nose compartment electrical components for condition and security of mounting all electrical harnesses and cables for frayed wires loose or broken clamps and fasteners lnspect nose door for obvious damage and security of latching F1 F2 Chapter 95 3 lnspect pitot tube s for security of ...

Page 72: ...shields for cracks distortion loose or missing rivets broken spot welds deteriorating seals and sealant E1 E2 Chapter 71 12 lnspect left power plant area for evidence of fuel and oil leaks flexible and rigid fuel and oil lines for wear chafing damage and security of attachment E1 Chapter 71 13 lnspect left engine mounts and accessories for damage and security of attachment E1 Chapter 76 14 lnspect...

Page 73: ...uct assembly Inspect duct assembly for delamination Inspect reverse flow baffle door for security of attachment and general condition Chapter 65 BHT 222 CR O 2 22 For all main rotor hub assemblies verify torque of main rotor grip s retaining bolts nuts Apply 100 foot pounds 135 Nm of torque to the nut in the tightening direction Provided 100 foot pounds 135 Nm of torque is reached without movement...

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Page 75: ... es for cracking and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Chapter 26 1 Inspect right and left engine fire bottles for proper pressure indication F3 F4 Chapter 27 Chapter 29 2 Remove access panel from bottom of aft fuselage and inspect bellcrank and directional control hydraulic actuator supports for ...

Page 76: ...corrosion wrinkles or other evidence of overstress T1 T2 Chapter 66 7 lnspect tail rotor driveshaft hanger bearings for roughness by disconnecting shaft from transmission and tail rotor gearbox Rotate by hand while feeling hangers Verify torque of tail rotor hanger splined adapter nut T1 T2 Chapter 53 8 Visually inspect horizontal stabilizer auxiliary fins for obvious damage and security of attach...

Page 77: ... after TB 222 98 156 torque the nut in the tightening direction while restraining the bolt head If 130 inch pounds 14 5 Nm of torque is reached without nut movement increase torque to 160 inch pounds 18 Nm of torque If the nut moves below 130 inch pounds 14 5 Nm proceed with 2 year Inspection Chapter 27 13 Remove aft right fuselage access panel and inspect control tube bellcrank and support assemb...

Page 78: ...ck for excessive radial play between the pitch control assembly and the tail rotor gearbox output shaft due to a worn or debonded guide bearing Radial play in excess of 0 018 inch 0 5080 mm is considered excessive b Check for worn areas on the tail rotor gearbox output shaft wear sleeve c Check for worn or rough crosshead bearing set d Check for rough or worn counterweight bellcrank bearings e Che...

Page 79: ...as of pitch change bearings BHT 222 CR O 3 b With the blade bolts torqued to the highest value of torque range visually inspect each bearing inner member neck area full 360 for cracks If cracks are found replace both bearings in blade BHT 222 CR O 3 c Visually inspect chamfered washers installed in direct contact with the outboard surface of the yoke for deformation Deformed washers must be replac...

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Page 81: ...____________________ GENERAL Paragraph 5 13 1 Perform a complete 50 hour inspection DETAIL Chapter 66 1 Inspect right and left nodal beam assembly as follows a Flexure assembly for cracks in fiberglass shear pad debond delamination security F5 F6 b Cam bearing for evidence of grease loss overheating and grease seal condition F5 F6 c Weight and cam arms for indications of misalignment and chafing F...

Page 82: ...leakage security of attachment and excessive wear of brake linings Check brake disc for damage Check reservoir for fluid level and discoloration R1 F6 Chapter 66 BHT 222 CR O 3 7 lnspect tail rotor driveshaft coupling overtemperature indicators TEMP PLATES for evidence of overheating discoloration and grease leakage R1 Chapter 66 BHT 222 CR O 3 8 lnspect main driveshafts overtemperature indicators...

Page 83: ...R1 BHT 222 CR O 2 14 Visually inspect the accessible portion of the main rotor elastomeric pitch axis bearings trunnion bearings and flapping springs for evidence of delamination or loss of elastomer R1 Chapter 65 15 lnspect main rotor blades for obvious damage and for cleanliness R1 Chapter 27 BHT ALL SPM 16 lnspect roof mounted cyclic and collective shaft assemblies and control tubes for bearing...

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Page 85: ...all installed control tubes links rod end bearings bellcranks supports and attachment bolts for corrosion evidence of wear and security of attachment lnspect spring cartridges and rotary actuators for security F1 F2 Chapter 12 2 Remove access panels along bottom centerline of fuselage to FS 356 00 Chapter 27 a lnspect directional control tubes rod end bearings bellcranks supports and attachment bo...

