BELL HELICOPTER 407 Series Maintenance Manual Download Page 57

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BHT-407-MM-1

5-00-00

Figure 5-1. Maintenance Zones

407_MM_05_0001

ZONE 1

ZONE 3

ZONE 7

ZONE 10

ZONE 8

ZONE 9

ZONE 4

ZONE 5

ZONE 6

ZONE 2

Zone 1

Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
Zone 7
Zone 8
Zone 9

Zone 10

- Main rotor hub and blade assembly
- Tail rotor hub and blade assembly
- Forward top deck
- Power plant
- Aft top deck
- Tailboom
- Cabin interior
- Foward fuselage
- Aft fuselage
- Landing gear

7 NOV 2006 Rev. 23

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Summary of Contents for 407 Series

Page 1: ...opter Textron Inc and Airworthiness Directives AD issued by the applicable regulatory agencies shall be strictly followed Export Classification C ECCN EAR99 22 FEBRUARY 1996 REVISION 47 2 MAY 2019 COPYRIGHT NOTICE COPYRIGHT 201 BELL HELICOPTER TEXTRON INC AND BELL HELICOPTER TEXTRON CANADA LTD ALL RIGHTS RESERVED MAINTENANCE MANUAL VOLUME 1 GENERAL INFORMATION ...

Page 2: ...er Textron Inc Garmin is a registered trademark of Garmin Ltd or its Subsidiaries Inclusion of Garmin products in these materials does not imply any endorsement by Garmin Ltd or its Subsidiaries or Affiliates PN Rev 35 10 DEC 2012 Export Classification C ECCN EAR99 DESTINATION CONTROL STATEMENT WARNING This document contains technical data whose export is restricted by the Arms Export Control Act ...

Page 3: ...LL 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 BELL IF YOU IDENTIFY OR SUSPECT THE USE OF PART...

Page 4: ...cal Customer Service Engineering CSE network please access http www bellflight com support and service support Model 206 407 or 505 Phone 450 437 2862 or 800 363 8023 U S Canada Fax 450 433 0272 E mail productsupport bellflight 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 productsupport bellflight com Model 204 205 212 or 412 Phone 450 437 ...

Page 5: ...e 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 appreciated Export Classi...

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Page 7: ...ail to the address on the next page 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 Export Classification C ECCN EAR99 ...

Page 8: ...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 TAPE HERE Export Classification C ECCN EAR99 ...

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

Page 10: ... 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 Export Classification C ECCN EAR99 ...

Page 11: ...ability 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 been repaired or altered outside Seller s factory...

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Page 13: ... 4 3 Tail Rotor Hanger Bearing Inspection 16 4 4 Tail Rotor Blade Inspection 18 4 5 Tailboom Assembly 300 Hour Inspection 19 4 6 Tailboom Assembly Daily Inspection 25 4 7 Tailboom Assembly 100 Hour Inspection 27 TABLES Table Page Number Title Number 4 1 Airworthiness Limitations Schedule 8 4 2 Inspection Limitations Schedule 12 The Airworthiness Limitations Schedule is approved by the Minister and...

Page 14: ...Export Classification C ECCN EAR99 REVISION NO DATE OF SIGNATURE APPROVAL SIGNATURE Original N A N A 1 29 March 1996 2 N A N A 3 26 October 1996 4 N A N A 5 18 July 1997 6 14 April 1998 7 N A N A 8 N A N A 9 30 November 1998 10 N A N A 11 N A N A 12 8 May 2001 ...

Page 15: ...ification C ECCN EAR99 13 14 21 September 2001 21 November 2001 15 N A N A 16 N A N A 17 N A N A 18 29 August 2003 19 N A N A 20 12 November 2004 21 16 November 2004 22 28 November 2005 23 7 November 2006 24 2 October 2007 REVISION NO DATE OF SIGNATURE APPROVAL SIGNATURE ...

Page 16: ...9 REVISION NO DATE OF SIGNATURE APPROVAL SIGNATURE 25 29 September 2008 26 23 December 2009 N A 27 23 February 2010 N A 28 29 July 2010 29 N A N A 30 8 April 2011 31 N A N A 32 N A N A 33 N A N A 34 N A N A 35 N A N A 36 N A N A 37 N A N A 38 N A N A 39 N A N A 40 21 February 2014 41 N A N A ...

Page 17: ...ED BHT 407 MM 1 4 00 00 Export Classification C ECCN EAR99 42 N A N A 43 N A N A 44 N A N A 45 9 January 2017 46 N A N A 47 2 MAY 2019 REVISION NO DATE OF SIGNATURE APPROVAL SIGNATURE 2 MAY 2019 Rev 47 Page 5 6 ...

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Page 19: ...IMIT IT MUST EITHER BE MADE UNSERVICEABLE OR MARKED IN A CONSPICUOUS MANNER TO PREVENT CONTINUED USE EVEN INADVERTENT USE THE TIME CALENDAR RIN LIFE MUST NOT BE EXCEEDED WITHOUT THE EXPRESS WRITTEN AGREEMENT OF BELL HELICOPTER AND THE LOCAL CERTIFICATION AUTHORITIES WHEN A REPLACEMENT PART IS INSTALLED THE PART NAME PART NUMBER SERIAL NUMBER AND CURRENT OPERATING HOURS IF APPLICABLE MUST BE RECORD...

Page 20: ... the component The airworthiness lives given to the components and assemblies are determined by experience tests and the judgment of Bell Helicopter engineers The 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 par...

Page 21: ...ellcrank Support 407 001 511 101 5000 hours TAIL ROTOR Blade 407 016 001 101 900 hours Yoke 406 012 102 109 5000 hours DRIVE SYSTEM Main Rotor Mast 407 040 038 101 5000 hours or 18 000 RIN Input Driveshaft 206 340 300 103 Input Driveshaft 206 340 300 105 Input Driveshaft 206 340 300 107 5000 hours Input Driveshaft 407 340 310 101 PYLON SUPPORT L H Pylon Side Beam 407 010 201 101 1000 hours or 5500...

Page 22: ...rd Crosstube Assembly High Gear Lightweight Float 407 050 201 101 5000 RIN Forward Crosstube Assembly High Gear Lightweight Float 407 724 101 5000 RIN Aft Crosstube Assembly High Gear Lightweight Float 407 050 202 101 5000 RIN Aft Crosstube Assembly High Gear Lightweight Float 407 725 104 5000 RIN Aft Crosstube Assembly High Gear Lightweight Float 407 704 007 119 2500 Landings 5000 RIN KITS Reserv...

Page 23: ...nd travel of the helicopter greater than 3 feet with the weight on the skids Refer to ASB 407 03 59 This crosstube is modified from crosstube assembly 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 When the helicopter is used for pilot training operations that include repeated ...

