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BHT-205A1-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.

Export Classification C, ECCN EAR99

REISSUE — 7 AUGUST 1990

REVISION 9 — 5 JULY 2016

COPYRIGHT NOTICE

COPYRIGHT

201

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

ALL RIGHTS RESERVED

MAINTENANCE MANUAL

VOLUME 1

GENERAL INFORMATION

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Содержание 205A-1

Страница 1: ...pter Textron Inc and Airworthiness Directives AD issued by the applicable regulatory agencies shall be strictly followed Export Classification C ECCN EAR99 REISSUE 7 AUGUST 1990 REVISION 9 5 JULY 2016 COPYRIGHT NOTICE COPYRIGHT 201 BELL HELICOPTER TEXTRON INC AND BELL HELICOPTER TEXTRON CANADA LTD ALL RIGHTS RESERVED MAINTENANCE MANUAL VOLUME 1 GENERAL INFORMATION ...

Страница 2: ...pose other than helicopter operation or maintenance is forbidden without prior written authorization from Bell Helicopter Textron Inc Export Classification C ECCN EAR99 DESTINATION CONTROL STATEMENT WARNING This document contains technical data whose export is restricted by the Arms Export Control Act Title 22 U S C Sec 2751 et seq or the Export Administration Act of 1979 as amended Title 50 U S C...

Страница 3: ...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 BELL IF YOU IDENTIFY...

Страница 4: ...uct Support Engineering PSE and your local Customer Service Engineering CSE network please access http www bellhelicopter com support Model 206 or 407 Phone 450 437 2862 or 800 363 8023 U S Canada Fax 450 433 0272 E mail pselight bh 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 bh com Model 204 205 212 or 412 Phone 450 437 6201 or 8...

Страница 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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Страница 7: ...ual 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 ...

Страница 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 ...

Страница 9: ...____________________________________________ Future Publications to be mailed to this address Address ____________________________________________________________________ City _______________________________________________________________________ State Province _______________________________________________________________ Zip Postal Code _________________________________________________________...

Страница 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 ...

Страница 11: ...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 been repaired or alte...

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Страница 23: ...urs for the Next Four Inspections 5 00 00 51 5 17 Each 25 Hours of Component Operation or 15 Days or Each 5 Days for Blades Operating in Salt Laden Atmosphere Whichever Occurs First 5 00 00 53 5 18 100 Hours After Each Installation 5 00 00 55 5 19 Main Rotor Grip Ultrasonic Inspection 5 00 00 57 5 20 Each 300 Hours of Component Operation 5 00 00 59 5 21 Each 300 Hours or 3 Months of Component Oper...

Страница 24: ...0 00 109 5 38 Deleted 5 00 00 111 5 39 Overspeed 5 00 00 113 5 40 Overtorque 5 00 00 117 5 41 Compressor Stall or Surge 5 00 00 121 5 42 Lightning Strikes 5 00 00 125 5 43 Magnetic Compass Malfunction 5 00 00 133 COMPONENT OVERHAUL SCHEDULE 5 44 Component Overhaul Schedule 5 00 00 135 FIGURES Figure Page Number Title Number 5 1 Inspection of Main Rotor Hub Grip Tangs and Barrel 20 5 2 Spiral Bevel...

Страница 25: ...ts Lead The Fleet LTF or any other special programs and the judgement of Bell Helicopter Textron engineers They are subject to change only by Bell Helicopter Textron or an approved Airworthiness Authority Changes to the TBO will be introduced by either revision to this chapter or a Technical Bulletin Every calendar and hourly inspection is a thorough visual inspection to determine the airworthines...

Страница 26: ... each situation Do the repair in accordance with the degree of damage to the specific part and the applicable repair procedures in this manual Call Product Support Engineering with your analysis of the crash damage 5 4 TYPES OF INSPECTIONS 1 The maintenance procedures may include scheduled inspections special inspections conditional inspections component interim inspections and component overhaul ...

Страница 27: ...the replacement of small standard parts not involving complex assembly operations Maintenance Inspection overhaul repair preservation and the replacement of parts but excludes preventive maintenance Operating time Time required to be recorded in historical record sheets or helicopter logs Operating time to be recorded may be identified as follows Time in service Time from the moment a helicopter l...

Страница 28: ... applicable governing aviation authority this is the responsibility of the owner operator Refer to the Lycoming T53 Series Maintenance and Overhaul Manual for inspection and overhaul tolerances The following provides examples of when hourly calendar or hourly calendar inspection tolerances have been applied Hourly Example 10 or up to a maximum of 100 hours whichever is less 300 HOUR INSPECTION DUE...

Страница 29: ...400 Hours July 30 2010 within 30 day calendar tolerance 4600 Hours July 31 2012 4600 Hours July 31 2012 10 of 1200 hours 120 hours maximum allowed is 100 hours or 10 of 24 months 2 4 months maximum allowed is 30 days 4700 Hours April 2 2012 100 hour tolerance applied 5900 Hours April 30 2014 5900 Hours April 30 2014 10 of 1200 hours 120 hours maximum allowed is 100 hours or 10 of 24 months 2 4 mon...

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Страница 31: ...05A1 MM 1 5 00 00 Export Classification C ECCN EAR99 SCHEDULED INSPECTIONS 5 7 SCHEDULED INSPECTIONS Inspect helicopter daily each 100 hours and each 1000 hours of flight operation 5 JUL 2016 Rev 9 Page 9 10 ...