Page 86: ...f attachment F1 F2 F3 F4 Chapter 25 8 lnspect seat cushions and seat backs for tears excessive deterioration and security of attachment F1 F2 F3 F4 Chapter 25 9 lnspect seat assemblies for security of attachment F1 F2 F3 F4 Chapter 25 10 lnspect safety belts and shoulder harnesses for deterioration and security of attachment F1 F2 F3 F4 Chapter 26 11 lnspect cabin fire extinguisher for security an...

Page 87: ...ine air inlet duct assembly Inspect duct assembly for delamination Inspect reverse flow baffle door for security of attachment and general condition Chapter 71 20 Inspect right power plant area for evidence of fuel and oil leaks flexible and rigid fuel and oil lines for wear chafing damage and security of attachment E2 Chapter 71 21 Inspect right engine mounts and accessories for damage and securi...

Page 88: ... the tightening direction Provided 100 foot pounds 135 Nm of torque is reached without movement of the nut torque the bolt nut to 125 foot pounds 169 Nm If any nut moves before 100 foot pounds 135 Nm of torque is reached remove grip from main rotor hub assembly Inspect repair pitch horn and grip assemblies R1 SCHEDULED INSPECTIONS 5 24 PROGRESSIVE INSPECTION EVENT 9 CONT DATA REFERENCE INSPECTION ...

Page 89: ... es for cracking and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Chapter 26 1 lnspect right and left engine fire bottles for proper pressure indication F3 F4 Chapter 27 Chapter 29 2 Remove access panel from bottom of aft fuselage and inspect bellcrank and directional control hydraulic actuator supports for ...

Page 90: ...security of attachment T1 T2 Chapter 53 8 Visually inspect upper and lower surface of stabilizer for indications of cracks immediately adjacent to stabilizer support attaching stabilizer to tailboom T1 T2 Chapter 53 9 lnspect tail skid for obvious damage and security of attachment T1 T2 Chapter 53 10 lnspect vertical fin assembly for damage T1 T2 CAUTION HARDWARE AND TORQUE REQUIREMENTS OF THE VER...

Page 91: ...or proper oil level T1 T2 Chapter 66 13 Remove tail rotor gearbox chip detector Inspect and clean detector and test electrical circuit Install chip detector R2 14 Inspect tail rotor gearbox retaining nuts for proper torque 15 Inspect tail rotor pitch control assembly as follows a Check for excessive radial play between the pitch control assembly and the tail rotor gearbox output shaft due to a wor...

Page 92: ...bly prior to upgrade per TB 222 06 174 Part II 18 Inspect tail rotor blades pitch change bearings as follows a Without removing the blade clean exposed areas of pitch change bearings BHT 222 CR O 3 b With the blade bolts torqued to the highest value of torque range visually inspect each bearing inner member neck area full 360 for cracks If cracks are found replace both bearings in blade BHT 222 CR...

Page 93: ...spection DETAIL Chapter 27 BHT ALL SPM 1 Open control tunnel access in the canted bulkhead behind the pilot station Inspect the lower and upper cyclic and collective pitch control bellcranks for evidence of bearing wear corrosion or mechanical damage to clevises and security of attachment to supports and control tube bearings F5 F6 Chapter 66 2 Inspect right and left nodal beam assembly as follows...

Page 94: ...r damage is found contact Product Support Engineering for repair procedure NOTE Examine inspection window s and or glass es for cracking and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Chapter 66 3 lnspect transmission for evidence of oil leakage and correct oil level F5 F6 Chapter 66 4 Remove transmission ...

Page 95: ...t engine oil tanks and lines for evidence of leakage Check for proper quantity of oil F5 F6 Chapter 66 11 Visually inspect the outboard and inboard collective lever idler link attachment points for condition in area of lugs in transmission top case R1 BHT 222 CR O 2 12 lnspect hydraulic actuator support attaching nuts for proper torque R1 Chapter 65 13 lnspect cyclic and collective control levers ...

Page 96: ...al damage wear and security of attachment F5 F6 NOTE Examine inspection window s and or glass es for cracking and discoloration If either of these conditions are present the part must be removed and replaced prior to returning helicopter for service Chapter 29 18 lnspect hydraulic lines for leaks system PC 1 and PC 2 reservoirs for proper level and discoloration of fluid and module for differentia...

Page 97: ... damage and clean battery mounting area prior to installing a serviceable battery F1 F2 Chapter 52 Chapter 96 2 lnspect nose compartment electrical components for condition and security of mounting all electrical harnesses and cables for frayed wires loose or broken clamps and fasteners lnspect nose door for obvious damage and security of latching F1 F2 Chapter 95 3 lnspect pitot tube s for securi...

