407-mm rev 25 29-sep-2008
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This Revision 25 updates the front matter, as well as Chapter 4, which incorporatesnew tailboom inspection requirements per ASB 407-08-84. In addition, Chapter 76
incorporates information on FADEC Software Version 5.358. General updates toChapters 7, 52, 53, 63, 65, 71, and 95 have also been included.
Please incorporate Revision 25 into the Maintenance Manual in accordance withthe Log of Pages attached.
Bell Helicopter would also like to thank its Customers for providing us withCustomer Feedback information. This information is very much appreciated and
allows us to improve the quality of our manuals with each revision.
REVISION ONLY BHT-407-MM
NOTICE
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NOTICE
The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or
MAINTENANCE MANUAL
VOLUME 1
GENERAL INFORMATION
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PROPRIETARY RIGHTS NOTICE
These data are proprietary to Bell Helicopter Textron Inc. Disclosure,
reproduction, or use of these data for any purpose other than helicopter
operation or maintenance is forbidden without prior written authorization from
Bell Helicopter Textron Inc.
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WARNING
THIS MANUAL APPLIES ONLY TO HELICOPTERS AND COMPONENTS
MAINTAINED IN ACCORDANCE WITH BELL HELICOPTER TEXTRON
(BELL) APPROVED PROCEDURES USING BELL APPROVED PARTS.
ALL INSPECTION, REPAIR AND OVERHAUL PROCEDURES PUBLISHED
BY BELL, INCLUDING PART RETIREMENT LIFE, ARE BASED SOLELY ON
THE USE OF BELL PARTS THAT HAVE BEEN MAINTAINED USING BELL
APPROVED DATA. THE DATA PUBLISHED HEREIN OR OTHERWISESUPPLIED BY BELL IS NOT APPLICABLE TO NON-BELL PARTS OR
PARTS THAT HAVE BEEN REPAIRED USING DATA AND/OR PROCESSES
NOT APPROVED BY BELL.
BELL IS NOT RESPONSIBLE FOR ANY PART OTHER THAN THOSE THAT
IT HAS APPROVED.
BEFORE PERFORMING ANY PROCEDURE CONTAINED IN THIS MANUAL
YOU MUST INSPECT THE AFFECTED PARTS AND RECORDS FOREVIDENCE OF ANY MANUFACTURE, REPAIR, REWORK OR USE OF A
PROCESS NOT APPROVED BY BELL.
IF YOU IDENTIFY OR SUSPECT THE USE OF PARTS NOT AUTHORIZED
BY BELL, EITHER REMOVE THE AFFECTED ITEM FROM THE AIRCRAFT
OR OBTAIN INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FROM
THE MANUFACTURER OR THE ORGANIZATION THAT APPROVED THE
REPAIR.
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CUSTOMER SUPPORT AND SERVICES
Flying smart means that no matter where you are, or what time it is, you can make a call
and get additional information, clarification, or advice on a technical or operational issue
concerning your helicopter or information contained in our Technical Publications.
Product Support Engineering (PSE) is just a phone call away and may be contacted as
follows:
For additional information on Customer Support and Services as well as Product Support
Engineering (PSE) and your local Customer Service Representative (CSR) network
MODEL 47, 206, OR 407
Phone: 450-437-2862 or 800-243-6407 (U.S./Canada)
Fax: 450-433-0272
E-mail: [email protected]
MODEL 222, 230, 427, 429, OR 430
Phone: 450-437-2077 or 800-463-3036 (U.S./Canada)
Fax: 450-433-0272
E-mail: [email protected]
MODEL 204, 205, 212, OR 412
Phone: 450-437-6201 or 800-363-8028 (U.S./Canada)Fax: 450-433-0272
E-mail: [email protected]
MODEL 210, 214, HUEY II, SURPLUS MILITARY
Phone: 817-280-3548
Fax: 817-280-2635
E-mail: [email protected]
BHT-407-MM-1
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected] -
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LOG OF REVISIONS
Insert latest revision pages and dispose of superseded ones.
On a revised page, the text and/or illustration affected by the latest revision is shown by a vertical line. A revised
page with only a vertical line next to the page number indicates that text has shifted or that non-technical
correction(s) were made on that page.
Page No. Rev No. Page No. Rev No. Page No. Rev No.
LOG OF PAGES
Original ........0 ............22 FEB 96
Revision....... 1 ............01 APR 96
Revision....... 2 ............01 JUN 96
Revision....... 3 ........... 28 OCT 96
Revision....... 4 ........... 16 DEC 96Revision....... 5 .............18 JUL 97
Revision....... 6 ............14 APR 98
Revision....... 7 ........... 01 MAY 98
Revision....... 8 ............01 SEP 98
Revision ...... 9............30 NOV 98
Revision ...... 10.......... 16 FEB 01
Revision ...... 11 ......... 23 MAR 01
Revision ...... 12..........08 MAY 01
Revision ...... 13.......... 21 SEP 01Revision ...... 14..........21 NOV 01
Revision ...... 15...........18 JAN 02
Revision ...... 16.......... 07 JUN 02
Revision ...... 17..........25 OCT 02
Revision .......18 .........29 AUG 03
Revision .......19 .........17 DEC 03
Revision .......20 .........12 NOV 04
Revision .......21 .........16 NOV 04
Revision .......22 .........28 NOV 05Revision .......23 .........07 NOV 06
Revision .......24 .........02 OCT 07
Revision .......25 ......... 29 SEP 08
VOLUME 1
Cover.......................................23
Title ..........................................25
PN............................................22
Warning ...................................25
CSS .........................................25
A D........................................25
HELP .......................................24Customer Feedback ................24
Helicopter Sale Notice .............24
Warranty ..................................25
BR............................................25
TR............................................23
i ii ..........................................23
Chapter 1
1/2............................................233 6.........................................23
7/8............................................23
Chapter 4
1 34.......................................25
35/36 25
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91 92 .................................... 24
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95/96 ....................................... 23
VOLUME 2
Cover....................................... 23
Title.......................................... 25PN ........................................... 22
Chapter 6
1/2 ........................................... 18
3/4 ........................................... 18
5/6 18
9/10..........................................22
Chapter 8
1 40.........................................2
41/42..........................................2
Chapter 9
1/2............................................183 4.........................................18
5/6............................................18
Chapter 10
1/2............................................18
3 12.......................................18
Chapter 11
1/2............................................223 20.......................................22
21/22........................................22
Chapter 12
1 2.........................................23
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LOG OF PAGES (CONT)
Page No. Rev No. Page No. Rev No. Page No. Rev No.