Page 24: ... pack coupling every 25 hours of operation Refer to ASB 407 97 13 Transport Canada AD CF 97 20R1 and FAA AD 97 24 17 Refer to Figure 4 1 for inspection details Refer to Figure 4 2 for inspection details Swashplate bearing must be removed from service no later than 31 December 1998 and replaced by bearing 406 310 402 103 Refer to ASB 407 97 11 and Transport Canada AD CF 97 22 Bell Note 1 above is n...

Page 25: ... removed from service no later than 31 May 2004 and replaced by bearing 407 340 339 107 Refer to ASB 407 04 63 Rev A dated 3 March 2004 or subsequent and Transport Canada AD CF 2002 18R3 Affected serial numbers of horizontal stabilizer 407 023 801 109 listed below must be removed from service no later than 30 September 2008 Do a functional check of the AFCS Trim Actuator Relay Chapter 22 11 12 13 ...

Page 26: ...BHT 407 MM 1 TC APPROVED 4 00 00 Page 14 Rev 47 2 MAY 2019 Export Classification C ECCN EAR99 Figure 4 1 Disc Pack Coupling Inspection ...

Page 27: ...TC APPROVED BHT 407 MM 1 4 00 00 2 MAY 2019 Rev 47 Page 15 Export Classification C ECCN EAR99 Figure 4 2 Main Rotor Yoke Inspection ...

Page 28: ...BHT 407 MM 1 TC APPROVED 4 00 00 Page 16 Rev 47 2 MAY 2019 Export Classification C ECCN EAR99 Figure 4 3 Tail Rotor Hanger Bearing Inspection Sheet 1 of 2 ...

Page 29: ...bearing seal during operation for a color change Bearings 406 040 339 ALL use Mobil 28 grease that is normally red purple but turns black when the bearing is damaged Also visually inspect the expelled grease that has accumulated for metal particles If there is no indication of roughness the expelled grease is not black there are no metal particles suspended in the expelled grease and the bearing s...

Page 30: ...g 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...

Page 31: ...n C ECCN EAR99 Figure 4 5 Tailboom Assembly 300 Hour Inspection Sheet 1 of 6 407_MM_04_0033a BS 157 00 BS 140 428 TAILBOOM IDENTIFICATION PLATE AREA D BS 107 397 BS 72 370 BS 39 00 AREA A AREA C AREA B AREA I AREA H 300 HOUR VISUAL INSPECTION CRITICAL INSPECTION AREAS SEE DETAILS ...

Page 32: ...BHT 407 MM 1 TC APPROVED 4 00 00 Page 20 Rev 47 2 MAY 2019 Export Classification C ECCN EAR99 Figure 4 5 Tailboom Assembly 300 Hour Inspection Sheet 2 of 6 ...

Page 33: ...TC APPROVED BHT 407 MM 1 4 00 00 2 MAY 2019 Rev 47 Page 21 Export Classification C ECCN EAR99 Figure 4 5 Tailboom Assembly 300 Hour Inspection Sheet 3 of 6 ...

Page 34: ... Tailboom Assembly 300 Hour Inspection Sheet 4 of 6 407_MM_04_0033d GENERAL VISUAL INSPECTION 300 HOURS CRITICAL INSPECTION AREA AREA C AND AREA D HORIZONTAL STABILIZER NOT SHOWN FOR CLARITY 2 0 IN 50 8 mm 139 7 mm 5 5 IN AREA D 7 3 3 6 2 0 IN BS 98 89 BS 120 75 50 8 mm 4 25 IN 108 0 mm 3 6 7 1 AREA C 2 4 ...

Page 35: ...TC APPROVED BHT 407 MM 1 4 00 00 2 MAY 2019 Rev 47 Page 23 Export Classification C ECCN EAR99 Figure 4 5 Tailboom Assembly 300 Hour Inspection Sheet 5 of 6 ...

Page 36: ...etails E F G and 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 ...

Page 37: ...ontal stabilizer Ref Upper support Ref Lower support 407 023 800 121 1 2 3 4 NOTES Paint and primer to be removed from these areas ASB 407 07 80 Examine these areas for cracks on left side of tailboom only Horizontal stabilizer not shown for clarity Daily check area 4 2 3 1 1 2 1 2 1 2 1 5 IN BS 98 89 BS 120 75 38 1 mm 2 0 IN 50 8 mm 1 5 IN 38 1 mm 2 0 IN 50 8 mm 3 407MM_04_0024 ...

Page 38: ...hown 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...

Page 39: ...27 Export Classification C ECCN EAR99 Figure 4 7 Tailboom Assembly 100 Hour Inspection Sheet 1 of 7 407_MM_04_0026 BS 140 428 BS 107 397 BS 39 00 BS 72 370 BS 90 00 AREA B AREA C AREA D AREA A 100 HOUR VISUAL INSPECTION CRITICAL INSPECTION AREAS SEE DETAILS ...

Page 40: ... SEE DETAIL E SEE DETAIL F SEE DETAIL G SEE DETAIL I SEE DETAIL G SEE DETAIL H AREA B DETAIL E GENERAL VISUAL INSPECTION 100 HOURS 100 HOUR INSPECTION 10X MAGNIFYING GLASS 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 LBL 7 50 BS 90 00 BS 74 370 BS 31 920 3 ...

Page 41: ...TC APPROVED BHT 407 MM 1 4 00 00 2 MAY 2019 Rev 47 Page 29 Export Classification C ECCN EAR99 Figure 4 7 Tailboom Assembly 100 Hour Inspection Sheet 3 of 7 ...

Page 42: ...BHT 407 MM 1 TC APPROVED 4 00 00 Page 30 Rev 47 2 MAY 2019 Export Classification C ECCN EAR99 Figure 4 7 Tailboom Assembly 100 Hour Inspection Sheet 4 of 7 ...

Page 43: ... 407_MM_04_0030 3 00 IN 76 2 mm BL 0 00 LBL 7 00 BS 107 397 AREA C VIEW J SEE VIEW J GENERAL VISUAL INSPECTION 100 HOURS 100 HOUR INSPECTION 10X MAGNIFYING GLASS 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 107 397 BS 120 75 BS 121 75 8 RIVETS LEFT SIDE ONLY 8 RIVETS LEFT SIDE ONLY ...

Page 44: ...N EAR99 Figure 4 7 Tailboom Assembly 100 Hour Inspection Sheet 6 of 7 407_MM_04_0031 VIEW D GENERAL VISUAL INSPECTION 100 HOURS 100 HOUR INSPECTION 10X MAGNIFYING GLASS 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 SEE VIEW D 3 FWD ...

Page 45: ...ks 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 H I Views J D and Area C Do not remove horizontal stabilizer Some tailboom components not shown for clarity If a crack is found on the t...