Page 98: ...terioration and security of attachment F1 F2 F3 F4 Chapter 25 7 lnspect seat assemblies for security of attachment F1 F2 F3 F4 Chapter 25 8 lnspect safety belts and shoulder harnesses for deterioration and security of attachment F1 F2 F3 F4 Chapter 26 9 lnspect cabin fire extinguisher for security and condition damage corrosion and quick opening clamp for operation and security F1 F2 Chapter 11 Ch...

Page 99: ... lever for wear or lost motion and for security of attachment E1 17 Inspect left engine ejector for security of attachment at plenum and support link Chapter 71 18 Remove left engine air inlet duct assembly Inspect duct assembly for delamination Inspect reverse flow baffle door for security of attachment and general condition Chapter 71 19 Inspect right power plant area for evidence of fuel and oi...

Page 100: ...in rotor grip s retaining bolts nuts Apply 100 foot pounds 135 Nm of torque to the nut in the tightening direction Provided 100 foot pounds 135 Nm of torque is reached without movement of the nut torque the bolt nut to 125 foot pounds 169 Nm If any nut moves before 100 foot pounds 135 Nm of torque is reached remove grip from main rotor hub assembly Inspect repair pitch horn and grip assemblies R1 ...

Page 101: ...of Main Beam and TB 222 91 129 Star Doubler Installation have been accomplished the inspection interval is 300 hours Paragraph 5 36 NOTE Additionally if referenced TBs have been accomplished and roof frame 222 031 503 105 or subsequent has been installed the inspection interval is 600 hours 1 Remove cover at FS 240 BL 12 on the right interior roof skin and inspect outboard side of main beam 222 03...

Page 102: ...o inspection with a 10 to 15 solution of cleaning compound C 318 and water 1 Using a bright light visually inspect nose landing gear trunnion webs for cracks and corrosion Pay particular attention to the left 45 web that extends from pivot shaft to cylinder attachment ring SCHEDULED INSPECTIONS 5 28 EVERY 100 HOURS OF COMPONENT OPERATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH...

Page 103: ...__________ _________________________ SWASHPLATE CONTROLS NOTE This inspection is applicable to drive pins 222 010 455 003 installed in rotating ring assemblies 222 010 403 005 and or 113 Chapter 65 1 Disconnect both drive link assemblies from swashplate rotating ring Inspect trunnion bearing for roughness and or looseness Replace bearing s if damaged or rough F5 F6 2 Check both swashplate rotating...

Page 104: ...sily be detected using procedures in step e and step f that follow An acceptable interference fit will allow zero pin rotation during the torque check procedure at 50 foot pounds 67 79 Nm of torque c Align the rectangular hole of torque test tool 230 210 100 101 on the wrenching flats of the drive pin to be tested Secure the tool to the pin with one thrust washer and nut Torque the retaining nut 6...

Page 105: ...ction of the swashplate rotating ring f Apply a maximum torque of 50 foot pounds 67 79 Nm in the counterclockwise left direction Verify the slip mark on the rotating ring drive pin joint Any misalignment of the slip mark indicating rotation of the drive pin is cause for rejection of the swashplate rotating ring BHT ALL SPM g If no rotation of the drive pin s is observed inspect the pin s for visib...

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Page 107: ..._________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN DRIVESHAFT Chapter 12 BHT 222 CR O 2 1 Inspect and lubricate right main driveshaft Chapter 12 BHT 222 CR O 2 2 Inspect and lubricate left main dr...

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Page 109: ...GISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ SWASHPLATE DUPLEX BEARING NOTE The following inspection is not required if triplex bearing set 222 310 476 101 is installed 1 Disconnect swashplate drive links and inspect swashplate duplex bearing 222 310 470 001 by applying pressure in both up an...

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Page 111: ... interference security of attachment mechanical damage or corrosion F5 F6 Chapter 65 2 Check collet friction and adjust as required 3 Remove pitch change links and inspect the following bearings a Upper pitch link bearing for axial looseness in excess of 0 015 inch 0 38 mm Replace bearing if limits are exceeded b Lower pitch link bearing in walking beam for roughness Check pitch link bearing by mi...

Page 112: ...ection of the torque wrench and the offset extension may be noticed when torque is applied This deflection could be perceived as pin rotation Therefore it is important that clear and precise index marks on the pins and the ring exist so that rotation can be verified by visible displacement between the marks NOTE The head of drive pin 230 010 402 101 103 has two flats that fit into a clearance slot...

Page 113: ...RQUE IN EXCESS OF 50 FOOT POUNDS 67 79 NM COULD RESULT IN A BREAKDOWN OF THE PRIMER ADHESION AND SUBSEQUENT PIN ROTATION WHICH IS CAUSE FOR REMOVAL FROM SERVICE OF THE RING ASSEMBLY e Apply a maximum torque of 50 foot pounds 67 79 Nm in the clockwise right direction Verify the slip mark on the rotating ring drive pin joint Any misalignment of the slip mark indicating rotation of the drive pin is c...