Chapter 18
1...............................................16
2 7...........................................2
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10 17....................................... 2
18.............................................19
19 25....................................... 2
26.............................................1626A/26B...................................16
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28 42....................................... 2
43/44..........................................2
VOLUME 3
Cover....................................... 23
Title.......................................... 23
PN............................................ 23
Chapter 21
1 20.........................................4
Chapter 25
1 4.........................................23
5/6............................................23
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55/56........................................23
57 84..................................... 23
85/86........................................23
Chapter 26
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VOLUME 4
Cover....................................... 18
Title.......................................... 22
PN............................................ 22
Ch t 28
VOLUME 5
Cover ...................................... 18
Title ......................................... 25
PN........................................... 24
Chapter 30
1/2 ............................................. 0
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Chapter 32
1 2 .......................................... 4
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Chapter 52
1 2 ........................................ 24
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Chapter 531 50 ...................................... 24
51/52 ....................................... 24
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93 ............................................ 24
94 ............................................ 25
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VOLUME 6
Cover ...................................... 23
Title ......................................... 25
PN........................................... 24
93.............................................24
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Chapter 631...............................................25
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VOLUME 7
Cover 23
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Chapter 65
1 4 .........................................23
5/6 ............................................23
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32 .............................................24
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40 .............................................25
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VOLUME 8
Cover .......................................23
Title ..........................................24
PN ............................................24
Chapter 67
1 94 .......................................23
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97 189...................................23
190 191.................................24
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VOLUME 9
Cover .......................................23
Title ..........................................25
PN 24
33 34.......................................7
35/36.......................................... 7
37 44.......................................7
45/46.......................................... 7
47 48.......................................7
49/50.......................................... 7
Chapter 751/2............................................ 22
3/4............................................ 22
Chapter 76
1 8.........................................25
9/10.......................................... 25
11 46 ..................................... 25
47/48........................................ 25
49 52..................................... 2553/54........................................ 25
55 68..................................... 25
69/70........................................ 25
71 86..................................... 25
87/88........................................ 25
Chapter 79
1 8...........................................4
9/10............................................ 411 14 ....................................... 4
15/16.......................................... 4
VOLUME 10
Cover.......................................24
Title.......................................... 25
PN............................................24
Chapter 951 8.........................................24
9 14.........................................4
15/16.......................................... 4
17 18..................................... 16
19 72.......................................4
73 25
124 ...........................................24
125 133...................................4
134 ...........................................24
135 .............................................4
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157 174...................................4
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181 193...................................4
194 ...........................................24
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Chapter 96
1 20 .......................................16
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27 30 .....................................24
31 102 ...................................16
103/104....................................16
105 176.................................16177/178....................................16
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VOLUME 11
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VOLUME 12
Cover.......................................18
Title ..........................................16
PN.............................................. 6
Chapter 98
1................................................. 7
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3/4.............................................. 45 10.........................................4
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50 .............................................. 7
50A/50B................................... 16
51 53.......................................4
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VOLUME 13
Cover.......................................18
Title ..........................................15
PN.............................................. 6
Chapter 99
1/2.............................................. 0
3...............................................15
4................................................. 8
MMS 1 ....................................1
MMS 5 ....................................0
MMS 6 ....................................0
MMS 7 ....................................0MMS 21 ..................................0
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SPARE PARTS WARRANTY
ONE YEAR/1,000 HOURS PRORATED
WARRANTY AND REMEDY: Seller warrants each new helicopter part or helicopter part reconditioned by seller to be free from defectin material and workmanship under normal use and service and if installed on Bell model helicopters. Sellers sole obligation under thiswarranty is limited to replacement or repair of parts which are determined to Sellers reasonable satisfaction to have been defectivewith 1,000 hours of operation or one (1) year after installation, whichever occurs first and reimbursement of reasonable freight charges.After 200 hours of use, there will be a prorated charge to the Purchaser for replacement parts (prorating the hours of total use againstthe then applicable part life or 2,000 hours, whichever is the lesser). Defective parts must be reported in writing to the Sellers WarrantyAdministration within 90 days of being found defective. Replacement of parts may be with either new or reconditioned parts, at Sellerselection. Warranty adjustment is contingent upon the Purchaser complying with the Warranty Remedies as described in theCommercial Warranty Information brochure and the Sellers Warranty Administration disposition instructions for defective parts. Failure
to comply with all of the terms of this paragraph may, at Sellers sole option, void this warranty.
NOTE: Parts, components and assemblies of all new helicopters may have been restored or reworked due to mars, blemishes, dentsor other irregularities during the manufacturing process. Such restoration and/or rework is permitted under Sellers approvedmanufacturing and engineering processes and guidelines. The restoration and/or rework so completed does not render such itemsdefective in material or workmanship.
THIS WARRANTY IS GIVEN AND ACCEPTED IN PLACE OF (i) ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS ORIMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR CONDITIONS OF MERCHANT ABILITY ANDFITNESS FOR A PARTICULAR PURPOSE AND (ii) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACTORIN TORT (DELICT), INCLUDING PRODUCT LIABILITIES BASED UPON STRICT LIABILITY, NEGLIGENCE, OR IMPLIED
WARRANTY IN LAW.
This warranty is the only warranty made by Seller. The Purchasers sole remedy for a breach of this warranty or any defect in a part isthe repair or replacement of helicopter parts and reimbursement of reasonable freight charges as provided herein. Seller excludesliability, whether as a result of a breach of contract or warranty, negligence or strict product liability, for incidental or consequentialdamages, including without limitation, damage to the helicopter or other property, costs and expenses resulting from required changesor modifications to helicopter components and assemblies, changes in retirement lives and overhaul periods, local customs fees andtaxes, and costs or expenses for commercial losses or lost profits due to loss of use or grounding of helicopters or otherwise.
Seller makes no warranty and disclaims all liability in contract or in tort (delict), including, without limitation, negligence and strict tort(delictual) liability, with respect to work performed by third parties at Purchasers request and with respect to engines, engineaccessories, batteries, radios, and avionics, except Seller assigns each manufacturers warranty to Purchaser to the extent suchmanufacturers warranty exists and is assignable.
This warranty shall not apply to any helicopter part which has been repaired or altered outside Sellers factory in any way so as, inSellers judgment, to affect its stability, safety or reliability, or which has been subject to misuse, negligence or accident, or which hasbeen installed in any aircraft which has been destroyed unless that helicopter has been rebuilt by Bell. A list of destroyed aircraft isobtainable from Bell Product Support. Repairs and alterations which use or incorporate parts and components other than genuine Bellparts or parts approved by Bell for direct acquisit ion from sources other than Bell itself are not warranted by Bell, and this warranty shallbe void to the extent that such repairs and alterations, in Sellers sole judgment, affect the stability, safety or reliability of the helicopteror any part thereof, or damage genuine Bell or Bell-approved parts. No person, corporation or organization, including Bell CustomerService Facilities, is authorized by Seller to assume for it any other liability in connection with the sale of its helicopters and parts.
NO STATEMENT, WHETHER WRITTEN OR ORAL, MADE BY ANY PERSON, CORPORATION OR ORGANIZATION, INCLUDINGBELL CUSTOMER SERVICE FACILITIES MAY BE TAKEN AS A WARRANTY NOR WILL IT BIND SELLER.
Seller makes no warranty and disclaims all liability with respect to components or parts damaged by, or worn due to, corrosion. Sellermakes no warranty and disclaims all liability for consumables (wear items) which are defined as items required for normal and routinemaintenance or replaced at scheduled intervals shorter than the warranty period. Consumables include but are not limited to engineand hydraulic oil, oil filters, packings and o-rings, anti-corrosion and/or sealing compounds, brush plating material, nuts, bolts, washers,screws fluids compounds and standard aircraft hardware that is readily available to aircraft operators from sources other than Seller
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BULLETIN RECORD
All applicable Alert Service Bulletins and Technical Bulletins issued prior to and including the bulletins listed below
have been incorporated in this manual. Subsequent bulletins will be incorporated in future revisions/reissues.
ALERT SERVICE BULLETINS
ASB NUMBER SUBJECT DATE
1407-08-84 Tailboom Assembly 407-030-801-201, 407-030-801-203, and
407-030-801-205, New Inspection Requirements
18 AUG 2008
1With the exception of ASB 407-98-16, 407-98-18, 407-99-30, 407-00-36, 407-00-38, 407-01-39, 407-01-41,
407-01-42, and 407-02-50 all applicable bulletins issued prior to, and including 407-07-81, have been
incorporated.
TECHNICAL BULLETINS
TB NUMBER SUBJECT DATE
1
407-07-77 I mproved Caution/Warning Panel 407-375-015-111,
Introduction of
04 JUN 2007
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TEMPORARY REVISION RECORD
This Temporary Revision Record provides a current listing of active Temporary Revisions against the manual.
Temporary Revisions, which have been canceled/incorporated, will only be maintained on the record until the next
revision is issued. If there are no Temporary Revisions shown on the record, this is confirmation that there are no
Temporary Revisions issued against the manual.