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Page 47: ...essive Inspection Event 3 5 00 00 18 5 15 Progressive Inspection Event 4 5 00 00 21 5 16 Progressive Inspection Event 5 5 00 00 25 5 17 Progressive Inspection Event 6 5 00 00 29 5 18 Airframe Periodic Inspection 5 00 00 33 5 18A 150 Hour Inspection 5 00 00 34A 5 19 300 Hour Inspection for Optional Equipment 5 00 00 35 5 20 600 Hour Inspection 5 00 00 37 5 21 600 Hour or 12 Month Inspection 5 00 00...

Page 48: ...TION SCHEDULE 5 33 Component Interim Inspection Schedule 5 00 00 89 COMPONENT OVERHAUL SCHEDULE 5 34 Component Overhaul Schedule 5 00 00 91 FIGURES Figure Page Number Title Number 5 1 Maintenance Zones 9 TABLES Table Page Number Title Number 5 1 Progressive Inspection Events 7 5 2 Rotor Brake Component Versus Inspection Document Table 38 5 3 Special Inspections 48 5 4 Component Interim Inspection ...

Page 49: ... Bell 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...

Page 50: ...t 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 conditiona...

Page 51: ...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 rot...

Page 52: ...f approval of the inspection and overhaul tolerance is required by the applicable governing aviation authority this is the responsibility of the owner operator Refer to the Rolls Royce Engine Operation and Maintenance Manual for inspection and overhaul tolerances The following provide examples of when hourly calendar or hourly calendar inspection tolerances have been applied Hourly Example 10 or u...

Page 53: ...ximum of 300 hours operating time 6 months calendar time whichever is less 1200 HOUR 24 MONTH INSPECTION DUE AT MAXIMUM ALLOWED TOLERANCE INSPECTION CARRIED OUT AT NEXT 1200 HOUR 24 MONTH INSPECTION DUE AT 3400 Hours August 31 2010 10 of 1200 hours 120 hours or 10 of 24 months 2 4 months 3400 Hours October 15 2010 within 10 calendar tolerance 4600 Hours October 31 2012 4600 Hours October 31 2012 1...

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Page 55: ... Airframe Progressive Inspection paragraph 5 12 at intervals of 50 hours After you complete Event Number 6 the cycle begins again with Event Number 1 Table 5 1 You must do a minimum of one complete cycle all six events within a 12 calendar month period If you do not complete all six events in a 12 calendar month period the remaining events must be completed prior to operating the helicopter The fo...

Page 56: ...00 hour inspection paragraph 5 24A 5 11 CHANGING INSPECTION PROGRAM You must use either the Airframe Periodic Inspection program or the Airframe Progressive Inspection program from the start You can change between the two programs at any airframe operating time To change from an Airframe Progressive Inspection program to an Airframe Periodic Inspection program or to change your progressive inspect...

Page 57: ...E 9 ZONE 4 ZONE 5 ZONE 6 ZONE 2 Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Zone 7 Zone 8 Zone 9 Zone 10 Main rotor hub and blade assembly Tail rotor hub and blade assembly Forward top deck Power plant Aft top deck Tailboom Cabin interior Foward fuselage Aft fuselage Landing gear 7 NOV 2006 Rev 23 Page 9 10 ...

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Page 59: ..._______________ ZONE 1 MAIN ROTOR SYSTEM PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Make sure you can read them they are applied correctly and they are in agreement with the applicable configuration of your helicopter MAIN ROTOR SYSTEM Chapter 62 1 Examine the main rotor system for condition and security Examine the components as follows a Main rotor hub and blades...

Page 60: ...d portion of the yoke for damage d Counterweights for damage e Weights and their supports for damage f Both blades of the tail rotor for damage g Inspect tail rotor blade s ASB 407 10 92 for evidence of delamination separation between skin plies and root end at trailing edge using a 10X magnifying glass If cracks are found or suspected at any location on the tail rotor blade or if excessive tail r...

Page 61: ...hapter 18 4 Dynamically balance the tail rotor hub and blade assembly DIRECTIONAL CONTROLS Chapter 67 1 Do a torque check of the bolts 60 to 80 inch pounds 6 7 to 9 Nm that attach the tail rotor pitch link assemblies to the tail rotor pitch horns BHT 407 FM X GROUND RUN 1 Complete a ground run at 100 NR to check for leaks and confirm system operation PROGRESSIVE INSPECTIONS 5 12 PROGRESSIVE INSPEC...

Page 62: ..._______ _________________________ ZONE 3 FORWARD TOP DECK PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Make sure you can read them they are applied correctly and they are in agreement with the applicable configuration of your helicopter AIRFRAME Chapter 53 1 Examine the forward and the transmission cowlings for condition Chapters 53 and 71 2 Examine the engine air in...

Page 63: ...anliness Chapter 67 b Rotate the outer ring Examine the duplex bearing for condition do this check before you lubricate the duplex bearing c Seals for signs of too much grease leakage d Pivot sleeve for wear and damage e Do a swashplate friction adjustment f Collective lever g Swashplate drive assembly HYDRAULIC Chapter 29 1 Examine the hydraulic system for condition leaks and security Examine the...

Page 64: ...assembly for condition and security Examine the components as follows a Up stops b Pylon beams c Corner mounts d Restraint spring assembly e Pylon stop transmission fitting f Pylon stop deck fitting 2 Examine the transmission assembly for damage leaks and security Examine the components as follows a Fluid flexible and rigid lines Chapter 96 b Electrical harness Chapter 63 c Impending bypass valve ...

Page 65: ...r mast bearing chip detectors for metal particles Examine the electrical circuit of the chip detectors for continuity GROUND RUN BHT 407 FM X 1 Complete a ground run at 100 NR to check for leaks and confirm system operation PROGRESSIVE INSPECTIONS 5 13 PROGRESSIVE INSPECTION EVENT 2 CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 66: ...ACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Make sure you can read them they are applied correctly and they are in agreement with the applicable configuration of your helicopter Chapter 71 ENGINE Chapter 53 1 Examine the engine cowling and the doors for condition and security 2 Examine the engine for condition leaks and security Examine the components as follows a Flu...

Page 67: ...intenance Manual 7 Do the applicable engine inspection Chapter 63 ENGINE TO TRANSMISSION DRIVESHAFT 1 Examine the engine to transmission driveshaft for condition and security Examine the components as follows a Driveshaft for corrosion surface damage and cracked spring b Flexframe and bolts for condition and signs of slippage Chapter 65 TAIL ROTOR FORWARD SHORT SHAFT ASSEMBLY 1 Examine the short s...

Page 68: ...for condition and security Chapter 71 STARTER GENERATOR 1 Remove and examine the starter generator for condition Examine the components as follows Brushes Commutator Drive spline 2 Examine the duct and the clamp for condition and security GROUND RUN Rolls Royce Engine Operation and Maintenance Manual 1 Do a FADEC manual mode check BHT 407 FM X 2 Complete a ground run at 100 NR to check for leaks a...