Page 114: ...ssembly for evidence of debonding or fretting of upper and lower sleeves Any evidence of looseness or fretting residue will require further disassembly of swashplate for inspection and repair c Move ball sleeve up and down through full range of travel and inspect swashplate support for surface damage and evidence of radial play between ball sleeve assembly and support Surface damage and or evidenc...

Page 115: ...me 222 031 503 from BL 0 0 to the right side attachment flange with the main beam 222 031 583 for cracks Pay particular attention to the area in line with the inboard leg of star doubler If a crack is found contact Bell Helicopter Textron Customer Representative HYDRAULIC PUMP SPLINES Paragraph 5 37 NOTE If TB 222 88 115 Hydraulic Pump Vespel Driveshaft has been accomplished inspection interval is...

Page 116: ...is inspection is not applicable to 222 035 250 107 and 109 1 X ray horizontal stabilizer 222 035 250 103 and 105 Refer to ASB 222 89 53 for inspection procedure SCHEDULED INSPECTIONS 5 32 EVERY 300 HOURS OF COMPONENT OPERATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 117: ... 900 hours of operation Chapter 66 1 Remove main driveshaft utilizing plate assembly T103031 107 or a suitable alternate hold engine adapter and verify retaining bolt torque 35 to 45 foot pounds 47 50 to 61 0 Nm If torque is low remove the bolt and perform visual and magnetic particle inspection Wear or crack indications on the bolt are cause for rejection Each time a low torque condition is encou...

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Page 119: ...________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ ENGINE FIRE EXTINGUISHER AND CARTRIDGE Chapter 26 Chapter 96 1 Inspect right engine fire extinguisher for dents and scratches Perform operational test of engine fire extinguisher system Chapter 26 Chapter 96 2 Inspect left engine fire ex...

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Page 121: ...________________ TAIL ROTOR DRIVESHAFT Chapter 12 BHT 222 CR O 3 1 Inspect and lubricate tail rotor driveshaft flexible coupling F5 F6 MAIN ROTOR MAST ASSEMBLY NOTE Removal of the main rotor hub assembly and main rotor swashplate assembly is not required to inspect the exposed external surfaces of the mast located above the transmission BHT 222 CR O 2 1 Inspect the electroless nickel coated area o...

Page 122: ......

Page 123: ... TB 222 86 92 Additional of Hi Lock Fastener TB 222 88 114 Installation of Main Beam and TB 222 91 129 Star Doubler Installation have not been accomplished the main beam roof frame joint shall be inspected every 100 hours 1 Remove cover at FS 240 BL 12 on the right interior roof skin and inspect outboard side of main beam 222 031 583 bulkhead joint for crack s 2 lnspect attachment flange of roof f...

Page 124: ...eplace bushing s per TB 222 02 169 NOTE The following inspections are not required on transmission modified in accordance with TB 222 84 65 or TB 222 84 66 and 222 00 163 and serviced with 555 lubricating oil specification DOD PRF 85734 AS 2 Visually inspect gear teeth of six pinions for excessive wear or pitting Pitting may be in the form of micropits very minute pit near the top or bottom edges ...

Page 125: ...shed the oil cooler blower drive splines shall be lubricated every 300 hours Chapter 71 1 Inspect left engine oil cooler blower Chapter 71 2 Inspect right engine oil cooler blower SCHEDULED INSPECTIONS 5 36 EVERY 600 HOURS OF COMPONENT OPERATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 9 SEP 2011 Rev 7 Page 107 108 ...

Page 126: ......

Page 127: ...____ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ HYDRAULIC PUMP SPLINES Paragraph 5 32 NOTE If TB 222 88 115 Hydraulic Pump Vespel Driveshaft has been accomplished inspection interval is 300 hours Chapter 29 1 Remove left hydraulic pump Inspect pump drive spline and transmission adapter gear spline for wear F5 Cha...

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Page 129: ...____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR HUB NOTE This inspection is applicable to all main rotor hub assemblies 222 011 101 and 222 012 101 Chapter 65 1 Remove main rotor hub and blades 2 Disassemble and clean main rotor hub NOTE It is not necessary to remove the flapping bearings from ...

Page 130: ...bolts NOTE Some of the bolts used in these applications are manufactured from non magnetic material For those bolts fluorescent penetrant inspection method BHT ALL SPM is acceptable in leu of magnetic particle inspection requirement b Flapping bearing to yoke attachment bolts BHT 222 CR O 2 5 Install new buffers on the pitch horn assemblies and flapping bearing assemblies BHT 222 CR O 2 6 Reassemb...