TEMP. REV. NO. TITLE DATE ISSUED DATE CANCELED
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TC APPROVED BHT-407-MM-1
CONTENTS MAINTENANCE PROCEDURES
Paragraph Chapter/Section Page
Number Title Number Number
CHAPTER 4 AIRWORTHINESS LIMITATIONS SCHEDULE
AIRWORTHINESS LIMITATIONS SCHEDULE
4-1 Airworthiness Limitations Schedule ........................................... 4-00-00 5
FIGURES
Figure Page
Number Title Number
4-1 Disc Pack Coupling (P/N 406-040-340-101) Inspection............................. 11
4-2 Main Rotor Yoke (P/N 407-010-101-101) Inspection ................................. 12
4-3 Tail Rotor Hanger Bearing (P/N 406-040-339-ALL) Inspection.................. 13
4-4 Tail Rotor Blade (P/N 407-016-001-101) Inspection .................................. 15
4-5 Tailboom Assembly (P/N 407-030-801-201, 407-030-801-203, and
407-030-801-205) 300 Hour Inspection..................................................... 16
4-6 Tailboom Assembly (P/N 407-530-014-101, 407-530-014-103, or
407-030-801-107) Daily Inspection............................................................ 22
4-7 Tailboom Assembly (P/N 407-530-014-101, 407-530-014-103, and
407-030-801-107) 100 Hour Inspection ..................................................... 24
4-8 Inspection of Pylon Side Beams (P/N 407-010-201-105/407-010-203-105) .. 31
4-9 Horizontal Stabilizer (P/N 407-023-801-109) Recurring 600 Hour/AnnualInspection ...................................................................................................... 34
TABLES
Table Page
Number Title Number
4-1 Airworthiness Limitations Schedule................................................................ 6
4-2 Inspection Limitations Schedule ..................................................................... 9
The Airworthiness Limitations Schedule is approved by the Minister and specifies the maintenance required by
li bl i thi ti l l l lt ti h b d b th
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REVISION NO. DATE OF SIGNATURE TC SIGNATURE
Revision 1 (01 Apr. 96) 29 March 1996
Revision 2 (01 Jun. 96) N/A Chapter 4 not affected
Revision 3 (26 Oct. 96) 26 October 1996
Revision 4 (16 Dec. 96) N/A Chapter 4 not affected
Revision 5 (18 Jul. 97) 18 July 1997
Revision 6 (14 Apr. 98) 14 April 1998
Revision 7 (01 May 98) N/A Chapter 4 not affected
Revision 8 (01 Sept. 98) N/A Chapter 4 not affected
Revision 9 (30 Nov. 98) 30 November 1998
Revision 10 (16 Feb. 01) N/A Chapter 4 not affected
Revision 11 (23 Mar. 01) N/A Chapter 4 not affected
Revision 12 (08 May 01) 8 May 2001
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Revision 13 (21 Sept. 01)
Revision 14 (21 Nov. 01)
21 September 2001
21 November 2001
Revision 15 (18 Jan. 02) N/A Chapter 4 not affected
Revision 16 (07 Jun. 02) N/A Chapter 4 not affected
Revision 17 (25 Oct. 02) N/A Chapter 4 not affected
Revision 18 (29 Aug. 03) 29 August 2003
Revision 19 (17 Dec. 03) N/A Chapter 4 not affected
Revision 20 (12 Nov. 04) 12 November 2004
Revision 21 (16 Nov. 04) 16 November 2004
Revision 22 (28 Nov. 05) 28 November 2005
Revision 23 (7 Nov. 06) 7 November 2006
REVISION NO. DATE OF SIGNATURE TC SIGNATURE
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REVISION NO. DATE OF SIGNATURE TC SIGNATURE
Revision 25 (29 Sept. 08) 29 September 2008
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AIRWORTHINESS LIMITATIONS SCHEDULE
4-1. AIRWORTHINESS LIMITATIONSSCHEDULE
WARNING
ALL REPAIR AND OVERHAUL
PROCEDURES LIVES PUBLISHED BY
BELL HELICOPTER TEXTRON,
INCLUDING COMPONENT RETIREMENT
LIFE, ARE BASED SOLELY ON THE USE
OF BELL APPROVED PARTS AND
PROCESSES. IF PARTS OR
PROCESSES DEVELOPED OR
APPROVED BY PARTIES OTHER THAN
BELL HELICOPTER ARE USED, THEN
THE DATA PUBLISHED OR OTHERWISE
SUPPLIED BY BELL HELICOPTER ARE
NOT APPLICABLE. THE USER IS
WARNED TO NOT RELY ON BELL
HELICOPTER DATA FOR PARTS AND
PROCESSES NOT APPROVED BY BELL
HELICOPTER. ALL APPLICABLE
INSPECTIONS AND REPAIR METHODS
MUST BE OBTAINED FROM THE
SUPPLIER OF THE PARTS OR
PROCESSES NOT APPROVED BY BELL
HELICOPTER. BELL HELICOPTER IS
NOT RESPONSIBLE FOR PARTS OR
PROCESSES OTHER THAN THOSE
WHICH IT HAS ITSELF DEVELOPED OR
APPROVED.
The mandatory airworthiness limitations schedule
(Table 4-1) summarizes the mandatory maximum life,
in hours, years or by Retirement Index Number (RIN)of components with a limited airworthiness life. Parts
that are not on the schedule have an unlimited
airworthiness life. The inspection limitations schedule
(Table 4-2) summarizes the mandatory inspection
interval in hours.
schedule applies to all the successive dashnumbers for that component unless it is
otherwise specified.
WARNING
SOME PARTS ARE INSTALLED AS
ORIGINAL EQUIPMENT ON BOTHMIL ITARY AND COMMERCIAL
HELICOPTERS AND MAY HAVE A
LOWER AIRWORTHINESS LIFE AND/OR
OVERHAUL SCHEDULE WHEN USED
ON A MIL ITARY HELICOPTER. IN
ADDIT ION, CIRCUMSTANCES
SURROUNDING THEIR USE MAY CALL
FOR OPERATION OF THE MILITARY
HELICOPTER OUTSIDE OF THEAPPROVED COMMERCIAL FLIGHT
ENVELOPE. CONSEQUENTLY, PARTS
THAT HAVE BEEN USED ON MILITARY
HELICOPTERS SHOULD NOT BE USED
ON COMMERCIAL HELICOPTERS.
CAUTION
AIRWORTHINESS LIFE OF SOME KIT
COMPONENTS MAY NOT BE COVERED
IN THIS SCHEDULE. REFER TO
APPLICABLE INSTALLATION
INSTRUCTION (II) OR MAINTENANCE
MANUAL SUPPLEMENT (MMS) FOR KIT
COMPONENTS SCHEDULE.
NOTE
The airworthiness life given or the failure to
give an airworthiness life to a component
does not constitute a warranty of any kind.
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airworthiness lives and inspection intervals cannot be
changed without the approval of the Minister of
Transport Canada.
Prior to disposing of unsalvageable helicopter parts
and materials, caution should be exercised to ensure
that the parts and materials are disposed of in a
manner that does not allow them to be returned for
service. Refer to FAA Advisory Circular 21-38 for
guidance on the disposal of unsalvageable helicopterparts and materials.