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Страница 33: ...tion for evidence of corrosion particularly when helicopter is flown near or over salt water or in areas of high industrial emissions FORWARD FUSELAGE AREA 1 Battery for security External connections for arcing and corrosion Vent lines for obstructions kinking and security 2 Battery case and cover for damage and distortion Mount bolts for security 3 Instrument tubing and wiring behind instrument p...

Страница 34: ...oating compound 17 Fuselage exterior structure for cracks dents corrosion defective and missing rivets or screws PYLON AND POWER PLANT AREA 1 Stabilizer bar assembly for visible damage in the form of scratches nicks dents cracks corrosion and excessively worn bearings 2 Stabilizer tubes 204 011 328 001 011 for cracks paying particular attention to an area covering 360 and 1 1 2 inch outboard from ...

Страница 35: ...g and trailing sides of grip barrel applicable to grip 204 011 121 005 only Refer to Figure 5 1 for location 8 Main rotor hub static stops for obvious deformation and or cracks 9 Main rotor yoke for general condition and security of pillow block assembly attachment paying particular attention to the area surrounding the pillow block bushing bores Visually inspect for sealant integrity around yoke ...

Страница 36: ... defective missing rivets Lift beam assembly for cracks 22 Antenna for security and corrosion 23 Antenna coupler for security and damage 24 Transmission for obvious damage loose accessories and fittings 25 Transmission for oil leaks and proper oil level Check oil sight gauge for discoloration or contamination Service transmission if required 26 Transmission external oil filter for bypass indicatio...

Страница 37: ...pling seals and surrounding area for evidence of grease leakage and temperature indicator TEMP PLATES for discoloration and overheat condition A change in color of temperature indicator TEMP PLATES from white or light gray to black indicates a possible overheat and or component degradation Cause of discoloration shall be determined and corrected prior to flight 35 Refer to engine manufacturer s ma...

Страница 38: ... flight 1 Tail rotor driveshaft and tail rotor driveshaft hanger assemblies for security and obvious damage Driveshaft hangers and surrounding area for evidence of grease leakage Driveshaft hangers for discoloration and overheat condition A multicolored appearance of hanger which darkens adjacent to the bearing indicates a possible overheat condition The cause shall be determined and corrected pri...

Страница 39: ...ecurity of attachment 6 Tail rotor hub bearing wear indicator for indication of trunnion bearing wear 7 Tail rotor blades for physical condition foreign object damage and security of attachment 8 Tail rotor hub and blade assembly installation hardware for security of attachment 9 Forward spar of the vertical fin for cracks loose or working rivets 10 Covers for worn hinges loose or working rivets 1...

Страница 40: ...ire extinguisher for security condition and state of charge 9 Interior lights for damage and security 10 Spare light bulbs available 11 Instruments for security Range markings for accuracy and legibility Cover glass for cracks cleanliness and alignment of slippage marks 12 Standby compass for leakage Correction card for legibility Mount for security 13 Altimeter for damage and security Exposed wir...

Страница 41: ...ponse 18 Check for indications of pop up red buttons on the integrated valve and filter assembly Indicator forward of pilot left foot NOTE Annotate completion of airworthiness check in logbook before flight 19 Helicopter documents for proper entries and location in helicopter SCHEDULED INSPECTIONS 5 8 DAILY INSPECTION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Страница 42: ...BHT 205A1 MM 1 5 00 00 Page 20 Rev 7 8 JUL 2013 Export Classification C ECCN EAR99 Figure 5 1 Inspection of Main Rotor Hub Grip Tangs and Barrel ...

Страница 43: ...ATURE _______________ _________________________ Accomplish complete daily inspection in conjunction with the following MAIN ROTOR 1 Main rotor blades for evidence of bond failure and leading edges for erosion 2 Main rotor pitch links for excessive radial or axial play in bearing 3 Scissors and sleeve assembly for condition and security PYLON 1 Stabilizer bar damper clamps for evidence of corrosion...

Страница 44: ...rticles are found investigate to determine cause Refer to transmission debris monitor if installed 3 Replace 10 micron external filter element 204 040 760 013 4 Inspect for general condition security and evidence of oil leaks 5 Inspect oil lines and hoses for pin holes or cracks due to chafing Inspect wire bundles and controls for chafing 6 Service transmission to proper oil level ENGINE ADAPTER F...

Страница 45: ...onnect electrical harness to monitor and short across magnets 2 places Verify XMSN caution light illuminates for each magnet 5 Install monitor in sump case with new packing MAST ASSEMBLY 1 Inspect mast assembly for security nicks dents and scratches Pay particular attention to the area contacted by main rotor hub static stops 2 Inspect for evidence of oil leaks at mast bearing caps TAIL ROTOR DRIV...

Страница 46: ...boom attachment fittings and longerons Using a bright light and mirror inspect visible portions of attachment fittings for cracks Give special attention to upper left attachment fitting particularly in area of most forward rivets Inspect longerons left and right sides from attachment fittings to aft bulkhead of baggage compartment for any evidence of corrosion b Remove three access doors on lower ...