Page 69: ...________________________ ZONE 5 AFT TOP DECK PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Make sure you can read them they are applied correctly and they are in agreement with the applicable configuration of your helicopter AIRFRAME Chapter 53 1 Examine the aft fairing for condition 2 Examine the aft top deck for condition leaks and security Chapters 63 and 79 OIL SY...

Page 70: ...helicopter Chapter 53 TAILBOOM STRUCTURE 1 Examine the tail rotor driveshaft cover and the gearbox cowling for condition and security CAUTION ANY CRACK CORROSION OR LOOSE OR SHEARED RIVET IS CAUSE FOR IMMEDIATE GROUNDING OF THE HELICOPTER UNTIL THE PROBLEM IS CORRECTED 2 Examine the tailboom assembly for condition and security Examine the components as follows a Tailboom skins for chafing damage o...

Page 71: ...chment hardware 150 to 180 inch pounds 17 to 20Nm d Driveshaft tube assemblies 2 Examine the driveshaft segment assemblies for any noticeable rotational or axial fore and aft play between the adapter and the tail rotor driveshaft at all four locations a If rotational or axial play is found remove the adapter from the applicable driveshaft assembly and examine the associated parts for allowable dam...

Page 72: ...Examine the tail rotor pitch control mechanism for condition and security Examine the components as follows a Boot b Pitch links c Crosshead sliding seal GROUND RUN BHT 407 FM X 1 Complete a ground run at 100 NR to check for leaks and confirm system operation PROGRESSIVE INSPECTIONS 5 15 PROGRESSIVE INSPECTION EVENT 4 CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 73: ... INTERIOR CREW AND PASSENGER COMPARTMENTS PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Make sure you can read them they are applied correctly and they are in agreement with the applicable configuration of your helicopter BHT 407 FM X INSTRUMENTS 1 Inspect instruments for condition and security Inspect for correct markings EQUIPMENT AND FURNISHING Chapter 53 1 Examine...

Page 74: ... 10 For helicopters S N 54300 and subsequent make sure the Bell Maintenance Pages can be accessed Chapter 67 CONTROLS 1 Examine the cyclic and the collective control sticks and pedals for condition and security Examine the directional control pedal for correct operation 2 Examine components of airspeed actuated pedal stop for condition security and correct operation Examine components that follow ...

Page 75: ...GE 1 Examine the forward fuselage for condition and security Examine the components as follows Chapter 52 a Doors door hinges and latches b Complete litter door caution light operational check c Battery door d Any fluid leaks e Windows Chapter 53 f Side body fairings g Upper fairings and cowlings h Upper roof deck i Upper structure of the vertical tunnel attached to the main roof beam assembly j L...

Page 76: ...al check of the battery hot annunciator circuit 4 Examine the External Power Receptacle for condition and security Chapter 95 5 Examine the pitot and the static ports for condition and security Examine the components as follows a Pitot tube for discoloration and visible obstruction b Drain moisture from the pitot and the static piping installation Chapter 97 6 Examine the antenna s for condition a...

Page 77: ...TURE _______________ _________________________ ZONE 9 AFT FUSELAGE PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Make sure you can read them they are applied correctly and they agree with the applicable configuration of your helicopter AIRFRAME CAUTION ANY CRACK CORROSION OR LOOSE OR SHEARED RIVET IS CAUSE FOR IMMEDIATE GROUNDING OF THE HELICOPTER UNTIL THE PROBLEM IS...

Page 78: ...he existing sealant application meets the intent of the Aft Fuselage Attachment Fittings Sealant Removal and Application procedure specified in Chapter 53 sealant removal is not required Chapter 53 4 If required for inspection purposes it is recommended to remove the sealant around the fasteners of the aft fuselage attachment fittings Chapter 53 5 Examine the tailboom attachment fittings on the fu...

Page 79: ...nnunciator circuit Chapter 29 HYDRAULIC 1 Examine the tail rotor hydraulic system for condition leaks and security Examine the components as follows a Pivot bolts of the pilot valve on the actuators for freedom of rotation b Actuator support ZONE 10 LANDING GEAR PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Make sure you can read them they are applied correctly and th...

Page 80: ...Manual Publication CSP21001 1 Do the applicable engine inspection CSSD PSE 87 001 CORROSION CONTROL 1 Perform corrosion inspection in accordance with the Corrosion Control Guide GROUND RUN Rolls Royce Engine Operation and Maintenance Manual 1 Do a FADEC manual mode check BHT 407 FM X 2 Complete ground run at 100 NR to check for leaks and confirm system operation PROGRESSIVE INSPECTIONS 5 17 PROGRE...

Page 81: ...__________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 5 paragraph 5 12 through paragraph 5 17 1 Do this inspection every 12 calendar months or every 300 hours of operation 2 Do all six events of the airframe progressive inspectio...

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Page 83: ...__________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ NOTE This inspection applies only to helicopters S N 53000 through 55466 and 54568 through 54800 ENGINE CONTROLS Rolls Royce Engine Operation and Maintenance Manual 1 Do a FAD...

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Page 85: ...___ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ NOTE Complete the following if applicable PARTICLE SEPARATOR Chapter 71 1 Examine the particle separator for condition and security ROTOR BRAKE Chapter 63 1 Examine the rotor brake assembly for condition and security DUAL CONTROL Chapter 67 1...

Page 86: ...ine the crosstube fairings for condition and security AUXILIARY FUEL TANK Chapter 99 1 Examine the auxiliary fuel tank installation for condition and security SCHEDULED INSPECTIONS 5 19 300 HOUR INSPECTION FOR OPTIONAL EQUIPMENT CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 87: ..._____ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ ROTOR BRAKE BHT 407 CR O V NOTE Inspection information for the caliper assemblies and disc is contained in Northwest Dynamics Document No B0223 OM B0223 OM4 or B0244 OM as identified in Table 5 2 1 Inspect the rotor brake if installed MAIN ROTOR FRAHM NOTE The foll...

Page 88: ...0 53442 Post BHT 407 II 30 600 Hours B0223 OM 407 340 302 103 206 706 502 109 S N 53632 54140 S N 54300 54380 600 Hours B0223 OM4 407 540 304 101FM Kit not applicable Field Mod per TB 407 05 67 upgrade of 407 340 302 101 and 101FM S N 53000 53631 Post TB 407 05 63 and TB 407 05 67 600 Hours B0223 OM4 427 340 352 113 206 706 502 115 S N 54141 54299 S N 54381 and subsequent S N 53000 53442 Post BHT ...

Page 89: ...VIRONMENTAL CONDITIONS THE RECOMMENDED INTERVAL FOR INSPECTION AND LUBRICATION MUST BE REDUCED TO 600 HOURS OR 6 MONTHS Chapter 62 MAIN ROTOR HUB AND BLADE 1 Remove main rotor blades from the main rotor hub assembly 2 Remove oil and grease from the main rotor hub blades and blade bolts with clean cloths C 516 dampened with aliphatic naphtha C 305 or drycleaning solvent C 304 3 Clean main rotor hub...