Table 4-1. Airworthiness Limitations Schedule
COMPONENT PART NUMBERRETIREMENT
YEARS/HOURS/RIN
MAIN ROTOR HUB AND BLADESYoke 407-010-101-101/-109
Grip 406-010-108-119/-121 1250 hrs
Grip 406-010-108-125/-131 5000 hrs
Pitch Horn 407-010-103-101/-107/-113 5000 hrs
Upper Plate 406-010-115-119/-127 2500 hrs
Lower Plate 406-010-117-115/-125 2500 hrs
Driving Ring Set 406-010-126-107/-113 48000 RINBlade Bolt, Expandable 406-310-103-101 5000 hrs
Lower Cone Seat 407-010-107-101 1250 hrs
Lower Cone Seat 407-010-107-103/-105 10000 hrs
MAIN ROTOR CONTROLS
Pitch Link Tube 406-010-413-119/-133/-139 5000 hrs
Clevis 406-010-416-101 5000 hrs
Bearing 406-310-405-101/-103 5000 hrsRod End Assembly 406-310-404-101 5000 hrs
Drive Link 406-010-426-101 5000 hrs
Drive Lever 406-010-425-107 5000 hrs
Gimbal Ring 406-010-427-109 5000 hrs
Drive Hub Set 406-010-428-109 5000 hrs
Swashplate Outer Ring 406-010-411-117 5000 hrs
Swashplate Inner Ring 406-010-410-121 5000 hrsAnti-Drive Link 406-010-432-101 5000 hrs
Anti-Drive Lever 406-010-431-109 5000 hrs
Collective Lever 406-010-408-101 5000 hrs
Collective Idler Link 406-010-407-101 5000 hrs
Cyclic Longitudinal Bellcrank 407 001 526 101/ 105 5000 hrs
12
8
3
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TC APPROVED BHT-407-MM-1
MAIN ROTOR CONTROLS (CONT)
Servo Actuator Support 407-001-500-101/-105 10000 hrs
Support Assembly 406-010-406-119 5000 hrs
Sleeve Assembly 406-010-409-107/-113 5000 hrs
Bellcrank Support 407-001-511-101 5000 hrs
TRANSMISSION
Transmission Top Case 406-040-052-105/-109
TAIL ROTOR
Blade 407-016-001-101 900 hrs
Blade 406-016-100-119 5000 hrs
Yoke 406-012-102-101/-109 5000 hrs
DRIVE SYSTEM
Main Rotor Mast 407-040-038-101/-105 5000 hrs or 18000 RINInput Drive Shaft 206-340-300-103
Input Drive Shaft 206-340-300-105
Input Drive Shaft 206-340-300-107 5000 hrs
Input Drive Shaft 407-340-310-101 5000 hrs
PYLON SUPPORT
L/H Pylon Side Beam 407-010-201-101 1000 hrs or 5500 RIN
L/H Pylon Side Beam 407-010-201-105 5000 hrs or 17000 RINR/H Pylon Side Beam 407-010-203-101 1000 hrs or 5500 RIN
R/H Pylon Side Beam 407-010-203-105 5000 hrs or 17000 RIN
Corner Mount 406-010-217-107 5000 RIN
Corner Mount 407-310-203-101
Pylon Restraint Spring 407-010-206-103 5000 hrs
TAILBOOM
Tailboom Assembly 407-030-801-107,407-530-014-101/-103
5000 hrs
LANDING GEAR
Fwd Crosstube Assembly
(Std. Gear)
407-050-101-101/-103 5000 RIN
Table 4-1. Airworthiness Limitations Schedule (Cont)
COMPONENT PART NUMBERRETIREMENT
YEARS/HOURS/RIN1
2
8
3
7
10
9
15
3 6
3 11
3 6
3 11
8
12
4
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BHT-407-MM-1 TC APPROVED
LANDING GEAR (CONT)
Fwd Crosstube Assembly
(High Gear/Lightweight Float)
407-050-201-101/-103 5000 RIN
Fwd Crosstube Assembly
(High Gear/Lightweight Float)
407-724-101 5000 RIN
Aft Crosstube Assembly
(High Gear/Lightweight Float)
407-050-202-101/-103 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
Reservoir 1271762 15 Years
NOTES:
Airworthiness limitation for the part number listed applies to all successive dash numbers for that component
unless otherwise specified.
RIN: Retirement Index Number. Components sensitive to operational events, such as torque events or run-on
landings, are assigned a maximum RIN number. This number is based on the fatigue damage that results from
normal helicopter lifts and take-offs (torque events) or from run-on landings, whichever applies.
New components will begin with an accumulated RIN of zero, which will increase as the helicopter is subjected to
torque events or run-on landings. The operator must record the number of torque events or run-on landings, and
increase the accumulated RIN as directed. When a component reaches the maximum RIN or retirement flight
hours, whichever occurs first, the component must be retired from service.
For every one (1) torque event, you add one (1) RIN to the previous total. A torque event occurs for every
takeoff (one takeoff plus the subsequent landing equals one RIN) and every load lift.
A load lift (internal or external) may be defined as a sling load, a rescue hoist load or any load that is added to the
helicopter while airborne. For example: if an operator performs one (1) takeoff, picks up and drops ten (10) sling
loads, and then lands, he must record eleven (11) torque events.
For every one (1) run-on landing, you add one (1) RIN to the previous total. A run-on landing is defined asone where there is forward ground travel of the helicopter greater than three (3) feet with the weight on the skids.
Refer to ASB 407-03-59.
This crosstube is modified from crosstube assembly P/N 407-050-202-101 per ASB 407-02-50. Depending
on status of part determined per Table 1 of ASB 407-02-50, crosstube may be subject to retirement upon
reaching 2500 landings.
Table 4-1. Airworthiness Limitations Schedule (Cont)
COMPONENT PART NUMBERRETIREMENT
YEARS/HOURS/RIN1
2
4
4 14
4
4 14
5
4
13
1
2
3
4
5
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NOTES (CONT):
These components were identified as life-limited items in Revision 6 of the airworthiness limitation schedule.
They are now on condition items. They will be removed from Table 4-1at a subsequent revision if their status
stays unchanged.
Input drive shaft 206-340-300-107 must be overhauled every 1,250 hours of operation. The overhaul is to be
done by Kamatics Corp. only.The input drive shaft 206-340-300-105 must be removed from service upon reaching 1250 hours in service.
Refer to ASB 407-01-45 for details.
Pylon side beams 407-010-201-105 and 407-010-203-105 are to be subjected to an airworthiness inspection.
See Table 4-2for details.
Tailboom assemblies 407-030-801-107, 407-530-014-101 and 407-530-014-103 are also subjected to an
airworthiness inspection. Refer to Table 4-2and ASB 407-07-80 for details. Tailboom assemblies
407-030-801-201, -203 and -205 are only subjected to an airworthiness inspection. See Table 4-2for details.
Reservoir per DOT-3HT and DOT exemption letter DOT-E-8162. This reservoir is part of reservoir assembly
P/N 407-073-848-101.
Aeronautical Accessories Incorporated (AAI) crosstube assemblies listed are BHT-approved production and
spare alternates.
Input drive shaft 407-340-310-101 must be overhauled every 2,500 hours of operation. The overhaul is to be
done by Kamatics Corp. only.
Table 4-1. Airworthiness Limitations Schedule (Cont)
COMPONENT PART NUMBERRETIREMENT
YEARS/HOURS/RIN1
2
8
9
10
11
12
13
14
15
Table 4-2. Inspection Limitations Schedule
COMPONENT PART NUMBERINSPECTION INTERVAL
(HRS OPERATING TIME)
Thomas Coupling Disks 406-040-340-101 25 hours
Pylon Side Beam 407-010-201-105, 407-010-203-105 300 hoursBearing, Tail Rotor Hanger 406-040-339-ALL 25 hours
Bearing, Tail Rotor Hanger 407-340-339-101/-103
Swashplate Bearing 406-310-402-101 50/150 hours
Tail Rotor Blade 407-016-001-101 300 hours
12
3
106
12
5
7
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BHT-407-MM-1 TC APPROVED
NOTES:
Inspection limitation for the part number listed applies to all successive dash numbers for that component
unless otherwise specified.
Refer to Chapter 5 for inspection requirements.
Inspect couplings 406-040-340-101 every 25 hours of operation. Refer to ASB 407-97-13, TransportCanada Aviation Airworthiness Directive CF-97-20R1 and Federal Aviation Authority Airworthiness Directive
97-24-17. Refer to Figure 4-1for inspection details.
Refer to Figure 4-2for inspection details.
The swashplate bearing 406-310-402-101 must be removed from service not later than December 31,
1998 and replaced by bearing 406-310-402-103. Refer to ASB 407-97-11 and Transport Canada Aviation
Airworthiness Directive CF-97-22 Bell.
Refer to Figure 4-3for inspection details.
Refer to Figure 4-4for inspection details.
You must do an inspection of tailbooms 407-030-801-201/-203, and -205 every 300 hours of operation.
Additional inspection requirements are applicable for tailbooms that have accumulated 6900 hours in service and
8600 hours in service. Refer to Figure 4-5for inspection details.
You must do an inspection of tailbooms 407-030-801-107 and 407-530-014-101/-103 daily and every 100
hours of operation. Refer to Figure 4-6and Figure 4-7for inspection details.You must do a 10X inspection of pylon side beams 407-010-201-105 and 407-010-203-105 that have
accumulated 1000 hours or more in service every 300 hours of operation. Do a fluorescent penetrant inspection
upon reaching 2500 hours in service. Refer to Figure 4-8for inspection details.
Contact Bell Helicopter Textron Product Support Engineering for changes or modifications to the structure
in area where a mandatory airworthiness inspection is specified.
The oil cooler blower and tail rotor segmented driveshaft bearings 407-340-339-101 and -103 must be
removed from service not later than May 31, 2004 and replaced by bearing 407-340-339-107. Refer to ASB407-04-63 Revision A, dated March 3, 2004 (or subsequent) and Transport Canada Aviation Airworthiness
Directive CF-2002-18R3.