Страница 47: ... third 100 hour inspection 300 hours or every 12 months ASB 205 90 39 7 Inspect tailboom joints splices longerons attachment fittings and attaching hardware for corrosion damage and cracks 8 Remove plug button at BS 99 00 NOTE Paint fissures are common in the splice area cracks will be evident by black powder emanating from cracked area and corrosion will leave evidence of white powder 9 Using a b...

Страница 48: ...t link and fitting for security and cracks TB 205 76 10 5 Inspect main beam caps in accordance with TB 205 76 10 ELECTRICAL 1 Check inverters for security of mounting and connections 2 Check voltage regulator for damage and security of mounting and terminals 3 Relays and main bus area for security of mounting and connections 4 Bus insulation for damage and condition BHT 205A1 MM 2 5 Operational ch...

Страница 49: ... corrosion 2 Check elevator attachment lugs at each end of elevator horn for cracks and security of attachment Check elevator horn to elevator spar attaching bolts and surrounding joints for cracks and security of attachment Every third 100 hour inspection 300 hours or 12 months 1 Check left and right elevator assemblies for excessive axial and radial play using a dial indicator mounted on the tai...

Страница 50: ...trol tube is normally installed Pull scale at right angle to arm verify friction is 26 to 32 pounds 115 65 to 142 34 N If friction is not within limits adjust shim thickness 5 Install left and right elevators HYDRAULIC SYSTEM 1 Inspect all lines fittings and hoses for security kinks general condition and pitting Pay particular attention to the condition of the hoses 2 Check hydraulic actuators for...

Страница 51: ...apter 28 2 Replace main fuel filter element Chapter 79 3 Replace engine external oil filter element INSTRUMENTS BHT 205A1 MM 2 1 Drain pitot static system of any accumulated moisture Leak check pitot static system per local aviation authority requirements ENGINE FIRE EXTINGUISHER 1 Check for secure mounting of container manifold and wiring 2 Check for correct charge at container indicator 3 Check ...

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Страница 53: ...ion with the following 2 Remove and replace components as scheduled in component overhaul schedule paragraph 5 44 3 Remove inspect and clean or replace the hydraulic filters 4 Calibrate fuel quantity system Chapter 29 5 Remove hydraulic accumulator disassemble clean and inspect for corrosion Assemble and install Chapter 28 6 Remove clean and reinstall ejector pumps in forward cells 7 Check baggage...

Страница 54: ...ect cyclic and collective flight control cylinder installations as follows a Inspect universal bearings for looseness b Inspect input lever bushings and bolts for wear and looseness c Retighten nuts attaching cylinders to upper supports d Inspect fasteners attaching cyclic cylinder lower supports to structure for looseness e Inspect cyclic cylinder lower bearings for looseness f Remove bolts attac...

Страница 55: ...stallation 9 Main Rotor Grip Ultrasonic Inspection 10 Each 300 hours of component operation 11 Each 300 hours or 3 months of component operation whichever occurs first 12 Each 500 hours of component operation 13 Each 600 hours 12 months of tail rotor driveshaft coupling operation 14 Each 600 hours or 12 months of component operation whichever occurs first 15 Each 6 months 16 Each 12 months 17 Each...

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Страница 57: ..._______________________ NOTE Accomplish daily or each 10 hours flight operation whichever occurs first until 250 hours on transmission with affected gears with 50 hours or more Chapter 66 ASB 205 89 32 SPIRAL BEVEL GEAR 204 040 701 103 Inspect NOTE This inspection is only applicable to transmissions helicopters with the spiral bevel gears shown in Figure 5 2 installed 1 Remove and inspect the tran...

Страница 58: ... set forth in step b Notify Product Support Engineering of serial number and total time of any gear replaced d Install quill pad cover or rotor brake quill 3 Spare uninstalled affected spiral bevel gears a Return spare affected serial numbered spiral bevel gears to Bell Helicopter Textron for inspection and reidentification Refer to Information Letter IL GEN 04 98 for shipping instructions SPECIAL...

Страница 59: ...BHT 205A1 MM 1 5 00 00 8 JUL 2013 Rev 7 Page 37 Export Classification C ECCN EAR99 Figure 5 2 Spiral Bevel Gear Serial Numbers 212_MM_05_0010 ...

Страница 60: ...ON COAST SIDE PATTERN VERY LIGHT LOCATED AT ONE OR TWO POSITIONS NOT ACCEPTABLE DETACHED STRIKE MARKS USUALLY ONE PER TOOTH USUALLY ON ONE OR MORE GROUPS OF 2 3 OR 4 TEETH TOE CONCAVE SIDE SCORED PATCH NOT ACCEPTABLE WILL BE ON ALL 62 TEETH 0 70 IN 17 78 mm APPROX 0 01 TO 0 04 IN 0 254 TO 1 016 mm ACCEPTABLE BAND OF BRIGHT MARKING ON ALL 62 TEETH 0 050 IN 1 270 mm APPROX PITCH DIA NORMAL GAP FROM ...

Страница 61: ...Export Classification C ECCN EAR99 Figure 5 3 Inspection of Spiral Bevel Gear Sheet 2 of 3 SPIRAL BEVEL GEAR UNACCEPTABLE PATTERN 204 040 701 REGISTRATION NO __________________________ SPIRAL BEVEL GEAR UNACCEPTABLE PATTERN 204 040 701 212_MM_05_0005 ...