Page 90: ... c Flight Control Computer FCC Chapter 22 d Mode Select Panel MSP Chapter 22 2 Do a functional check of the AFCS SEALED LEAD ACID SLA BATTERY Chapter 96 BHT 407 CR O V Chapter 96 1 Service the battery as follows a Remove the battery b Perform capacity check according to the manufacturer s component maintenance manual c Inspect the vent lines for obstructions or damage d Clean the battery mounting ...

Page 91: ...n paragraph 5 10 or one complete cycle all six events of the progressive inspection paragraph 5 9 have been completed in the last 12 calendar month period 2 Inspect all fuel system oil system and hydraulic system filler caps for proper functioning and sealing Make sure the sealing O rings within the filler caps are in good condition Repair or replace the filler caps or replace sealing O rings as r...

Page 92: ...mponents that follow a Solenoid b Cam c Release cable 3 Operate the airspeed actuated pedal stop manual cable release mechanism for the cam Examine for correct operation and free movement of cable Safety the cable release handle with lockwire C 554 Chapter 96 4 Perform a pedal restrictor control system functional test Chapter 67 5 Examine all fluid flexible and rigid lines for condition leaks and ...

Page 93: ...CAUTION ANY CRACK CORROSION OR LOOSE OR SHEARED RIVET IS CAUSE FOR IMMEDIATE GROUNDING OF THE HELICOPTER UNTIL THE PROBLEM IS CORRECTED Chapter 53 8 Examine the structure for condition in the locations that follow a Pedestal b Crew seats c Bulkhead at fuselage station 81 08 d Vertical tunnel Examine interface between upper section of vertical tunnel and roof beam assembly for possible crack damage...

Page 94: ...eck Chapter 28 2 Examine the operation of the check valves for the forward fuel cell transfer pumps Turn on each transfer boost pump assembly individually and visually confirm flow of fuel from outlet of fuel transfer line in aft fuel cell Fuel system may have to be defueled until fuel level is below transfer line outlet 3 Examine the fuel system shutoff valve and components for condition leaks an...

Page 95: ...g 407 040 038 111T1 expanded repair of the tungsten carbide coating Chapter 62 2 Remove the main rotor hub BHT 407 CR O Chapter 63 3 For the mast pole 407 040 038 101 105 109 or 111R examine the lower cone clamping journal for sleeve debonding voids and corrosion ASB 407 11 94 BHT 407 CR O Chapter 63 4 For the mast pole 407 040 038 111 111T or 111T1 examine the lower cone clamping journal for corr...

Page 96: ...eaks and confirm system operation GARMIN SOFTWARE S N 54300 AND SUBSEQUENT Chapter 95 1 Verify latest software version configuration available on the Bell Helicopter website www bellhelicopter net 2 Upgrade the helicopter to the latest software version SCHEDULED INSPECTIONS 5 22 12 MONTH INSPECTION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER Page 44B Rev 46 1 MAR 2018 ...

Page 97: ...fuel transfer fuel boost pump assemblies Look into the fuel cells Examine them for unwanted material water contamination and fungus growth 2 Disassemble examine and functionally test the fuel transfer fuel boost pump check thermal relief valves for condition Chapter 95 3 Do a calibration of the fuel quantity system Chapter 67 CONTROLS 1 Inspect the cyclic spring link for condition FLIGHT CONTROL B...

Page 98: ..._______ FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 67 CONTROLS 1 Remove and examine the tail rotor pitch change control tube inside the tailboom for condition Page 44D Rev 40 1...

Page 99: ..._____________ _________________________ Chapter 67 PILOT CYCLIC CONTROL STICK 1 Perform a 1200 hour or 24 month inspection of the pilot cyclic control stick Chapter 67 AUTOMATIC FLIGHT CONTROL SYSTEM AFCS 407 706 061 NOTE The following steps are only applicable to the 407GX with the AFCS installed 1 Visually examine the nylatron strips on the following components inside the vertical tunnel for con...

Page 100: ..._ SIGNATURE _______________ _________________________ Chapter 67 CONTROLS NOTE For new and in service pitch link assemblies the first 2500 hour inspection occurs at 5000 hours of component operating time and subsequent inspections occur every 2500 hours For main rotor pitch link assemblies already removed from service due to reaching the 5000 hour life limit previously required i e Pre Revision 28...

Page 101: ...________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ NOTE Refer to the requirements from your government authority for the applicable interval s Chapter 97 1 Do an operational check of the pressure altitude reporting and A...

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Page 103: ...tion C ECCN EAR99 SPECIAL INSPECTIONS 5 25 SPECIAL INSPECTIONS A special inspection Table 5 3 is temporary or of a special time interval that is not consistent with the scheduled inspection Torque Friction Check Table 5 3 Freewheel Lubrication System paragraph 5 25A ...

Page 104: ...FTER INITIAL INSTALLATION SIGNATURE AFTER GROUND RUN 1 TO 5 HOURS 10 TO 25 HOURS 25 5 HOURS 100 10 HOURS MECH OTHER Main Rotor Hub Mast Nut Torque Check X X Main Rotor Hub Through Bolt Torque Check X X Main Rotor Hub Lower Cone Torque Check X X Tail Rotor Gearbox Torque Check X All Tail Rotor Driveshaft Disc Pack Couplings Torque Check X Tail Rotor Hub Mast Nut Torque Check X Engine Mounts Torque ...

Page 105: ...ht hours specified in progressive inspection Repeat the swashplate tilt friction check every 10 to 25 hours until the friction has stabilized within limits Also repeat the tilt friction check every 300 flight hours specified in progressive inspection Complete fuel system operational check immediately after fuel system maintenance or component change Chapter 28 Do a tension check of the expandable ...

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Page 107: ...ection is required to ensure that there is no debris or blockage of restrictor 406 040 623 101 and restrictor 406 040 624 101 located on the left side of the forward engine firewall WARNING THE FREEWHEEL LUBRICATION SYSTEM INSPECTION MUST BE DONE AFTER ANY OF THE FOLLOWING EVENTS Installation of the transmission Refer to the transmission operational check The disconnection replacement or reconnect...

Page 108: ...fication C ECCN EAR99 Figure 63 76 Transmission oil pressure transmitter 30 Hose assembly either end 8 Union and fitting 26 Tube assembly either end 25 Cap 28 SPECIAL INSPECTIONS 5 25A FREEWHEEL LUBRICATION SYSTEM CONT DATA REFERENCE INSPECTION TASK DESCRIPTION ...

Page 109: ...s for each of these components must agree with the part number and the serial number of each of the other components Put a tag on the removed part s sent for analysis that states THIS NAME OF PART WAS REMOVED FROM SERVICE BECAUSE OF A REASON FOR REMOVAL Events that require a conditional inspection include but are not limited to the following Hard landing Sudden stoppage main rotor power ON or OFF ...