Selected serial numbers of horizontal stabilizer 407-023-801-109 must be removed from service no later
than 30 September 2008. Refer to BHT ASB 407-06-72 for listing of serial numbers affected. Applicable
horizontal stabilizers must be inspected every 600 hours or annually until replaced Refer to Figure 4-9 for
Table 4-2. Inspection Limitations Schedule (Cont)
COMPONENT PART NUMBERINSPECTION INTERVAL
(HRS OPERATING TIME)1
2
1
2
3
4
5
6
7
8
9
10
11
12
13
C O
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BHT 407 MM 1 TC APPROVED
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TC APPROVED BHT 407 MM 1
12.0 IN.
NO REPAIR
TO SKIN PERMITTED
STA14.50
This inspection applies to the tail rotor blade 407-016-001 only.
Do this inspection every 300 hours of component operation.
Remove the tail rotor blade.
Crazing will look like a series of minute cracks on the surface of the skin and
will make the surface of the skin look cloudy.
Using a coin or heavy washer, lightly tap the outer surface of the blade in the
blade root area to detect delamination in the skin. An area of delamination will
sound hollow when gently tapped. If delamination is detected, remove the blade
from service.
If no crazing or delamination is detected, return the blade to service.
Install the tail rotor blade.
Balance the tail rotor (Chapter 18).
NOTES
1.
(304.8 mm)
4
2.
3.
5.
6.
7.
8.
Inspect the blade roots inboard of blade station 14.50 for signs of damage.
Examine the inside of the blade root pocket (where the tail rotor yoke is
inserted) for signs of crazing on the surface of the blade skins. If crazing is
detected, remove the blade from service.
4
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BS157.00
BS140.428
TAILBOOM IDENTIFICATION PLATE
AREA D
BS107.397
BS72.370
BS
39.00
AREA A
AREA C
AREA B
AREA I
AREA H
300-HOUR VISUAL INSPECTION
CRITICAL INSPECTION AREAS (SEE DETAILS)
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GENERAL VISUAL INSPECTION (300 HOURS)
AREA C AND AREA D(HORIZONTAL STABILIZER NOT SHOWN FOR CLARITY)
2.0 IN.(50.8 mm)
(139.7 mm)5.5 IN.
AREA D73
36
2.0 IN.
BS
98.89
BS
120.75
(50.8 mm)
4.25 IN.
(108.0 mm)
3 6 7
1
AREA C2 4
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1.
2.
3.
Upper tailboom skin
Horizontal stabilizer
Left upper stabilizer attachment support
1.
2.
3
4
5
6
7
8.
9.
AT EVERY 300-HOUR INTERVAL:
Inspect the complete tailboom assembly for general condition.
On the left side of the tailboom only, do a detailed inspection of all areas shown
for cracks in the tailboom skin and loose rivets. Do not remove the paint or primer. If a loose rivet is found,
remove rivet and inspect hole for cracks using a 10X magnifying glass. If no cracks are found, install
correct diameter rivet. Do not exceed maximum diameter prescribed.
Use a 10X magnifying glass to inspect for cracks in tailboom skin and around fastener heads as
indicated in area shown in Details E, F, G, Areas C, D, H and I.
Do not remove horizontal stabilizer.
FOR TAILBOOMS IN SERVICE FOR 6900 FLIGHT-HOURS OR MORE, OR WITH TOTAL TIME UNKNOWN:
Inspect Area H and Area I at every 150-hour interval using 10X magnifying glass inspection method,
or at every 500-hour interval using Eddy current inspection method.
FOR TAILBOOMS IN SERVICE FOR 8600 FLIGHT-HOURS OR MORE, OR WITH TOTAL TIME UNKNOWN:
Visually check Area C and Area D daily or at every 50-hour interval using 10X magnifying glass inspection
method. Do not exceed a distance of 12 inches (30.48 cm) from the tailboom surface when conducting the
daily visual inspection.
Pay close attention to skin just above edge of upper support.
Some tailboom components not shown for clarity.
If a crack is found on the tailboom skin, replace the tailboom before the next flight and contact Product
Support Engineering using the following information:
Bell Helicopter Textron Product Support Engineering
Light Helicopters
Tel: 1-800-243-6407 (Continental USA and Canada)
Tel: 1-800-363-8023 (Continental USA)
Tel: 1-800-361-9305 (Within Canada)
NOTES
BHT-407-MM-1 TC APPROVED
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Tailboom
assem
bly(Re
f)
Ho
rizon
tals
tabilizer
(Re
f)
Up
persupport
(Re
f)
Lowersupport
(407-0
23-8
00-1
21)
1.
2.
3.
4.
NO
TES
Paintan
dprimer
toberemove
dfrom
theseareas
(ASB407-0
7-8
0).
Exam
ine
theseareas
forcra
ckson
lefts
ideo
ftailboom
on
ly.
Ho
rizon
tals
tabilizerno
ts
ho
wn
forc
lari
ty.
Dailyc
hec
karea
4
2
3
1
1 21
2
1
2
BS
120
.75
1.5
IN
(3
8.1
mm
)
2.0
IN
(50
.8mm
)
3.
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DAILY INSPECTION
NOTES
1. Before the first flight of the day, do a check of the left side of the tailboom assembly in the areas where
paint was removed for cracks, as follows:
a) If required, use a clean cloth moistened with cleaning compound (C-318) prepared in accordance with
manufacturers recommendations to remove any exhaust residues or dirt, from both areas that require
checking, as shown.
b) Make sure that the tailboom skin is clean and that adequate lighting exists. Visually inspect the two
areas where original paint and primer was removed and protected with clear paint coating. Look for
cracks from a distance not exceeding 12 inches (30.48 cm).
c) Pay close attention near the edge of the stabilizer upper support.
d) If a crack is found on the tailboom skin, replace the tailboom before the next flight and contact
Product Support Engineering at the following numbers:
Bell Helicopter Textron
Product Support Engineering
Light Helicopters
Tel: 1-800-243-6407 (Continental USA and Canada)
Tel: 1-800-363-8023 (Continental USA)
Tel: 1-800-361-9305 (Within Canada)
Tel: 1-450-437-2682 (All other areas - call collect)
Fax: 450-433-0272 Internet: [email protected]
e) If no crack is found, the intent of the daily inspection is complete.
2. Make an entry in the helicopter records to show that the daily inspection is completed.
3. Comply with subsequent 100 hour inspection requirements described in Figure 4-7 when time is reached.
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BS140.428
BS107.397
BS39.00
BS72.370
BS90.00
AREA B
AREA C
AREA D
AREA A
100 HOUR VISUAL INSPECTION
CRITICAL INSPECTION AREAS (SEE DETAILS)
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AREA B
SEEDETAILE SEE
DETAIL FSEEDETAIL G
SEE
DETAIL I
SEEDETAIL G
SEEDETAIL H
AREAB
DETAIL E
FWD
BL
0.00
BS
39.000
LBL
7.50
BS
45.515
BL
0.00
0.50 IN.
(12.7 mm)0.50 IN.
(12.7 mm)
9 FASTENERS(LEFT SIDE ONLY)
BS
45.515
BS
52.600
BS
58.995
BS
72.475
BS
77.000
BS
85.955
LBL7.50
BS
90.00
BS
74.370BS
31.920
3
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3.00 IN.
BL0.00
LBL7.00
BS107.397
AREA C
SEEVIEW J
3
4
3
FWD
4.0 IN.
(101.6 mm) 4.0 IN.
(101.6 mm)
2.0 IN.
(50.8 mm)
2.0 IN.
(50.8 mm)
HORIZONTAL
STABILIZER
(REF)
BS
97.89
BS
98.89
BS
107.397BS
120.75
BS
121.75
8 RIVETS
(LEFT SIDE ONLY)
8 RIVETS
(LEFT SIDE ONLY)
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D
AREA D
BS
140.428
BS
140.428
6.00 IN.
(152.4 mm)
BL
0.00
LBL
5.00
LEFT SIDE ONLY
6 RIVETS
(LEFT SIDE ONLY)
SEEVIEW D
3
FWD
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100 HOURS OF OPERATION
1.
2.
3
4
5.
6.
7.