Страница 62: ...Export Classification C ECCN EAR99 Figure 5 3 Inspection of Spiral Bevel Gear Sheet 3 of 3 SPIRAL BEVEL GEAR UNACCEPTABLE PATTERN 204 040 701 SPIRAL BEVEL GEAR UNACCEPTABLE PATTERN 204 040 701 212_MM_05_0006 REGISTRATION NO __________________________ ...

Страница 63: ..._ _________________________ NOTE Accomplish between 5 and 10 hours of flight after each installation Chapter 65 MAIN ROTOR 1 Torque check main rotor retaining nut 520 to 780 foot pounds 705 to 1057 Nm Chapter 65 2 Main rotor hub blade attachment bolts torque check nuts 260 to 300 foot pounds 353 to 407 Nm TAIL ROTOR 1 Torque check tail rotor retaining nut 900 inch pounds 101 69 Nm 2 Torque check t...

Страница 64: ...CCN EAR99 Chapter 66 INTERMEDIATE GEARBOX Torque check intermediate gearbox retaining bolts 50 to 70 inch pounds 5 7 to 7 9 Nm SPECIAL INSPECTIONS 5 13 BETWEEN 5 AND 10 HOURS OF FLIGHT AFTER EACH INSTALLATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Страница 65: ..._____________ Accomplish inspection of fin spar caps 212 030 447 001 and 212 030 447 101 every 8 flight hours NOTE Fin spar cap 212 030 447 117 can be identified by the presence of decals that identify the cold worked holes This special inspection is not required if fin spar cap 212 030 447 117 has been installed as original equipment or in accordance with TB 205 00 111 FIN SPAR CAP 212 030 447 00...

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Страница 67: ...ot attempt to turn bolts Bolt movement will fail loctite bond and cause bolt wear 1 Grasp swashplate rotating ring 204 011 403 and attempt to move it in a horizontal plane on an axis in line with gimbal ring attach points to support assembly 204 011 404 Maximum allowable axial looseness across the gimbal ring bearings and attaching bolts is 0 005 inch 2 Repeat step 1 on an axis 90 to check in step...

Страница 68: ...ve the input quill at the 12 o clock position that as been previously reworked per the BHT 205A1 CR O 1 by doing the following a Visually inspect for signs of oil leakage in case wall If noted remove assembly and do an NDI on the case assembly b If no leakage is noted thoroughly clean the area with alcohol naphtha and visually inspect with minimum 3X magnifying glass for signs of cracks c Any crac...

Страница 69: ...ght Inspect the tail rotor blade skin leading edge spar doublers grip plates and trailing edge for cracks corrosion nicks dents and scratches Refer to Chapter 65 for damage limits 3 Carry out a further detailed visual inspection with a 10X magnifying glass and a bright light of the shaded area shown in Figure 5 4 between stations 20 00 and 35 00 of both sides of the blade 4 If any blistering peeli...

Страница 70: ...7 Repair damage and or corrosion found on tail rotor blades in accordance with Chapter 65 8 Replace any blade that has a crack No cracks are permitted 9 If paint was removed during the previous steps carry out paint touch up refinishing SYNCHRONIZED ELEVATOR 205 030 856 035 AND 037 NOTE Elevators 205 030 856 091 093 do not require this inspection 1 Remove plug button from top of synchronized eleva...

Страница 71: ...0 00 Export Classification C ECCN EAR99 Figure 5 4 Tail Rotor Blade Special Inspection 412_MM_05_0003 STA 5 00 STA 51 00 STA 20 00 STA 35 00 10X MAGNIFICATION 3X MAGNIFICATION 3X MAGNIFICATION 8 JUL 2013 Rev 7 Page 49 50 ...

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Страница 73: ...pections after installation or initial inspection of hanger bearings NOTE All newly installed hanger bearings must contain a scribe or paint witness mark and will require an initial inspection ASB 205 95 63 1 Perform helicopter run up for 5 minutes Shut down helicopter and inspect tail rotor hanger bearings for movement of the dust shields identified by breakage of the witness marks Remove any bea...

Страница 74: ...ication C ECCN EAR99 3 Remove any hanger bearing from service where the witness marks indicate that the grease shield has moved SPECIAL INSPECTIONS 5 16 EACH 25 HOURS FOR THE NEXT FOUR INSPECTIONS CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Страница 75: ...SCRIPTION INITIAL MECH OTHER DATE __________________W O _____________________ FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR BLADES Chapter 65 1 Refer to preventive maintenance ...

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Страница 77: ...E __________________W O _____________________ FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 53 1 Torque check tailboom attachment bolts 8 JUL 2013 Rev 7 Page 55 56 ...

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Страница 79: ... with less than 4000 hours TIS do not require inspection until reaching 4000 hours This inspection is not applicable to main rotor grips P N 204 011 121 125 A start stop cycle is defined as any time one or both of the helicopter engines are started followed by a shutdown ASB 205 02 88 MAIN ROTOR GRIPS P N 204 011 121 117 Chapter 65 1 Carry out ultrasonic inspection 2 Any indication of a crack dete...

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Страница 81: ...________W O _____________________ FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ STARTER GENERATOR Chapter 96 1 Check starter generator for allowable brush wear 8 JUL 2013 Rev 7 Page 59 60...

