Bell 206L, Maintenance Manual

Page 1: ...Inc and Airworthiness Directives AD issued by the applicable regulatory agencies shall be strictly followed Export Classification C ECCN EAR99 3267 2 2 257 257 7 6 REISSUE 2 DECEMBER 1994 REVISION 24 18 JULY 2019 COPYRIGHT NOTICE COPYRIGHT 201 BELL HELICOPTER TEXTRON INC AND BELL HELICOPTER TEXTRON CANADA LTD ALL RIGHTS RESERVED MAINTENANCE MANUAL VOLUME 1 GENERAL INFORMATION ...

Page 2: ...rpose 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 ...

Page 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 IDENTIF...

Page 4: ...local Customer Service Engineering CSE network please access http www bellflight com support and service support Model 206 407 or 505 Phone 450 437 2862 or 800 363 8023 U S Canada Fax 450 433 0272 E mail productsupport bellflight com Model 222 230 427 429 or 430 Phone 450 437 2077 or 800 463 3036 U S Canada Fax 450 433 0272 E mail productsupport bellflight com Model 204 205 212 or 412 Phone 450 43...

Page 5: ... 17 07 NOV 12 Revision 18 07 JUN 13 Revision 19 17 FEB 14 Revision 20 07 NOV 14 Revision 21 08 JAN 15 Revision 22 10 MAR 17 Revision 23 25 JUN 19 Revision 24 18 JUL 19 Export Classification C ECCN EAR99 VOLUME 1 Cover 23 Title 24 PN 23 Warning 23 CSS 23 A D 24 E F 24 Help 17 Customer Feedback 23 Helicopter Sales Notice 23 Warranty 23 BR 23 TR 23 i ii 23 Chapter 1 1 2 0 3 6 0 Chapter 4 1 12 23 Chap...

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Page 7: ... 0 Chapter 52 1 2 24 3 4 24 5 38 0 39 40 0 41 11 42 0 43 44 11 45 51 0 52 60 24 61 62 24 Chapter 53 1 2 24 3 4 5 5 6 5 7 11 8 9 5 10 12 11 12A 11 12B 20 13 14 5 15 16 11 17 18 5 19 28 24 VOLUME 6 Cover 24 Title 24 PN 24 Chapter 62 1 20 2 24 3 4 20 5 6 20 7 12 20 13 14 24 14A 14B 24 15 18 20 19 22 24 22A 22B 24 23 28 24 29 33 20 34 24 35 66 20 Chapter 63 1 4 13 5 6 11 7 11 8 10 0 10A 10B 11 11 14 0...

Page 8: ... 24 30C 30D 24 31 32 24 33 10 34 0 35 36 24 36A 36B 24 37 39 0 40 24 41 43 11 44 24 45 11 46 0 47 48 11 49 50 11 51 11 52 55 0 56 11 57 58 11 59 60 11 61 62 24 62A 62B 24 63 67 0 68 24 69 70 0 71 72 24 73 74 24 75 11 76 77 0 78 11 79 80 0 81 82 0 83 86 0 87 88 0 89 96 0 97 98 0 99 102 0 VOLUME 9 Cover 24 Title 24 PN 24 Chapter 71 1 2 24 3 4 24 5 6 11 7 9 0 10 11 11 12 0 13 11 14 16 24 16A 16B 24 1...

Page 9: ...7 0 28 11 29 30 0 31 32 0 Chapter 96 1 4 24 5 6 24 7 10 0 11 12 0 13 16 24 16A 16D 24 16E 16F 24 17 27 0 28 11 29 30 0 31 35 0 36 11 37 38 0 39 40 0 41 46 0 47 48 0 49 50 0 51 54 19 55 56 19 VOLUME 11 Cover 11 Title 11 PN 11 Chapter 97 1 26 0 27 28 0 VOLUME 12 Cover 24 Title 24 PN 24 Chapter 98 1 24 2 20 3 4 20 5 20 6 24 7 20 8 24 9 15 20 16 18 24 18A 18B 24 19 58 20 18 JUL 2019 Rev 24 E F ...

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Page 11: ...e do and you discover it we would appreciate your telling us about it so that we can change whatever is incorrect or unclear Please be as specific as possible Your complaint or suggestion will be acknowledged and we will tell you what we intend to do You may use the enclosed Customer Feedback form as applicable to inform us where we have erred Your assistance is sincerely appreciated Export Classi...

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Page 13: ..._____________________________________________ _______________________________________________________________________ _______________________________________________________________________ Should Read ___________________________________________________________ _______________________________________________________________________ __________________________________________________________________...

Page 14: ...TAPE HERE From POSTAGE NECESSARY Product Support Engineering 12 800 rue de l Avenir Mirabel Québec Canada J7J 1R4 FOLD ON DOTTED LINES AND TAPE TAPE HERE Export Classification C ECCN EAR99 ...

Page 15: ...New Operator _______________________________________________________ Future Publications to be mailed to this address Address ____________________________________________________________________ City _______________________________________________________________________ State Province _______________________________________________________________ Zip Postal Code _________________________________...