Inspect the complete tailboom assembly for general condition.
On the left side of the tailboom only, do a detailed inspection of all areas shown, for cracks in the tailboom
skin and loose rivets. Do not remove the paint or primer. If a loose rivet is found, remove rivet and inspect
hole for cracks using a 10X magnifying glass. If no cracks are found, install correct diameter rivet. Do not
exceed maximum diameter prescribed.
Use a 10X magnifying glass to inspect for cracks in tailboom skin and around fastener heads as
indicated in area shown in Detail E, F, G, H, I, View J, View D and Area C .
Do not remove horizontal stabilizer.
Some tailboom components not shown for clarity.
If a crack is found on the tailboom skin, replace the tailboom before the next flight and contact
Product Support Engineering at the following numbers:
Bell Helicopter Textron
Product Support EngineeringLight Helicopters
Tel: 1-800-243-6407 (Continental USA and Canada)
Tel: 1-800-363-8023 (Continental USA)
Tel: 1-800-361-9305 (Within Canada)
Tel: 1-450-437-2682 (All other areas - call collect)
Fax: 450-433-0272 Internet: [email protected]
Contact Bell Helicopter Textron Product Support Engineering for changes or modifications to thestructure in areas where a mandatory airworthiness inspection is specified.
NOTES
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NOTES
Inspect the upper outboard flange and flange/web area for cracks. Inspect the area
between 1.25 inches (31.7 mm) and 2.0 inches (50.8 mm) above the mounting pad.
If a crack is found in a pylon side beam, replace before the next flight and contact Product Support
Engineering at the following numbers:
Bell Helicopter Textron
Product Support Engineering
Light Helicopters
Tel: 1-800-243-6407 (Continental USA and Canada)
Tel: 1-800-363-8023 (Continental USA)
Tel: 1-800-361-9305 (Within Canada)
Tel: 1-450-437-2862 (All other areas - call collect)
Fax: 450-433-0272 Internet: [email protected]
2
3.
1
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NOTES
SEALANT MIL-PRF-81733 (C-392)
Washer12.
Screw11.
Support bracket10.
Screw9.Rivet8.
Horizontal stabilizer7.Tailboom6.
Lower attachment support5.
Upper attachment support4.
Rivet3.
Slat assembly2.
Finlet1.
InsertsNut
23.
Washer
22.
Screw21.
Spacer (left side only)
20.
Flap
19.
Casting supports
18.17.
Upper and lower doubler16.
Screw15.
Washer14.
Washer13.
20 TO 25 IN-LBS(2.26 TO 2.83 Nm)
2
5
12
9
SEE DETAILA
DETAILA
22
21
201
7
18
16
1
2
17
13
11
1514
19 26
8
4
12
9
173
10
SEE DETAILB
DETAILB
INSPECTION AREA
Inspect stabilizer on upper and lower surfaces
FWD
23
1.5 IN.(38.1 mm)
SECTIONC-CC C
24
Identification tag24.
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Inspect the horizontal stabilizer (7) as follows:
Horizontal stabilizer does not require to be removed from tailboom.
1.
PROCEDURE
CAUTION
PROTECTION UNDERNEATH STABILIZER IS REQUIRED TO NOT DAMAGE
STABILIZER OR TAILBOOM WHEN STABILIZER IS DETACHED FROM UPPER
SUPPORTS. SLAT MAY REMAIN INSTALLED HOWEVER SIDE MOVEMENT WILL BELIMITED. ENSURE NO DAMAGE TO SLATS AND/OR TAILBOOM SURFACES.
NOTE
Do not damage liquid shim compound between upper and lower supports (4 and 5)
and stabilizer (7). If liquid shim is damaged during removal of the parts, the
shimming procedure shall be repeated as described in BHT-407-MM, Chapter 53.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Remove the screws (9) and the washers (12) from the L/H and R/H lower supports (5). Remove the nuts (22),
washers (21) and screws (20).
Remove L/H and R/H lower supports (5).
Protect tailboom (6) underneath stabilizer (7) with padding or equivalent.
Hold the stabilizer (7). Remove the screws (9) and the washers (12) that attach the L/H and R/H upper
supports (4) to stabilizer (7).
Carefully lower stabilizer (7) and move to left side.
Refer to Figure Detail B. Clean and prepare surface of the stabilizer for inspection using cheesecloth (C-486)
moistened with acetone (C-316).
Inspect stabilizer in area of the inserts (23), on upper and lower surfaces for cracks and deformation using a
10X power magnifying glass. Inspect the area around each insert and between inserts for debonding using
tap test method.
If any damage is found, the stabilizer is not repairable. Replace the stabilizer.
If no damage is found, continue with the inspection.
Carefully move stabilizer (7) to the right side.
Repeat step 7 to 9 for the R/H side of stabilizer in area of inserts (23).
NOTE
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NOTICE
The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or
MAINTENANCE MANUAL
VOLUME 2
HANDLING AND SERVICING
BHT-407-MM-2
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PROPRIETARY RIGHTS NOTICE
These data are proprietary to Bell Helicopter Textron Inc. Disclosure,
reproduction, or use of these data for any purpose other than helicopter
operation or maintenance is forbidden without prior written authorization from
Bell Helicopter Textron Inc.
BHT-407-MM-2
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BHT-407-MM-2
7-3. LIFTING THE COMPLETE HELICOPTERNOTE
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WITH THE MAST NUT
WARNING
DO NOT GO INTO OR CLIMB ONTO THE
HELICOPTER WHILE IT IS SUPPORTED
ON THE JACKS OR BEING RAISED. IF
YOU DO NOT OBEY, INJURY TO
PERSONNEL CAN OCCUR.
CAUTION
ALL OF THE LIFT EQUIPMENT MUST BE
RATED FOR A MINIMUM CAPACITY OF
7500 POUNDS (3400 KG). IF YOU USEEQUIPMENT THAT IS NOT RATED FOR
THIS CAPACITY, DAMAGE TO THE
HELICOPTER CAN OCCUR.
1. Make the area around the helicopter safe. Put
ropes around the area. Put warning signs up that have
the message, "THIS HELICOPTER IS ON A HOIST".
2. Remove the main rotor fairing and the Frahmdamper (if installed) (Chapter 62).
3. If applicable, use the tail rotor strap and safety
the tail rotor (Chapter 10).
NOTE
If you lift the helicopter higher than you can
hold it, attach a rope to the tail skid. Make a
person hold the rope.
7. Put a person at the tail skid. Tell the person to
keep the helicopter in a level position when you lift the
helicopter.
8. Operate the hoist (1). Apply a constant force and
slowly lift the helicopter from the ground.
7-4. LIFTING THE HELICOPTER WITH THE
MAIN ROTOR AND THE MAST ASSEMBLY
REMOVED
WARNING
DO NOT GO INTO OR CLIMB ONTO THEHELICOPTER WHILE IT IS SUPPORTED
ON THE JACKS OR BEING RAISED. IF
YOU DO NOT OBEY, INJURY TO
PERSONNEL CAN OCCUR.
CAUTION
ALL OF THE LIFT EQUIPMENT MUST BE
RATED FOR A MINIMUM CAPACITY OF
7500 POUNDS (3400 KG). IF YOU USE
EQUIPMENT THAT IS NOT RATED FOR
THIS CAPACITY DAMAGE TO THE
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
T102137-101 Lifting Eye Clevis
206-070-469-001 Tail Rotor Strap
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
T103314-101 Lift Plate
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NOTICE
The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or
MAINTENANCE MANUAL
VOLUME 5
AIRFRAME
BHT-407-MM-5
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PROPRIETARY RIGHTS NOTICE
These data are proprietary to Bell Helicopter Textron Inc. Disclosure,
reproduction, or use of these data for any purpose other than helicopter
operation or maintenance is forbidden without prior written authorization from
Bell Helicopter Textron Inc.
BHT-407-MM-5
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VIEW C
SECTION A-A
1
2
B-BSECTION
CSEE VIEW
SEE VIEW D
2
3
1
1
32
23
1
1.
2.3.