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Страница 83: ...NATURE _______________ _________________________ MAIN DRIVESHAFT 205 040 004 017 Chapter 66 BHT 205A1 CR O 1 1 Remove inspect and lubricate main driveshaft Chapter 66 2 Remove inspect lubricate and install engine driveshaft adapter 3 Wipe all grease from exterior surfaces of couplings and from clamp sets 4 Install main driveshaft 5 Wipe all grease from surrounding structure BHT 205A1 FM 6 Start en...

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Страница 85: ...___ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ FIRE DETECTOR SYSTEM BHT 205A1 MM 2 1 Test fire detector system with Pyrotector 30 502 tester or equivalent HYDRAULIC SHUTOFF VALVE Chapter 29 1 Perform functional check of shutoff valve 204 076 191 single hydraulic systems only BATTERY TEMPE...

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Страница 87: ..._________ NOTE Accomplish each 600 hours of component operation or 12 months whichever occurs first no Non Destructive Inspection NDI required TAIL ROTOR DRIVESHAFT FLEXIBLE COUPLINGS 1 Remove tail rotor driveshaft assemblies NOTE Disassemble flexible couplings only to the extent necessary to remove old grease and repack 2 Clean visually inspect and repack tail rotor hanger assembly flexible coupl...

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Страница 89: ...03 011 AND 103 Chapter 66 BHT 205A1 CR O 1 1 Remove inspect and lubricate main driveshaft Chapter 66 2 Remove inspect lubricate and install engine driveshaft adapter 3 Wipe all grease from exterior surfaces of couplings and from clamp sets 4 Install main driveshaft BHT 205A1 FM 5 Start engine and operate for 5 minutes at 100 N2 6 Carefully inspect coupling and surrounding structure for evidence of...

Страница 90: ... driveshaft for obvious mechanical damage flexplate looseness corrosion and or fretting at flexplate bolted joints 4 Reinstall driveshaft SPECIAL INSPECTIONS 5 24 EACH 600 HOURS OR 12 MONTHS OF COMPONENT OPERATION WHICHEVER OCCURS FIRST CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Страница 91: ...__________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 52 1 Perform operational check of crew doors emergency ejection system Chapter 52 2 Perform operational check of passenger cargo door escape panels 8...

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Страница 93: ... __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ GENERAL 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 ...

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Страница 95: ... __________________W O _____________________ FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 65 BHT 205A1 CR O 1 1 Inspect main rotor blades 204 011 250 ALL 8 JUL 2013 Rev 7 Page 73...

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Страница 97: ... 001 051 001 212 001 060 001 and 212 076 151 001 003 005 007 009 011 Supersedes ASB 205 76 8 ASB 205 76 8 Flight Control Tube Assemblies are identified by the following sub assemblies 204 001 957 001 contains tube assembly 204 001 957 003 205 001 053 007 contains tube assembly 205 001 053 009 205 001 021 007 contains tube assembly 205 001 021 009 205 001 041 001 contains tube assembly 205 001 041 ...

Страница 98: ...ly inspect external surfaces of control tubes for mechanical damage and or corrosion Refer to the BHT 205A1 CR O Manual for limits d If serviceable coat the control tube threaded area with corrosion preventive compound C 101 reinstall clevis into control tube and adjust to recorded length 2 Inspect control tubes 204 001 957 001 205 001 053 007 205 001 021 007 205 001 041 001 and 205 001 040 001 as...

Страница 99: ...OURS OF COMPONENT OPERATION DELETED DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER NOTE The Each 1200 Hours of Component Operation special inspection has been moved to the 1200 Hours or 24 Months Whichever Occurs First special inspection paragraph 5 30 8 JUL 2013 Rev 7 Page 77 78 ...

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Страница 101: ...ROTOR HUB PINS 204 012 104 003 005 AND INBOARD STRAP FITTINGS 204 012 102 005 009 BHT 205A1 CR O 1 Remove the four pins and two inboard strap fittings from the main rotor hub assembly 2 Inspect pins and inboard strap fittings by magnetic particle method 3 Magnetic particle indication interpreted as cracks are not acceptable and the pin or inboard strap fitting must be scrapped 4 If any strap pins ...

Страница 102: ...ntion to the lower tangs lower surface from the blade bolt bushing flange to the trailing and leading edge of the tang Crack indications require the grip to be removed from service for further evaluation Figure 5 5 3 For main rotor grip 204 011 121 005 inspect grip barrels on both leading and trailing sides for hairline cracks 4 Check for gap 360 between flange of blade bolt bushing and surface of...

Страница 103: ...N EAR99 6 Inspect buffer pads on tang inner surfaces for delamination Any delamination will require buffer pad replacement Figure 5 5 SPECIAL INSPECTIONS 5 30 EACH 1200 HOURS OR 24 MONTHS WHICHEVER COMES FIRST CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Страница 104: ...BHT 205A1 MM 1 5 00 00 Page 82 Rev 7 8 JUL 2013 Export Classification C ECCN EAR99 Figure 5 5 Inspection of Main Rotor Hub Grip Tangs and Barrel 1200 Hours 24 Months ...

Страница 105: ...______________________________ SIGNATURE _______________ _________________________ NOTE Accomplish each 24 months of flight control system bolt operation Chapter 27 and Chapter 65 ASB 205 89 34 FLIGHT CONTROL SYSTEM BOLTS NOTE Refer to Chapter 4 for retirement life of flight control system bolts Inspect 1 Remove the following flight control bolts a Two fixed swashplate to right and left cyclic boo...