Page 131: ...___ FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ STANDBY ATTITUDE INDICATOR Chapter 95 1 Test the pilot standby attitude indicator power supply 9 SEP 2011 Rev 7 Page 113 114 ...

Page 132: ......

Page 133: ..._______________________ SIGNATURE _______________ _________________________ PITOT STATIC SYSTEM Chapter 95 1 Drain any accumulated moisture from the pitot static system piping F1 F2 FLIGHT CONTROLS 1 Inspect flight control bolts R1 NOTE More frequent inspection of control bolts may be required when operating in adverse environmental conditions Chapter 65 BHT ALL SPM a Remove the following bolts Ma...

Page 134: ... corrosion preventive compound C 101 VERTICAL FIN Chapter 53 BHT ALL SPM 1 Remove vertical fin Discard nuts 2 Inspect the vertical fin and tailboom fittings for cracks elongation of bolt holes distortion and corrosion 3 Inspect attaching bolts for serviceability 4 Temporarily install vertical fin to tailboom using serviceable hardware Tighten hardware 5 inch pounds 0 5 Nm plus tare Using feeler ga...

Page 135: ...hank only of all attaching bolts CAUTION HARDWARE AND TORQUE REQUIREMENTS OF THE VERTICAL FIN INSTALLATION ARE AFFECTED BY ACCOMPLISHMENT OF TB 222 98 156 Chapter 53 BHT ALL SPM 7 Install vertical fin to tailboom using bolts washers and nuts Torque attaching bolts nuts as required 8 Coat all bolt heads nuts and washers with corrosion preventive compound C 101 SCHEDULED INSPECTIONS 5 40 EVERY 2 CAL...

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Page 137: ...__________________________ SIGNATURE _______________ _________________________ HYDRAULIC SYSTEM RESERVOIR Chapter 29 1 Replace hydraulic system PC 1 reservoir baffle F6 Chapter 29 2 Replace hydraulic system PC 2 reservoir baffle F5 EMERGENCY FLOTATION SYSTEM NOTE This inspection applies to any reservoir cylinder that has been manufactured or last retested prior to July 1 2006 Chapter 99 BHT 222 SI...

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Page 139: ...tations for squib replacement intervals Chapter 26 1 Remove the right fire extinguisher reservoir Do a hydrostatic test in accordance with specification DOT 4 DA DOT 4 DS or DOT SP 7945 as marked on container F4 Chapter 26 2 Remove the left fire extinguisher reservoir Do a hydrostatic test in accordance with specification DOT 4 DA DOT 4 DS or DOT SP 7945 as marked on container F3 EMERGENCY FLOTATI...

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Page 141: ..._____________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR MAST ASSEMBLY TORQUEMETER BHT 222 CR O 2 1 Mast assembly must be disassembled and inspected for corrosion both externally and internally in addition to the inspection criteria of the BHT 222 CR O 2 The torquemeter shaft must be removed to inspect the inside diameter The m...

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Page 143: ...s of operation following each installation Engine Tailpipe Coupling after 5 to 10 hours of operation following each installation Vertical Fin after 5 to 10 hours of operation following each installation Main Rotor Hub after 5 to 10 hours of operation following each installation Hydraulic Actuator Support after 5 to 10 hours of operation following each installation Tail Rotor Hub and Blades after 5...

Page 144: ......

Page 145: ...______________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR HUB NOTE This inspection is to be performed every time the main rotor hub is disassembled to the extent allowing inspection of the buffers installed on the pitch horns and the flapping bearings BHT 222 CR O 2 1 When the main rotor hub is disassembled inspect condition of...

Page 146: ......

Page 147: ..._____________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR TRUNNION BHT 222 CR O 2 1 Verify torque of main rotor trunnion bolts in the tightening direction minimum 45 foot pounds 61 Nm Provided 45 foot pounds 61 Nm is reached without movement of bolts torque bolts to 53 foot pounds 72 Nm If any bolt moves before 45 foot pounds 61 Nm is reached remove all s...

Page 148: ......

Page 149: ...______ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ TAIL ROTOR HUB RETENTION NUT Chapter 66 1 Following each installation verify torque of retention nut attaching the tail rotor hub assembly to the tail rotor gearbox output shaft Repeat the torque verification ever...

Page 150: ......

Page 151: ...tion verify torque of nut to 475 to 675 foot pounds 644 to 915 Nm after a minimum of 5 hours but not to exceed 10 hours of service R1 ENGINE TAILPIPE COUPLING 1 Following each installation verify torque of coupling nut 70 to 100 inch pounds 7 9 to 11 3 Nm after initial engine run and every 5 to 10 hours thereafter until torque remains within limit for three consecutive inspections Chapter 53 VERTI...