Page 110: ...BHT 407 MM 1 5 00 00 Export Classification C ECCN EAR99 CONDITIONAL INSPECTIONS 5 26A DELETED DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER Page 52B Rev 45 9 JAN 2017 ...

Page 111: ...cking of the fuselage pylon structure or the landing gear After a hard landing If the cabin fuselage is resting on the ground or shows signs of having touched the ground think of it as having been exposed to loads in excess of 10 G If you think that the helicopter had a hard landing do the steps that follow Chapter 62 MAIN ROTOR HUB AND BLADES 1 Examine the main rotor blades for evidence of contac...

Page 112: ...e main rotor Frahm is serviceable TAIL ROTOR BLADE ASSEMBLY Chapter 64 1 Examine the tail rotor blade assembly for damage If you find any damage complete this inspection and also do a SUDDEN STOPPAGE TAIL ROTOR inspection 2 If you do not find any damage the tail rotor hub and blade assembly is serviceable AIRFRAME Chapter 53 1 Examine the airframe for damage 2 If you find any one of the signs that...

Page 113: ...formation or damage to of the bulkheads at stations 76 and 155 Chapter 53 INTERMEDIATE FUSELAGE m Distortion or damage to the upper longerons n Cracks or damage at the side or forward engine mount to fuselage attachment points o If the fuselage composite skin needs to be replaced p If the engine pan needs to be replaced q Deformation or damage to the aft fuselage tailboom attachment points 1 If th...

Page 114: ...rike protection system lower and upper cutter assemblies If there is evidence of main rotor blade contact with the upper cutter assembly inspect main rotor blades for damage Chapter 62 Chapter 53 TAILBOOM 1 The signs that follow show that the tailboom must be aligned in a Bell Helicopter approved fixture a tailboom skin deformation buckling or cracks b damaged bolts or bolt holes at the attachment...

Page 115: ... and the mounting points is not cause to send the tailboom for repair on an alignment fixture Repair or replace the damaged parts Chapter 53 6 Examine the tailboom skin for damage in the area of the tail rotor blade tip path Repair or replace the damaged area Chapter 32 LANDING GEAR 1 Examine the landing gear for condition and security Examine the components that follow a Skid tubes b Skid saddles...

Page 116: ...ints four elastomeric mounts at the corners of the top case and two elastomeric mounts at the bottom of the main case one on each side Use a 10X power magnifying glass and look for cracks deformation or movement of the attachment fittings d Signs of damage to the roof structure where the side beams attach to the roof e Examine for loose attaching hardware in the locations that follow 1 Transmissio...

Page 117: ...1 Do the engine hard landing inspection NOTE After a hard landing if the cabin fuselage is resting on the ground or shows signs of having touched the ground think of it as having been exposed to loads in excess of 10 G Chapter 53 2 Examine the engine mounts and the fuselage attachment points for condition If you find deformed engine mount legs replace them If you find deformed attachment points th...

Page 118: ...tor hub assembly and write THIS HUB ASSEMBLY WAS REMOVED FROM SERVICE BECAUSE OF A HARD LANDING Send the hub assembly to an approved facility for overhaul Chapter 62 c Remove the swashplate and support assembly Put a tag on the swashplate and support assembly and write THIS SWASHPLATE AND SUPPORT ASSEMBLY WAS REMOVED FROM SERVICE BECAUSE OF A HARD LANDING Send the swashplate and support assembly t...

Page 119: ...oints h Fuel probe attachment points i Auxiliary fuel tank for leakage j Boost pump for correct operation k Fuel quantity indicator for correct operation l All fluid flexible and rigid lines Chapter 53 2 Replace the damaged components Repair the damaged structure GROUND RUN BHT 407 FM X 1 If you find any damage during the inspection make sure that it is repaired Make sure that all of the systems a...

Page 120: ...OR POWER ON OR OFF Sudden stoppage is any fast deceleration of the main rotor drive system This may be caused by the seizure of the transmission or by contact of the main rotor blades with the ground water snow dense vegetation or other objects of sufficient mass to cause a fast deceleration of the main rotor When a sudden stoppage has occurred do the steps that follow Chapter 62 MAIN ROTOR BLADES...

Page 121: ...ain rotor hub to an approved facility for overhaul 4 If a main rotor blade s is damaged sufficiently to be sent to an approved facility for repair remove the main rotor hub assembly Put a tag on the main rotor hub and write THIS MAIN ROTOR HUB WAS REMOVED FROM SERVICE BECAUSE OF A SUDDEN STOPPAGE Send the main rotor hub to an approved facility for overhaul 5 If the main rotor mast was cut in two d...

Page 122: ...om the hydraulic servo actuator to the main rotor hub pitch horns Chapter 67 CONTROL SYSTEM 1 Examine the main rotor control tubes for condition If you replace a bent or broken tube do step 3 2 Examine the main rotor pitch horns for condition If you replace a broken pitch horn do step 3 3 Examine all of the control bolts for condition If you find damage in steps 1 or 2 discard all of the control b...

Page 123: ...IS MAST AND TRANSMISSION ASSEMBLY WAS REMOVED FROM SERVICE BECAUSE OF A SUDDEN STOPPAGE Send the mast and transmission assembly to an approved facility for overhaul 5 If there is large damage to the mast other than torsional yielding replace mast assembly and top case of transmission 6 Examine the transmission corner mounts and restraint elastomeric for condition Replace damaged parts Chapter 63 E...

Page 124: ...ment point location send the fuselage to an approved repair facility for repair Repair damaged beam 2 Examine the left hand and the right hand restraint stops for damage at the deck fitting to the transmission fitting pin interface If the roof structure is damaged at the attachment point location send the fuselage to an approved repair facility for repair Replace damaged restraint stops and deck f...

Page 125: ...y for damage If any damage is found complete this inspection and also do a SUDDEN STOPPAGE TAIL ROTOR inspection 2 If damage is not found the tail rotor hub and blade assembly is serviceable Chapter 53 TAILBOOM 1 Examine the tailboom skin for damage in the area of the tail rotor blade tip path Repair or replace the damaged area CONDITIONAL INSPECTIONS 5 28 SUDDEN STOPPAGE MAIN ROTOR POWER ON OR OF...

Page 126: ...ation of the rotor drive system This may be caused by the seizure of the tail rotor drive system or by contact of the tail rotor blades with the ground water snow dense vegetation or other objects of sufficient mass There is a sudden stoppage when a tail rotor blade strikes some object with a force sufficient to require a blade to be discarded When sudden stoppage has occurred do the steps that fo...

Page 127: ...emaining hanger and bearing assemblies Put tags on the hanger and bearing assemblies and write THIS HANGER AND BEARING ASSEMBLY WAS REMOVED FROM SERVICE BECAUSE OF A SUDDEN STOPPAGE Send the hanger and bearing assemblies to an approved facility for overhaul 3 If a tail rotor driveshaft fails because of a torsional load discard all of the tail rotor driveshaft assemblies the forward short shaft the...