Страница 106: ...S23D or 20 057 6S24D m Two scissors to drive link bolts 20 057 8S69D n Two scissors 204 011 406 pivot bolts 20 057 8S90D o Two stabilizer bar pivot bolts 20 057 10S27D or 20 057 10S29D p Three hydraulic cylinder to lower support bolts 205 001 311 001 212 001 304 001 212 001 304 003 or 212 001 323 001 q Two scissors 212 010 407 pivot bolts 212 010 411 001 or 212 010 411 005 r Two stabilizer bar dam...

Страница 107: ...ironmental conditions which erodes the hard film corrosion preventive compound may warrant periodic touch up of control bolts external surfaces Prior to touch up visually check exposed surfaces of hardware for evidence of corrosion and fretting Remove clean and inspect bolts as conditions warrant 5 After bolts have been installed and nuts torqued and safetied coat head of bolt nuts and lockwire wi...

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Страница 109: ..._______ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR MAST BHT 205A1 CR O 1 1 Inspect inside and outside diameters of mast for corrosion and mechanical damage FLIGHT CONTROLS ASB 205 76 8 2 Inspect flight control tubes and bellcr...

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Страница 111: ...taining bolts a Using torque wrench check each of the 32 bevel gear retaining bolts for minimum torque of 300 inch pounds 33 9 Nm NOTE Torque check is accomplished with increasing torque not breakaway or loosening torque BHT ALL SPM Chapter 2 BHT 205A1 CR O 1 b If torque value of any one retaining bolt is less than 300 inch pounds 33 89 Nm remove bevel gear and inspect mating surfaces of gear and ...

Страница 112: ...tail parts to determine cause for bearing inner race rotation and replace parts as required 6 Disassemble input quill sufficiently to remove the freewheel clutch BHT 205A1 CR O 1 Chapter 66 a Perform complete inspection of clutch 205 040 350 101 103 FORMSPRAG BHT 205A 1 CR O 1 7 Visually inspect bevel gear teeth and main input pinion teeth for general condition and wear pattern BHT 205A1 CR O 1 Ch...

Страница 113: ...TING DAMAGE BHT 205A1 CR O 1 Chapter 66 10 Remove tail rotor drive quill to gain access to accessory drive and sump gears Visually inspect accessory case input quill gear and tail rotor drive quill gear for general condition and wear pattern BHT 205A1 CR O 1 11 Assemble transmission SPECIAL INSPECTIONS 5 33 EACH 3100 HOURS OF COMPONENT OPERATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INIT...

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Страница 115: ...ed overtorque compressor stall or surge lightning strikes and after magnetic compass malfunction 2 If overhaul evaluation is specified complete both the conditional inspection and normal inspection procedures as applicable for that component listed in BHT 205 CR O 1 manual 3 If applicable conditional inspection does not provide complete information on a specific type of incident or if any doubt ex...

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Страница 117: ...lts in yielding or cracking the mounting lugs of the transmission support case or noticeable yielding or cracking of fuselage pylon support structure or landing gear This definition is confined only to those accidents not involving sudden stoppage of main rotor or tail rotor NOTE Components removed from a helicopter following a hard landing shall be evaluated as an interrelated group Annotate all ...

Страница 118: ...urn helicopter to flight status provided no further evidence of damage is found g If damage is more extensive than landing gear crosstube yielding a hard landing has occurred comply with requirements of step 2 through step 4 2 If a hard landing has occurred the following steps shall be accomplished a Remove and perform an overhaul evaluation inspection of the following components NOTE If there is ...

Страница 119: ...l rotor static stop 6 Tail rotor yoke 7 Anti torque controls 8 Intermediate gearbox 9 Tail rotor gearbox 10 Tail rotor driveshafts 11 Tail rotor driveshaft hangers 12 Swashplate and support assembly 13 Scissors and sleeve assembly 14 Stabilizer bar assembly 15 Main rotor controls c Check all cowling and doors for proper fit and alignment Remove cowling and inspect all attachment fittings CONDITION...

Страница 120: ...f pylon dampers have yielded they are non airworthy and non repairable g Install serviceable mast transmission assembly and main driveshaft assembly Reinstall removed pylon control components h Check all engine mount fittings and bolts for damage and looseness i Inspect engine firewalls for evidence of warping crushing or other damage j Make a complete inspection of area where tailboom is attached...

Страница 121: ...tem for damage Make engine ground run and visually check fuel oil and pneumatic lines for leaks 3 Inspect power plant in accordance with engine manufacturer s engine inspection guide 4 If no significant damage has been found no further inspection is necessary CONDITIONAL INSPECTIONS 5 35 HARD LANDING CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 8 JUL 2013 Rev 7 Page 99 100 ...

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Страница 123: ...e which inhibits free rotation of drive system If the blade strike or rotating system torque spike is the result of crash damage or results in crash damage all rotating system components shall be considered unserviceable and non repairable Crash damage is any damage sustained beyond the scope of that identified in conditional inspections A blade strike is any incident during which a rapid decelera...

Страница 124: ...lding has occurred replace the tail rotor yoke and static stop Tail rotor driveshafts Twisting out of roundness or bowing that exceeds the limits specified in Chapter 65 Tail rotor drive adapters Distortion beyond the limits specified in Chapter 66 A rotating system torque spike is defined as any other incident that results in a rapid deceleration of the drive system These incidents include but ar...