Page 152: ... 222 CR O 3 1 Inspect tail rotor blade attaching bolts nuts for correct torque after a minimum of 5 hours but not to exceed 10 hours of operation after each installation Apply highest value of specified torque range to the nut while restraining the bolt head Repeat the torque verification every 1 to 5 hours until torque stabilizes R2 HYDRAULIC ACTUATOR SUPPORT BHT 222 CR O 2 1 Following each insta...

Page 153: ...___ SWASHPLATE Chapter 65 1 Verify swashplate friction adjustment 25 hours after initial installation R1 MAIN ROTOR TRUNNION BHT 222 CR O 2 NOTE Retorque is not required if flapping springs 222 310 117 105 are installed 1 Verify torque of main rotor trunnion bolts in the tightening direction minimum 45 foot pounds 61 Nm Provided 45 foot pounds 61 Nm is reached without movement of bolts torque bolt...

Page 154: ......

Page 155: ..._W O _____________________ FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ TAIL ROTOR GEARBOX Chapter 66 1 Verify torque of tail rotor gearbox retaining nuts T1 T2 9 SEP 2011 Rev 7 Page 137...

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Page 157: ...er Such events include but are not limited to the following Hard Landing Sudden Stoppage Power ON or OFF Overtorque Lightning Strike Overspeed Compressor Stall or Surge Components removed from a helicopter for evaluation as a result of conditional inspection shall be evaluated as an interrelated group Removal records accompanying each component shall cross reference part and serial numbers of othe...

Page 158: ......

Page 159: ...th mast which results in cracking or yielding of the transmission or nodal beam support structure or imparts unusually high loads on the landing gear A hard landing relative to retractable landing gear is any landing that causes any of the tires and or shock struts to bottom out when properly serviced or induces high side loads on any of the landing gear The following condition at touchdown could ...

Page 160: ...s c Inspect wheel yokes for yielding and twist removal of yoke from landing gear is required Fluorescent penetrant inspect yoke for cracks Check holes for elongation d Inspect main and nose gear drag arm and landing gear housing for deformation and for damage at airframe attachment points Check airframe attachment fittings for cracks and damaged rivets NOTE If the landing gear airframe attachment ...

Page 161: ...s provided no further evidence of damage is found 6 If damage is more extensive than landing gear crosstube yielding or if a hard landing has occurred comply with step 7 through step 22 7 Inspect main and tail rotor blades for evidence of strike damage If no obvious damage is discovered the blades may be retained in service for continued usage However if either rotor comes into contact with the gr...

Page 162: ...nd lift link attachment fittings 3 Transmission outboard quill case and forward lift links 4 Transmission redundant pylon up stop plates and up stop pins 5 Nodal beam travel up and down stops and flexure fittings 6 Main driveshaft transmission end coupling grease retainer sleeves and adjoining shaft area 10 For main rotor hub inspection proceed as follows a The main rotor flexure may be inspected ...

Page 163: ...op If distance is less than 0 025 inch 0 635 mm static stop has yielded excessively and must be replaced Modeling clay wax or any other material that will give a suitable impression may be used 1 Press small amount of modeling clay against yoke to static stop intersection to form an impression in clay 2 Carefully remove clay and inspect offset with a 0 025 inch 0 635 mm gauge 3 If offset is less t...

Page 164: ...nd loose rivets especially in the tailboom aft fuselage splice area and at the tail rotor gearbox attachment fitting 16 lnspect vertical fin for damage and distortion paying particular attention to the tail skid the mounting structure and the vertical fin attachment fitting NOTE If significant damage has been found in any area of the airframe inspection shall be expanded in those areas until it ex...

Page 165: ... interconnect valve will be detectable by observing a yellow ring adjacent to the frangible section If the ring is visible the valve has actuated and requires replacement 22 Perform a thorough visual inspection of the following components If inspection does not reveal any discrepancies or obvious damage to components they may be retained in service a Tail rotor hub and controls b Tail rotor gearbo...

Page 166: ......

Page 167: ...und water snow dense vegetation or other object of sufficient mass to cause deceleration Tail rotor blade damage when caused by striking some object sufficient to require blade replacement is considered sudden stoppage When sudden stoppage occurs inspect helicopter and replace components as follows NOTE If sudden stoppage is the result of main rotor strike comply with step 1 If sudden stoppage is ...

Page 168: ... more of the following discrepancies in step a through step d are found the swashplate and levers assembly and the drive assembly shall be removed and an overhaul inspection shall be performed a Main rotor blade damage requiring overhaul or replacement b Obvious damage or deformation to pitch horn or connecting bolts c Pitch change link failure of any type d Damage to lift link upper or lower atta...