Lower windowScrew
Washer
6.0 IN. (152.4 mm)
LONG. APPLY TO
FILL DIMPLED ZONE
TO FILL ALONG
LOWER WINDOW
TO FILL ALONG
LOWER WINDOW
VIEW D
A
A B
B
1
2
2
1
2
1
1
2 2
BHT-407-MM-5
b. Examine the lower windows (1) for abrasions,
scratches cracks holes and other defects that can
6. Install 33 screws (2) and washers (3) to attach the
lower window (1) to the nose skin floor panel and
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scratches, cracks, holes, and other defects that can
decrease visibility. Repair the lower windows, as
specified in Figure 52-12.
c. You can temporarily repair cracks, holes, or
other damage by stop drilling, with repair patches, or
by following other standard practices for acrylic plastic.
d. Examine the lower windows (1, Figure 52-14)
for loose screws (2).
e. Make sure the sealant (C-392) has no cracks,holes, or deterioration that permit water leakage.
f. To stop water leaks, apply sealant (C-392) to
the area of the leak.
52-67. Lower Windows Installation
1. Clean the fiberglass area of the window (1,
Figure 52-14) with aliphatic naphtha (C-305).
2. Apply a layer of sealant (C-328) to the faying
surfaces of the lower window (1).
3. Clean the excess sealant (C-328) from the
window.
4 Apply sealant (C 392) at the locations shown on
lower window (1) to the nose skin, floor panel, and
console structure.
7. Seal the window edges with sealant (C-308).
8. Clean the lower window (Chapter 12).
52-68. SKYLIGHT DESCRIPTION
The two skylights are made of light grey tinted acrylic
plastic. The skylights are flush mounted on the forward
cabin roof and part of the sidebody fairings. Theskylights are installed with double-sided self-adhesive
tape and four screws. The skylights are sealed for
water tightness.
52-69. Skylight Removal
1. Remove the nuts (2, Figure 52-15), washers (3),
spacers (4), and screws (5).
2. Lubricate a wire 0.025 inch (0.635 mm) in
diameter with a soap/detergent and water solution.
3. Push the wire in between the window and frame.
4. Attach a wooden dowel at each end of the wire.
Safety the wire with lockwire (C-405).
Refer to BHT-ALL-SPM for specifications.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-305 Aliphatic Naphtha
C-328 Sealant
C-392 Sealant
Refer to BHT-ALL-SPM for specifications.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-305 Aliphatic Naphtha
C-392 Sealant
C-405 Lockwire
C-407 Abrasive Pad
BHT-407-MM-5
VERTICAL FIN
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53-53. VERTICAL FIN
The vertical fin (3, Figure 53-26) is an aerodynamic
surface that gives stability to the helicopter while it is in
flight. The vertical fin is installed with the leading edge
at a 9 angle (with reference to the helicopter
longitudinal axis) outboard. This helps unload the tail
rotor while the helicopter is in forward flight. The
vertical fin is made of an aluminum honeycomb core
with aluminum outer skins. The forward and the aft
edge caps are made of formed aluminum alloy. The
anti-collision light (1) is installed on the top fairing (2)
of the vertical fin. The rubber bumper and the tail skid
(9) are installed on the lower edge of the vertical fin.
The tail skid absorbs shocks in a tail low landing.
(Refer to Chapter 32.)
On helicopters S/N 53057 and subsequent, and on
helicopters S/N 53000 through 53056 Post TB
407-96-2, a flap is installed along the trailing edge of
the vertical fin.
53-54. VERTICAL FIN REMOVAL
1. Remove the tail rotor gearbox fairing (paragraph53-83).
2. Disconnect the wires of the anti-collision light (1,
Figure 53-26) at the quick disconnects or at the
terminal board on the tail rotor gearbox support
casting (Chapter 96).
3. Put insulation on the wire ends and stow wires to
prevent damage.
4. Hold the vertical fin (3). Remove the bolts (5) and
53-55. VERTICAL FIN INSPECTION AND
REPAIR
WARNING
CORROSION AT THE FAYING EDGES
OF THE VERTICAL FIN FITTINGS CAN
CAUSE THE BOLTS (5, FIGURE 53-26)TO LOOSEN. THIS CAN RESULT IN
DAMAGE TO THE FITTINGS AND THE
BOLTS AND THE LOSS OF THE
VERTICAL FIN.
NOTE
For information on damage and repair
procedures not contained in this chapter,please contact Product Support
Engineering for assistance.
1. Examine the attachment area of the vertical fin (3,
Figure 53-26) for cracks, extended bolt holes, loose
bolts, distortion, and corrosion.
NOTE
Step 2 applies if the vertical fin has been
removed.
2. Examine the bolts (5), the barrel nuts (13), and
the nut retainers (12) for wear or thread damage.
3. On helicopters S/N 53057 and subsequent, andon helicopters S/N 53000 through 53056 Post TB
407-96-2, examine the flap (4) for cracks, dents,
damage, and loose rivets.
BHT-407-MM-5
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Helicopter S/N 53000 through 53056 Post TB 407-96-2 and
helicopter S/N 53057 and subsequent.
Apply a coating of corrosion preventive compound (C 104) to
NOTES
1
Anticollision light
FairingVertical fin
Flap
Bolt
Thin aluminium washer
Sleeve and plug
Former tail rotor gearbox fairing
Tail skid assembly
Tail rotor gearbox support casting
and fin support
TailboomNut retainer
Barrel nut
1.
2.3.
4.
5.
6.
7.
8.
9.
10.
11.12.
13.
12
75 TO 95 IN-LBS(8.5 TO 10.7 Nm)
13
SEE DETAIL A
DETAIL A
5
6
12
3
4 1
8
7
9
11
10
SEE DETAIL B
CORROSION PREVENTIVE COMPOUND (C-104)
2
2
103
3 (4 PLACES)
3
(4 PLACES)
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NOTICE
The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or
MAINTENANCE MANUAL
VOLUME 6
MAIN ROTOR/MAIN ROTOR DRIVE SYSTEM
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PROPRIETARY RIGHTS NOTICE
These data are proprietary to Bell Helicopter Textron Inc. Disclosure,
reproduction, or use of these data for any purpose other than helicopter
operation or maintenance is forbidden without prior written authorization from
Bell Helicopter Textron Inc.