Page 128: ...for condition and correct operation Replace all of the damaged parts 2 If you see one or more of the following defects discard the pitch change mechanism a Tail rotor hub pitch horn failure b Control tube bent or broken c Damaged tail rotor gearbox output shaft 3 Discard all of the rotating control bolts 4 If you do not see any damage after a close visual inspection of the tail rotor control syste...

Page 129: ...and blade assembly to an approved facility for overhaul Chapter 53 TAILBOOM CAUTION ANY CRACK CORROSION OR LOOSE OR SHEARED RIVET IS CAUSE FOR IMMEDIATE GROUNDING OF THE HELICOPTER UNTIL THE PROBLEM IS CORRECTED 1 Examine the tail boom for condition a Internally b Externally 2 Examine the four tailboom attachment fittings on the fuselage and on the tailboom for condition and security Pay particula...

Page 130: ...rea Chapter 64 9 Examine the support yield indicator for damage If the support yield indicator clearance is decreased discard the support yield indicator and proceed as follows a Discard tail rotor yoke b Inspect tail rotor blades for delamination c Inspect pitch links for condition d Inspect pitch horns for condition e Inspect tailboom for condition in tail rotor blade tip path area Chapter 18 10...

Page 131: ...SIGNATURE _______________ _________________________ MAIN ROTOR OVERSPEED A main rotor overspeed is an incident in which 118 main rotor RPM is exceeded AFTER OVERSPEED BELOW 118 1 When a main rotor overspeed below 118 has occurred no airframe inspection is required Rolls Royce Engine Operations and Maintenance Manual 2 Do the engine overspeed inspection AFTER OVERSPEED OF 118 AND ABOVE When a main ...

Page 132: ...acility for overhaul a If a grip is deformed discard it b If the yoke is delaminated discard it 6 If the main rotor hub has no damage it is serviceable 7 Examine the main rotor Frahm if installed TB 407 03 51 for internal and external damage If the main rotor Frahm shows signs of damage remove it Put a tag on the Frahm and write THIS FRAHM WAS REMOVED FROM SERVICE BECAUSE OF A MAIN ROTOR OVERSPEED...

Page 133: ...ter 65 DRIVE SYSTEM 1 Examine the chip detectors of transmission freewheel and tail rotor gearbox If there is no unwanted material the drive system is serviceable If the chip detector shows signs of unwanted material remove the applicable component Put a tag on the applicable component and write THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A MAIN ROTOR OVERSPEED Send the applicable component...

Page 134: ... ECCN EAR99 BHT 407 FM X 6 Do a ground run for a minimum of one hour with the helicopter light on its skids Examine the fuel and the oil systems for leaks CONDITIONAL INSPECTIONS 5 30 MAIN ROTOR OVERSPEED CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 135: ...______________ _________________________ OVERTORQUE An overtorque is an incident in which torsional loads greater than those permitted are applied to the helicopter dynamic system NOTE The torque values given in this section are those displayed by the torque indicator The FADEC ECU EEC will record torque values that are different Refer to Chapter 76 and Rolls Royce Engine Operations and Maintenanc...

Page 136: ...to an approved facility for overhaul a If any grip is deformed discard it b If the yoke is delaminated discard it c If the elastomeric bearings or the lead lag damper is separated or crumbled discard it d If the elastomeric damper or the lead lag damper is separated discard it 5 If the main rotor hub has no damage it is serviceable Chapter 63 DRIVE SYSTEM AND PYLON MOUNTS 1 Examine the chip detect...

Page 137: ... POLE WAS REMOVED FROM SERVICE BECAUSE OF A MAIN ROTOR OVERTORQUE Send the mast pole to Bell Helicopter Textron for analysis to determine if the mast has sustained torsional yielding 6 If Bell Helicopter Textron finds that the mast has torsional yielding discard the mast assembly transmission assembly engine to transmission driveshaft and the freewheel the outer race the inner race and the clutch ...

Page 138: ...or blades from the hub Put a tag on the applicable component and write THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A MAIN ROTOR OVERTORQUE Send the tail rotor blade to an approved facility for analysis Send the tail rotor hub to an approved facility for overhaul Rolls Royce Engine Operations and Maintenance Manual POWER PLANT 1 Do an engine overtorque inspection AFTER THE FIRST 25 FLIGHT HO...

Page 139: ...rmed When on overtorque has exceeded 120 remove the components that follow Put a tag on the component and write THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A MAIN ROTOR OVERTORQUE Send the component to an approved facility for overhaul Chapter 62 1 Main rotor hub Chapter 63 2 Main rotor mast Chapter 63 3 Main transmission replace the top case of the main transmission Chapter 63 4 Freewheel ...

Page 140: ...vibration or a rapid rise in Measured Gas Temperature MGT depending on the severity of stall or surge When a stall or surge is suspected follow steps as dictated by reported conditions NOTE The components removed from the helicopter for evaluation following a compressor stall or surge shall be evaluated as a matched group The records accompanying each component shall cross reference part and seria...

Page 141: ...action If no blockage is found do step 2 2 Remove the induction fairing and examine the compressor intake area as follows a Examine the compressor rotor for contamination If contamination is found perform a compressor wash Refer to the Rolls Royce Operation and Maintenance Manual b Inspect compressor rotor for foreign object damage in accordance with the Rolls Royce Operation and Maintenance Manua...

Page 142: ...nd the component to a Bell Helicopter Textron approved facility for overhaul 2 Examine the tail rotor driveshafts for condition and security of attachment 3 Examine the tail rotor disc pack couplings for cracks or gapping greater than 0 015 inch 0 38 mm 4 Examine the tail rotor steel driveshaft and adapters for structural failure or distortion exceeding specified limits 5 Examine the tail rotor dr...

Page 143: ... overhaul Chapter 64 2 Examine the tail rotor blade s for condition If any damage suspected to be related to the stall or surge is found remove the tail rotor blade s Make an entry on the Historical Service Record and attach a tag on the tail rotor blade s and write THIS BLADE WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL OR SURGE Send the tail rotor blade s assembly to a Bell Helicopter ...

Page 144: ...AS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL SURGE Send the component to a Bell Helicopter Textron approved facility for overhaul 5 If no defects were detected on main rotor hub the main rotor hub is serviceable 6 If defects are detected in step 1 step 2 and step 4 perform a main rotor sudden stoppage inspection SPECIAL INSPECTION After 25 hours of operation examine chip detectors of tran...

Page 145: ...ASSEMBLY BHT 407 CR O 1 Remove the transmission input pinion and triplex bearing 2 Inspect the following gear teeth for scoring and other mechanical damage a Input pinion gear b Main input driven bevel gear 3 If any damage suspected to be related to the stall or surge is found make an entry on the Historical Service Record and attach a tag on the transmission assembly and write THIS COMPONENT WAS ...