Page 169: ...o show reason for removal was sudden stoppage BHT 222 CR O 2 f Transmission and Mast Assembly 1 If mast has evidence of torsional yielding the mast and transmission shall be considered unserviceable and scrapped If a main driveshaft required replacement step d the outboard quill will be unserviceable and scrapped BHT 222 CR O 2 2 If mast does not have torsional yielding main driveshafts were retai...

Page 170: ...ng of tail rotor driveshaft disc couplings exceeds 0 005 inch 0 127 mm c Any evidence of torsional yielding has been found in tail rotor driveshaft tubes d Inspection of gear tooth coupling in step 2 revealed chipping or other damage to coupling teeth BHT 222 CR O 3 h Tail Rotor Hub and Blade Assembly BHT 222 CR O 3 If sudden stoppage originated at main rotor or transmission tail rotor hub and bla...

Page 171: ...n as listed in step 1 and there is no obvious damage which would render hanger assemblies unserviceable the hanger assemblies shall have an overhaul evaluation performed Make an entry in component record to show reason for removal was sudden stoppage Chapter 66 b Tail Rotor Driveshafts NOTE If one or more of conditions listed in step a through step d are noted all driveshaft and bearing hangers sh...

Page 172: ...ginated at tail rotor driveshaft or tail rotor gearbox remove tail rotor hub and blade assembly and perform overhaul evaluation inspection Make an entry in component record to show reason for removal was sudden stoppage BHT 222 CR O 3 d Tail Rotor Gearbox 1 Inspect torque on tail rotor gearbox retaining nuts for 100 to 140 inch pounds 11 to 16 Nm 2 Remove tail rotor gearbox Check for cracks sheare...

Page 173: ... items are scrapped as unserviceable remove transmission and perform the following evaluation Make an entry in component record to show reason for removal was sudden stoppage BHT 222 CR O 2 1 Replace the collector gear BHT 222 CR O 2 2 lnspect collector gear shaft for excessive runout of gear mounting flange Runout of gear flange must not exceed 0 0004 inch 0 0101 mm when gear shaft is mounted on ...

Page 174: ......

Page 175: ...n which torsional loads are introduced into the helicopter dynamic system in excess of established limits This can involve either an overtorque of mast or engine Honeywell 101 650C 750C Series Operation and Maintenance Manual LTS 101 2 2 Refer to the engine manufacturer s manual for engine overtorque limits and inspection requirements 1 Model 222B When main rotor overtorque has exceeded 105 but di...

Page 176: ...tic stop contact area on the mast If any set of opposing measurements vary in excess of 0 002 inch 0 051 mm the mast is suspected of bending and a runout inspection must be performed 3 Start engine and check main rotor while in a flat pitch condition for any evidence of a 1 rev vibration If one or more of the previous inspection requirements of step 1 or step 2 reveals an unsatisfactory condition ...

Page 177: ...mission Make entry in component record to show reason for removal was overtorque Clean all transmission system oil lines and replace oil coolers c After the next 25 hours following an overtorque conduct a thorough inspection of the following 1 Main rotor hub assembly 2 Main rotor mast 3 Transmission top case 4 Transmission mount nodal beam link assemblies link attachments and arm and support assem...

Page 178: ... Tail rotor hub Chapter 65 BHT 222 CR O 2 5 Inspect the main rotor blades Pay particular attention to blade skins for distortion or debonding b Perform a thorough visual inspection of the following components If no visual damage is found the components may be retained in service 1 Swashplate and lever assembly 2 Drive assembly 3 Main rotor and tail rotor blades a Do a visual and tap inspection b I...

Page 179: ...llowing an overtorque conduct a thorough inspection of the following 1 Main rotor hub and blades 2 Transmission mount fittings upper and lower attachment points 3 Cabin roof at transmission mount fittings 4 Transmission restraint attachments 5 Transmission electric chip detectors 6 Tail rotor hub blades and attachments 7 Swashplate and lever assembly 8 Drive assembly CONDITIONAL INSPECTIONS 5 54 O...

Page 180: ......

Page 181: ... engine torque has exceeded 86 4 but did not exceed 103 perform the following a Record duration and maximum engine torque in main transmission maintenance record Honeywell 101 650C 750C Series Operation and Maintenance Manual LTS 101 2 2 b Refer to the engine manufacturer s manuals for engine overtorque inspection requirements if engine torque exceeded 100 c If engine torque exceeded 100 inspect m...

Page 182: ...ing a Record duration and maximum engine torque in main transmission maintenance record Honeywell 101 650C 750C Series Operation and Maintenance Manual LTS 101 2 2 b Refer to the engine manufacturer s manuals for engine overtorque inspection requirements BHT 222 CR O 2 c Perform overhaul of main transmission Make entry in component record that reason for removal was OEI overtorque operation 1 The ...