Страница 125: ... for skin cracks BHT 205A1 CR O 1 2 If any blade is damaged sufficiently to require blade replacement return all blades to an authorized overhaul facility Make an entry in component record to show reason for removal is sudden stoppage Refer to the BHT 205A1 CR O 1 for repair limits 3 If no evidence of damage is found on any blade all blades may be retained in service b Main rotor hub 1 If main rot...

Страница 126: ... hub and sleeve assembly may be retained in service d Replace all rotating control bolts Discard removed bolts BHT 205A1 CR O 1 e Remove and disassemble main driveshaft Visually inspect components for damage in accordance with BHT 205A1 CR O 1 If no visual evidence of damage is detected reassemble If damage is detected perform an overhaul evaluation Make an entry in the component record to show re...

Страница 127: ...lies to which damaged shaft was attached shall be scrapped If a tail rotor driveshaft is visibly twisted all hanger assemblies and shafts shall be scrapped BHT 205A1 CR O 1 2 If inspection reveals no damage that would render hanger assemblies unrepairable hanger assemblies shall have an overhaul evaluation performed Make an entry in component record to show reason for removal is blade strike or to...

Страница 128: ...hall be performed Make an entry in component record to show reason for removal was blade strike or torque spike BHT 205A1 CR O 1 3 If the inspection is being conducted as a result of a tail rotor driveshaft intermediate gearbox assembly or tail rotor gearbox assembly induced torque spike an overhaul evaluation of the tail rotor hub and blade assembly shall be performed Make an entry in component r...

Страница 129: ...o damage is found install quill assembly Transmission assembly may be retained in service BHT 205A1 CR O 1 3 If inspection of the tail rotor output quill assembly reveals discrepancies or gear contact with sump case is evident remove transmission assembly and an overhaul evaluation of the transmission assembly shall be performed Make an entry in component record to show reason for removal was blad...

Страница 130: ......

Страница 131: ...BHT 205A1 MM 1 5 00 00 Export Classification C ECCN EAR99 CONDITIONAL INSPECTIONS 5 37 DELETED DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 5 JUL 2016 Rev 9 Page 109 110 ...

Страница 132: ......

Страница 133: ...BHT 205A1 MM 1 5 00 00 Export Classification C ECCN EAR99 CONDITIONAL INSPECTIONS 5 38 DELETED DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 5 JUL 2016 Rev 9 Page 111 112 ...

Страница 134: ......

Страница 135: ...rotor RPM is exceeded and or engine overspeed limits in engine manufacturer s manual are exceeded NOTE Components removed from helicopter following an overspeed shall be evaluated as an interrelated group Annotate Historical Service Records that reason for removal was Overspeed 1 Perform overspeed inspection as follows a Refer to engine manufacturer s inspection guide for engine overspeed and insp...

Страница 136: ...d Indicate percent and duration if known d Tail rotor hub and blades 1 Remove tail rotor hub and blade assembly 2 Remove tail rotor blades 3 Replace tail rotor blade retention bolts e Tail rotor blades 1 Check for bond separations anywhere on the blade If any separation exists scrap the blade 2 If any movement of the tip or root end balance weights has occurred scrap the blade 3 Check the retentio...

Страница 137: ...tor mast 5 Main input driveshaft 6 Tail rotor driveshaft hangers 7 Stabilizer bar 8 Swashplate 9 Scissors and sleeve 10 Tail rotor hub 11 Tail rotor driveshaft 204 040 620 11 h Install a serviceable main rotor hub and blade assembly Install serviceable tail rotor blades Balance and install tail rotor hub and blade assembly CONDITIONAL INSPECTIONS 5 39 OVERSPEED CONT DATA REFERENCE INSPECTION TASK ...

Страница 138: ......

Страница 139: ...rque is defined as any incident in which torsional loads are introduced into the helicopter dynamic system in excess of established limits NOTE Components removed from helicopter following an overtorque shall be evaluated as an interrelated group Annotate Historical Service Records that reason for removal was Overtorque 1 Refer to engine manufacturer s inspection guide for engine overtorque inspec...

Страница 140: ...ep 2 above b Inspect main transmission chip detector c Inspect main transmission internal filter and pump inlet screen d If metal particles indicating internal failure are found remove the transmission for overhaul evaluation Make entry in component record that reason for removal was Overtorque Remove all transmission system oil lines and oil cooler Replace external oil filter element Flush and re...

Страница 141: ... f Replace main rotor hub pillow block bolts 204 011 171 1 only if installed g Remove fifth mount bolts and remove fifth mount Perform a thorough inspection of bolts and fifth mount support Check for bent bolts and bent fifth mount support Check for proper bolt hole alignment between transmission and fifth mount support Install fifth mount 4 When overtorque has exceeded 61 PSI a Remove and condemn...

Страница 142: ... thorough inspection of bolts and fifth mount support Check for bent bolts and bent fifth mount support Check for proper bolt hole alignment between transmission and fifth mount support Install fifth mount d Install serviceable components CONDITIONAL INSPECTIONS 5 40 OVERTORQUE CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Страница 143: ...reports severe engine vibration and a rapid rise in exhaust gas temperature EGT depending on severity of surge When a surge has been reported progressively perform step 1 step 2 and step 3 as indicated by discrepant conditions NOTE Components removed from a helicopter following a compressor stall or surge shall be evaluated as an interrelated group Annotate Historical Service Records that reason f...