Page 146: ...pect tailboom attachment fittings for cracks 3 Inspect the vertical fin for condition and security of attachment Chapter 63 Chapter 65 GROUND RUN BHT 407 FM X 1 Perform a ground run for a minimum of 30 minutes with the helicopter light on its skids Remove and examine the chip detectors of the transmission assembly freewheel assembly and tail rotor gearbox 2 If any of the chip detectors show signs ...

Page 147: ... were found the transmission assembly freewheel assembly and or tail rotor gearbox are serviceable CONDITIONAL INSPECTIONS 5 31A ENGINE COMPRESSOR STALL OR SURGE CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 29 JUL 2010 Rev 28 Page 82G ...

Page 148: ... or as small weld marks where the metal has melted and become solid again Honeycomb and other composite materials may show signs of delamination NOTE In all instances below if you find damage in any area extend the inspection in those areas until you find no more damage If any component shows signs of arc burns discard it Use a magnetometer with a range no larger than 5 gauss Put the arrow or the ...

Page 149: ... tailboom structures h the tail rotor hub and blades i the external surfaces of the helicopter for signs of arcing Pay particular attention to the areas that follow 1 between the aft fuselage skin panels and the airframe structure at FS 155 0 and at FS 231 0 2 on the vertical fin and on the attaching bolts 3 on the horizontal stabilizer and finlet attachment supports 4 the tailboom and attachment ...

Page 150: ... rotor hub Put a tag on the main rotor hub and write THE MAIN ROTOR HUB WAS REMOVED FROM SERVICE BECAUSE OF A LIGHTNING STRIKE Send the main rotor hub to an approved facility for overhaul If a component shows signs of arcing or delamination discard it b If you do not see signs of arcing the main rotor hub is serviceable 3 Main rotor Frahm if installed TB 407 03 51 a If you see signs of arcing burn...

Page 151: ...CAUSE OF A LIGHTNING STRIKE Send the swashplate assembly to an approved facility for overhaul If a part shows signs of arcing discard it Chapter 63 TRANSMISSION AND MAST ASSEMBLY 1 Remove the mast assembly Disassemble it and examine for condition as follows a Examine all of the components for signs of arc burns Pay particular attention to the bearing ring raceways b If you do not see arc burns and...

Page 152: ... the tail rotor driveshaft then the freewheel is serviceable You do not have to inspect the freewheel 2 If you find arc burns on the transmission assembly or on any component of the tail rotor driveshaft then remove the freewheel Put a tag on the freewheel and write THIS FREEWHEEL WAS REMOVED FROM SERVICE BECAUSE OF A LIGHTNING STRIKE Send the freewheel to an approved facility for overhaul 3 If th...

Page 153: ...IS TAIL ROTOR GEARBOX WAS REMOVED FROM SERVICE BECAUSE OF A LIGHTNING STRIKE Send the tail rotor gearbox to an approved facility for overhaul 3 If the tail rotor gearbox is serviceable then after 5 to 10 hours of operation remove and inspect the chip detector If you see signs of unwanted material then remove the tail rotor gearbox Put a tag on the tail rotor gearbox and write THIS TAIL ROTOR GEARB...

Page 154: ...HIS PITCH CHANGE MECHANISM WAS REMOVED FROM SERVICE BECAUSE OF A LIGHTNING STRIKE Send the pitch change mechanism to an approved facility for overhaul If a part shows signs of arcing discard it Chapter 96 and Chapter 97 ELECTRICAL AND AVIONICS Make sure that the electrical systems and the avionics equipment operate correctly and that they show no signs of a lightning strike If a system does not op...

Page 155: ...nterim Inspection Schedule examine the components every 60 months of component operation Table 5 4 Component Interim Inspection Schedule NOMENCLATURE PART NUMBER TIME BETWEEN INTERIM INSPECTION DRIVE TRAIN Mast Assembly 407 040 011 101 60 months Transmission 407 040 006 103 60 months Transmission 407 040 007 103 60 months Freewheel 406 040 500 123 60 months Tail Rotor Gearbox 406 040 400 115 60 mo...

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Page 157: ...UENTLY PARTS THAT HAVE BEEN USED ON MILITARY HELICOPTERS SHOULD NOT BE USED ON COMMERCIAL HELICOPTERS CAUTION OVERHAUL SCHEDULE FOR SOME KIT COMPONENTS AND OR PARTS IS NOT COVERED IN THIS SCHEDULE REFER TO APPLICABLE MAINTENANCE MANUAL SUPPLEMENT FOR KIT COMPONENTS SCHEDULE NOTE Refer to paragraph 5 6 for information on overhaul tolerance NOTE Neither assignment of a time period for overhaul of a ...

Page 158: ...0 123 3000 hours Transmission 407 040 006 103 107 2500 hours Transmission 407 040 006 111 4500 hours Transmission 407 040 006 115 123 127 5000 hours Transmission 407 040 007 103 5000 hours Mast Assembly 407 040 011 101 2500 hours Rotor Brake Caliper 407 340 302 101 1800 hours Rotor Brake Caliper 407 340 302 101FM 1800 hours Rotor Brake Caliper 407 340 302 103 3000 hours Input Driveshaft 407 340 31...

Page 159: ...Letter IL GEN 04 98 Refer to Chapter 4 for retirement life Input driveshaft 407 340 310 101 must be overhauled every 2500 hours of operation Overhaul is to be accomplished by Kamatics Corporation only Return driveshaft to Bell Helicopter Textron BHT per Information Letter IL GEN 04 98 As used on S N 53000 through 53442 Pre BHT 407 II 30 refer to Northwest Dynamics Document No B0223 OM for overhaul...

Page 160: ...117 117FM that have been modified per TB 407 00 21 and TB 407 01 31 Part I or Part II and gearboxes 406 040 400 119 and subsequent As used on S N 53000 through 53442 Post BHT 407 II 30 and S N 53443 and subsequent refer to Northwest Dynamics Document No B0223 OM4 or B0244 OM for overhaul instructions BHT 407 CR O V When disc is installed as inertia weight rotor brake kit not installed no overhaul ...

Page 161: ...sure that the required Special Inspections are completed Refer to the applicable chapter of this manual or to the Maintenance Manual Supplement 4 Replace all of the life limited components that have completed their specified operating life Chapter 4 5 Remove and overhaul all of the components that have completed their specified operating life Refer to the Component Overhaul Schedule Table 5 4 in t...

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Page 163: ...make a record of the defect s that you identified during this inspection For any equipment with a defect if this equipment is not required under the current operating conditions and is not on the Master Minimum Equipment List MMEL you can remove it for repair DEFECT CORRECTION DEFECT CORRECTION DEFECT CORRECTION DEFECT CORRECTION DEFECT CORRECTION 16 FEB 2012 Rev 34 Page 97 98 ...

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