Page 183: ...follow if significant damage has been found in any area inspection shall be expanded in those areas until it extends beyond the zone of damage 1 Visually inspect all external surfaces of the helicopter with particular attention to main rotor blades and hub the transmission and mast assembly tail rotor blades and hub tail rotor gearbox horizontal stabilizer auxiliary fins and vertical fin Check ele...

Page 184: ... Remove main rotor hub grips 1 Visually inspect bearings for signs of electrical arcing burning or delamination 2 Visually check pitch change links at the drive assembly connections for arcing burns BHT 222 CR O 2 3 If indications of arcing or burning are present overhaul main rotor hub and drive assembly and replace the affected pitch change link including all attaching hardware BHT 222 CR O 2 4 ...

Page 185: ...3 c Remove output quill assembly from tail rotor gearbox Visually inspect gear teeth for signs of electrical arcing or burning Rotate tail rotor mast to check for smooth rotation of bearings 1 If evidence of arcing or burning is found or if bearings do not rotate smoothly remove gearbox and return it for overhaul stating lightning strike as reason for removal BHT 222 CR O 3 2 If no indications of ...

Page 186: ......

Page 187: ...Operation and Maintenance Manual LTS 101 2 2 Rotor overspeed is defined as any incident in which 109 main rotor speed is exceeded Refer to engine manufacturer s manual for engine overspeed limits and inspection requirement 1 If main rotor overspeed exceeds 109 but not more than 113 perform a thorough visual inspection of the following components If no damage is found no further inspection is requi...

Page 188: ... for service h Tail rotor controls i Main transmission j Main driveshaft 2 Perform the following inspection if main rotor overspeed exceeds 113 but not more than 120 a Remove and perform a thorough visual inspection as listed in step 1 b Verify torque of tail rotor gearbox attachment studs 3 Perform the following inspections if main rotor overspeed exceeds 120 Remove and perform overhaul inspectio...

Page 189: ...tor driveshafts h Tail rotor driveshaft hanger assemblies i Tail rotor gearbox j Tail rotor hub and blades k Tail rotor controls CONDITIONAL INSPECTIONS 5 57 OVERSPEED CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 9 SEP 2011 Rev 7 Page 171 172 ...

Page 190: ......

Page 191: ...ngine vibration and a rapid rise in measured gas temperature MGT depending on severity of surge When a surge has been reported progressively perform step 1 through step 6 as dictated by discrepant condition Compressor stall may cause severe torsional loading of the main driveshaft resulting in scoring of the transmission input quill gears and damage to the main driveshaft and distortion or damage ...

Page 192: ...or gearbox and inspect for metal particles 2 If no indication of metal particles is found on chip detectors clean chip detectors and reinstall Return helicopter to limited flight status and repeat chip detector inspection in 5 to 10 hours If positive indication of metal chips is found on chip detectors on initial or 5 to 10 hour inspection return unit for overhaul noting the reason b If compressor...

Page 193: ...noting compressor stall as reason for return BHT 222 CR O 2 4 Remove both main driveshafts and engine adapters and perform overhaul with particular attention to magnetic particle inspection Main rotor mast assembly may be retained in service 5 If no metal chips were found in step 1 and no scoring or damage was found in step 2 and step 3 return helicopter for limited flight and repeat chip detector...

Page 194: ... show that reason for removal was compressor stall or surge 5 Main Rotor Hub and Blades a Perform a close visual inspection of the main rotor hub and blades b Remove main rotor trunnion bearing to yoke attachment bolts and check for deformation shear offset c Inspect main rotor trunnion bearings for delamination security of attachment and play in bearing housing d If any discrepancies are noted re...

Page 195: ...on buckles skin cracks and sheared or loose rivets paying particular attention to tailboom mid fuselage splice and hanger bearing support structure c Make close visual inspection of main pylon support and engine mount attachment structure for distortion buckles cracks sheared or loose rivets etc d If discrepancies found during inspection in step a through step c cannot be repaired by standard proc...

Page 196: ......

Page 197: ... IS NOT COVERED IN THIS SCHEDULE REFER TO APPLICABLE SERVICE INSTRUCTIONS FOR KIT COMPONENTS SCHEDULE NOTE Refer to paragraph 5 6 for information on inspection and overhaul tolerance NOTE Neither assignment of a time period for overhaul of a component or failure to assign a time period for overhaul of a component constitutes a warranty of any kind The only warranty applicable to helicopter and any...

Page 198: ...spection is required at 3000 hours for a new transmission and 3000 hours after each overhaul BHT 222 CR O 2 An interim inspection is required at 3000 hours for a new tail rotor gearbox and 3000 hours after each overhaul BHT 222 CR O 3 A 600 hour interval inspection may be required Refer to Every 600 Hours of Component Operation Transmission assembly may be modified to the equivalent of transmissio...

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