Страница 144: ...ough step 4 and step 3 1 Remove and condemn long tail rotor driveshaft 204 040 620 3 and 7 2 Remove tail rotor gearbox from helicopter and remove input quill Inspect gear teeth on pinion and gear for damage with a 10X magnifying glass If no evidence of scoring or scuffing is found and there is no other damage that would render the gearbox unserviceable it may be reassembled and reinstalled for con...

Страница 145: ... also be replaced and procedures outlined in step a through step e performed a Remove inboard and outboard drag brace bolts Check bolts for deformation and perform a magnetic particle inspection If satisfactory return to service b Visually inspect stabilizer bar outer tubes for bending Allowable deflection is 0 150 inch 3 81 mm in each tube c Remove main rotor pillow blocks from main rotor yoke an...

Страница 146: ...ll new skin c Make close visual inspection of complete tailboom structure for distortion buckles skin cracks and sheared or loose rivets paying particular attention to tailboom attachment points at FS 195 and adjacent fuselage to tailboom structure and intermediate gearbox support structure d Make close visual inspection of main pylon support and engine mount attachment structure for distortion bu...

Страница 147: ...y damage found anywhere on helicopter shall be recorded in detail and copies of these records shall be provided along with any component returned for overhaul to assist overhauling facility in evaluating component When helicopter is suspected of receiving a lightning strike perform the following steps 1 Visually inspect all external surfaces with particular attention to main rotor blades stabilize...

Страница 148: ...g driveshaft and return it to Bell Helicopter Textron for evaluation IL GEN 04 98 Do not disassemble the couplings d Remove the tail rotor output coupling from the main transmission assembly and all other crown tooth couplings from the tail rotor drive system for inspection 1 Disassemble to same extent required for coupling repack and clean couplings 2 Visually inspect couplings for any evidence o...

Страница 149: ...e and inspect tail rotor and intermediate gearbox chip detectors h If the tail rotor hub and blades or tail rotor couplings exhibit evidence of damage which can be attributed to a lightning strike or excessive debris is found on chip detectors remove tail rotor and intermediate gearboxes and tail rotor driveshaft hangers for overhaul Tag components stating Lightning Strike as reason for removal Ad...

Страница 150: ...esent overhaul main rotor hub stabilizer bar and drive assembly Replace affected pitch change links and attaching hardware 4 If no indications are found assemble main rotor hub 4 Prior to first flight after a suspected or confirmed lightning strike verify proper function of all drive system component chip detectors as follows a Remove electrical connector from chip detector b Remove chip detector ...

Страница 151: ...boxes and tailboom structure for magnetization Using a magnetometer with a range no larger than 5 gauss place arrow or red dot depending on magnetometer model within 0 5 inch 12 7 mm of item being checked and point it directly at item If any items or components have a reading greater than 1 gauss those items shall be degaussed c Remove and bench test voltage regulator s Operationally check DC gene...

Страница 152: ...edures b Check fixed controls and support system components for possible arcing damage Bearings in rod ends bellcranks and supports should be most susceptible to arcing damage Check bearings for smooth rotation Visibly inspect attaching hardware of support for signs of lightning damage damaged finish and or burns If damage is evident remove supports and inspect mounting holes and mating surfaces f...

Страница 153: ... 100 hours of flight 7 Inspect avionics systems a Perform standard proflight test on all avionics systems If system does not function properly make necessary repairs b Inspect antennas for damage If damaged repair and make VSWR measurements as necessary or replace CONDITIONAL INSPECTIONS 5 42 LIGHTNING STRIKES CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 5 JUL 2016 Rev 9 Page...

Страница 154: ......

Страница 155: ..._ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ 1 Check magnetic compass for accuracy If excessive error is indicated the compass must be calibrated using standard compensating methods 2 After compensating and while still on the compass rose swing for residual deviations on 12 symmetrical he...

Страница 156: ......

Страница 157: ...OME KIT COMPONENTS AND OR PARTS 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 a...

Страница 158: ...aring 212 040 136 001 204 040 366 015 2500 hours Mast 204 040 366 017 2500 hours Mast 204 040 366 021 5000 hours Tail Rotor Driveshaft Hangers 204 040 600 009 1000 hours Transmission 205 040 001 023 027 1000 hours Transmission 205 040 001 033 037 045 049 101 2000 hours Transmission 212 040 001 135 6000 hours Rotor Brake Quill 412 040 123 101 3000 hours Tail Rotor Gearbox 209 040 400 001 007 1000 h...

Страница 159: ...tinguisher Container 2241 009 5 years Starter Generator 204 060 200 001 1000 hours MISCELLANEOUS Oil Cooler Fan 204 062 540 001 1000 hours NOTES The operating time specified for overhaul of any part number contained in this component overhaul schedule applies to all successive dash numbers or suffixes for that item unless otherwise specified If tube assemblies 212 010 311 101 or 540 011 319 001 ar...

Страница 160: ...or brake quill is 3000 hours If servo actuators have Greene Tweed type seals installed then overhaul interval is conditional Servo actuators with assembly date of April 30 1974 or later were fitted with Greene Tweed type seals at time of manufacture However servo actuators without Greene Tweed type seals installed shall be overhauled at 1000 hours If servo actuators have Greene Tweed type seals in...

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