BHT-407-MM-6
CHAPTER 63 MAIN ROTOR DRIVE SYSTEM
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TABLE OF CONTENTS
Paragraph Chapter/Section Page
Number Title Number Number
MAIN ROTOR DRIVE SYSTEM
63-1 Main Rotor Drive System............................................................... 63-00-00 9
63-2 Main Rotor Drive System Operational Check ...................... 63-00-00 9
63-3 Main Rotor Drive System Scheduled Inspection.................. 63-00-00 21
63-4 Main Rotor Drive System Condition and Security Inspection 63-00-00 2463-5 Transmission Top Case Torque Check Special
Instructions........................................................................ 63-00-00 25
63-6 Mast 12 Month Inspection ............................... ...... ....... 63-00-00 25
63-7 Mast 60 Month Inspection ............................... ...... ....... 63-00-00 25
63-8 Transmission 60 Month Inspection............................... 63-00-00 26
63-9 Freewheel 60 Month Inspection ................................... 63-00-00 26
63-10 Main Rotor Drive System Permitted Leakage Rate ............. 63-00-00 26
63-11 Serviceability Check....................................................................... 63-00-00 27
63-12 Transmission and Freewheel Assemblies ServiceabilityCheck........................................................................................ 63-00-00 27
63-13 Unwanted Particles ........................................................................ 63-00-00 28
63-14 Unwanted Particles Visual Identification .............................. 63-00-00 28
63-15 Unwanted Particles Chemical Identification ......................... 63-00-00 31
MAST ASSEMBLY
63-16 Mast Assembly............................................................................... 63-00-00 33
63-17 Mast Assembly Removal...................................................... 63-00-00 3363-18 Mast Assembly Cleaning...................................................... 63-00-00 36
63-19 Mast Assembly Inspection and Repair................................. 63-00-00 37
63-20 Mast Assembly Installation................................................... 63-00-00 37
TRANSMISSION ASSEMBLY
63-21 Transmission Assembly................................................................. 63-00-00 39
63-22 Transmission Removal......................................................... 63-00-00 39
63-23 Transmission Cleaning......................................................... 63-00-00 4363-24 Transmission Inspection and Repair.................................... 63-00-00 43
63-25 Transmission Installation...................................................... 63-00-00 44
63-26 Transmission Input Seal....................................................... 63-00-00 47
63-27 Transmission Input Magnetic Carbon Seal Removal ... 63-00-00 47
63 28 Transmission Input Magnetic Carbon Seal Cleaning 63 00 00 49
BHT-407-MM-6
TABLE OF CONTENTS (CONT)
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Paragraph Chapter/Section Page
Number Title Number Number
PYLON ASSEMBLY
63-35 Pylon Assembly ............................................................................. 63-00-00 69
63-36 Pylon Beam Assembly.............................................................. 63-00-00 69
63-37 Pylon Beam Assembly Removal .. ............. ...... ............. 63-00-00 69
63-38 Pylon Beam Assembly Cleaning .................................. 63-00-00 70
63-39 Pylon Beam Assembly Inspection................................ 63-00-00 70
63-40 Pylon Beam Assembly Repair...................................... 63-00-00 8063-41 Pylon Beam Assembly Installation .................. ...... ....... 63-00-00 80
63-42 Pylon Stop Transmission Fitting ............................................... 63-00-00 83
63-43 Pylon Stop Transmission Fitting Removal.................... 63-00-00 83
63-44 Pylon Stop Transmission Fitting Cleaning.................... 63-00-00 83
63-45 Pylon Stop Transmission Fitting Stripping....... ............. 63-00-00 84
63-46 Pylon Stop Transmission Fitting Inspection .................. 63-00-00 84
63-47 Pylon Stop Transmission Fitting Painting..................... 63-00-00 84
63-48 Pylon Stop Transmission Fitting Installation................. 63-00-00 84
63-49 Pylon Stop Deck Fitting ............................................................ 63-00-00 8663-50 Pylon Stop Deck Fitting Removal................................. 63-00-00 86
63-51 Pylon Stop Deck Fitting Cleaning................................. 63-00-00 86
63-52 Pylon Stop Deck Fitting Inspection............................... 63-00-00 86
63-53 Pylon Stop Deck Fitting Installation.............................. 63-00-00 86
63-54 Restraint Spring Assembly ....................................................... 63-00-00 88
63-55 Restraint Spring Assembly Removal............................ 63-00-00 88
63-56 Restraint Spring Assembly Disassembly...................... 63-00-00 90
63-57 Restraint Spring Assembly Cleaning............................ 63-00-00 90
63-58 Restraint Spring Assembly Inspection.......................... 63-00-00 9063-59 Restraint Spring Assembly Repair ..... ............. ...... ....... 63-00-00 90
63-60 Restraint Spring Assembly Assembly .......................... 63-00-00 93
63-61 Restraint Spring Assembly Installation......................... 63-00-00 93
ENGINE TO TRANSMISSION DRIVESHAFT
63-62 Engine to Transmission Driveshaft ................................................ 63-00-00 97
63-63 Engine to Transmission Driveshaft Removal ....................... 63-00-00 97
63-64 Engine to Transmission Driveshaft Cleaning ....................... 63-00-00 10563-65 Engine to Transmission Driveshaft Inspection..................... 63-00-00 105
63-66 Engine to Transmission Driveshaft Repair........................... 63-00-00 110
63-67 Engine to Transmission Driveshaft Installation.................... 63-00-00 110
BHT-407-MM-6
5. Examine the engine to transmission driveshaft
(paragraph 63-65).
4. Use a bright light and examine the mast (1) inside
diameter for corrosion and condition of the protective
coating
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63-5. Transmission Top Case Torque Check
Special Instructions
1. Apply the minimum torque required for the nut
(11, Figure 63-14). If the fastener does not move, the
test is completed.
2. If the fastener moved, examine the split line at the
top case, the ring gear gearshaft support case, and
the lower case to make sure that there are no cracks
in the sealant. If there is a crack in the sealant, clean
the old sealant and apply sealant (C-308).
3. If the fastener moved, do the transmission top
case torque check again at the same scheduled
interval (Chapter 5) until the fastener does not move.
63-6. Mast 12 Month Inspection
1. Remove the Frahm assembly (Chapter 62).
coating.
5. If there is corrosion, the mast (1) must beremoved, inspected, and repaired as per the
BHT-407-CR&O.
6. If the protective coating is removed, scratched, or
cracked, remove the mast (1) and refer to the
BHT-407-CR&O for protective coating application.
7. Install the plastic cap plug (10).
CAUTION
DO NOT APPLY THIXOGREASE TO THE
THREADS OF THE MAST OR MAST NUT.
8. Apply a thin layer of Thixogrease (C-561) to thesurface of the upper cone that contacts the mast nut
(Chapter 62).
NOTE
Do not disturb the lower cone hardware.
9. Install the mast nut (Chapter 62).
10. If applicable, install the Frahm assembly
(Chapter 62).
11. Do a mast nut torque check (Chapter 5).
63-7. Mast 60 Month Inspection
1. Do this inspection if an overhaul inspection has
not been done in the last 60 months. Do not do a non
destructive inspection.
2. If the primer protective coating of the mast inside
is damaged, refer to the BHT-407-CR&O for primer
Refer to BHT-ALL-SPM for specifications.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-308 Sealant
Refer to BHT-ALL-SPM for specifications.
MATERIALS REQUIRED
NUMBER NOMENCLATURE
C-561 Thixogrease
BHT-407-MM-6
6. Assemble the mast assembly (BHT-407-CR&O).
f f
63-9. Freewheel 60 Month Inspection
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7. Apply paint on the outer surface of the mast
where damaged (BHT-407-CR&O).
8. Install the mast assembly (paragraph 63-20).
63-8. Transmission 60 Month Inspection
1. Do this inspection if an overhaul inspection has
not been done in the last 60 months. Do not do a non
destructive inspection. It is not necessary to paint strip
the parts.
2. Remove the transmission assembly (paragraph
63-22).
3. Remove the transmission top case, the planetary
assembly, and the sungear (BHT-407-CR&O).
4. Do not disassemble the planetary assembly.
5. Examine all of the visible parts and assembled
components for condition (BHT-407-CR&O).
6. Insert a mirror between the spiral bevel gear edge
and the lower case and use a bright light to examine
the input pinion gear and surrounding areas for
condition.
7. Remove the transmission lower chip detector and
chip detector housing and screen (paragraph 63-195).
Use a bright light and a mirror to examine the spiral
bevel gear, the gearshaft, the accessory drive gear
and the surrounding areas for condition.
8. Install the transmission chip detector housing and
screen and the lower chip detector (paragraph63-197).
9. Install the sungear, the planetary and the top
case (BHT-407-CR&O).
1. Do this inspection if an Overhaul Inspection has
not been done in the last 60 months. Do not do a Non
Destructive Inspection. It is not necessary to paint stripthe parts.
2. Remove the freewheel assembly (paragraph
63-69).
3. Disassemble the freewheel assembly
(BHT-407-CR&O).
4. Inspect the freewheel parts for condition
(BHT-407-CR&O).
5. Assemble the freewheel assembly
(BHT-407-CR&O).
6. Apply paint where damaged (BHT-407-CR&O).
7. Install the freewheel assembly (paragraph 63-72).
63-10. MAIN ROTOR DRIVE SYSTEM
PERMITTED LEAKAGE RATE
Table 63-1. Maximum Permitted Leakage Rates for
the Transmission and Freewheel Assembly
COMPONENT TYPE LEAKAGE RATE
Transmission
and
Freewheel
Assembly
Static The input quill
leakage must not be
more than 5 drops
per minute.
The total
transmission
leakage at all
sources with the
BHT-407-MM-6
63-11. SERVICEABILITY CHECK
63 12 TRANSMISSION AND FREEWHEEL
g. Remove the jet assemblies No. 1, No. 2, No. 3
and No. 4.
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63-12. TRANSMISSION AND FREEWHEEL
ASSEMBLIES SERVICEABILITY
CHECK
1. Drain the transmission and freewheel oil system
(Chapter 12) through a paper filter and save the paper
filter for the inspection. Flush the transmission with
clean oil.
2. Examine the electrical magnetic element of the
transmission top chip detector for unwanted particles.
3. Examine the electrical magnetic element of the
transmission lower chip detector and the screen of the
chip