Page 16: ... MAILED IN THE UNITED STATES COMMERCIAL PUBLICATION DISTRIBUTION CENTER P O BOX 482 FORT WORTH TEXAS 76101 0482 FOLD ON DOTTED LINES AND TAPE BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 1744 FORT WORTH TEXAS Export Classification C ECCN EAR99 ...

Page 17: ... 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 alt...

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Page 19: ...ervice Bulletins have not been incorporated 206L 11 168 TECHNICAL BULLETINS TB NUMBER SUBJECT DATE 206L 12 246 Fuel Transfer Pump and Centrifugal Boost Pump Canister Upgrade of 30 October 2012 The following Technical Bulletins have not been incorporated 206L 12 244 206L 09 239 206L 07 227 206L 07 225 206L 07 223 206L 02 207 206L 01 209 206L 01 204 206L 00 203 206L 96 189 206L 96 187 206L 95 182 20...

Page 20: ...rated 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 TR Rev 23 25 JUN 2019 NOTE For tracking purposes Temporary Revisions are now being numbered Example TR 1 Export Classification C ECCN EAR...

Page 21: ...is 18 Air Distribution Ventilation 21 Equipment and Furnishings 25 Fire Protection 26 Fuel System 28 Hydraulic System 29 Ice and Rain Protection 30 Landing Gear 32 Doors and Windows 52 Fuselage 53 Main Rotor 62 Main Rotor Drive System 63 Tail Rotor 64 Tail Rotor Drive System 65 Flight Controls 67 Power Plant 71 Air System 75 Engine Controls 76 Engine Oil System 79 Instrument System 95 Electrical S...

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Page 23: ... Page Number Title Number 4 1 Tailboom Upper Left Attachment Fitting 206 032 409 001 Recurring 110 Hour Inspection 12 TABLES Table Page Number Title Number 4 1 Airworthiness Limitations Schedule 6 4 2 Inspection Limitations Schedule 11 The Airworthiness Limitations Schedule is approved by the Minister and specifies the maintenance required by any applicable airworthiness or operational rules unles...

Page 24: ... 25 JUN 2019 Export Classification C ECCN EAR99 REVISION NO DATE OF SIGNATURE APPROVAL SIGNATURE Original 2 October 1992 Reissue 2 December 1994 1 21 April 1998 2 N A N A 3 9 December 2002 4 22 December 2003 5 N A N A 6 30 October 2007 7 26 May 2009 ...

Page 25: ...CCN EAR99 25 JUN 2019 Rev 23 Page 3 REVISION NO DATE OF SIGNATURE APPROVAL SIGNATURE 8 25 September 2009 9 N A N A 10 N A N A 11 N A N A 12 N A N A 13 N A N A 14 8 April 2011 15 29 February 2012 16 1 June 2012 17 7 November 2012 18 N A N A 19 N A N A 20 N A N A ...

Page 26: ...BHT 206L4 MM 1 TC APPROVED 4 00 00 Page 4 Rev 23 25 JUN 2019 Export Classification C ECCN EAR99 21 N A N A 22 N A N A 23 25 June 2019 REVISION NO DATE OF SIGNATURE APPROVAL SIGNATURE ...

Page 27: ...THE AIRWORTHINESS OF THE HELICOPTER THE COMPONENT MUST BE REMOVED FROM THE HELICOPTER NOT LATER THAN THE END OF THE LIFE LIMIT IT MUST EITHER BE MADE UNSERVICEABLE OR MARKED IN A CONSPICUOUS MANNER TO PREVENT CONTINUED USE EVEN INADVERTENT USE WHEN A REPLACEMENT PART IS INSTALLED THE PART NAME PART NUMBER SERIAL NUMBER AND CURRENT OPERATING HOURS IF APPLICABLE MUST BE RECORDED IN THE HISTORICAL SE...

Page 28: ...ase Agreement for the helicopter or the component The airworthiness lives given to the components and assemblies are determined by experience tests and the judgment of Bell Helicopter engineers The lives 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 a...

Page 29: ... 14 400 hours POWER TRAIN Tail Rotor Gearbox Duplex Bearing 206 040 410 003 005 101 3000 hours Main Rotor Mast 206 040 535 105 109 5000 hours 44 000 RIN Sun Gear 206 040 662 101 TAIL ROTOR HUB AND BLADES Tail Rotor Yoke 206 011 819 105 109 5000 hours Tail Rotor Blade 206 016 201 001 107 113 2400 hours Tail Rotor Blade 206 016 201 127 131 135 2500 hours Tail Rotor Yoke 406 012 102 107 113 5000 hour...

Page 30: ...the suffix U added to the serial number Refer to ASB 206L 87 44 dated 23 April 1987 for list of serial numbers affected Reserved Main rotor hub tension torsion straps 206 011 147 and 206 011 154 have airworthiness lives of 1200 hours or 24 months whichever occurs first The calendar life of 24 months starts when new straps are installed in a main rotor hub and blade assembly and are subjected to ro...

Page 31: ...s allows maintenance personnel to convert torque events to RIN by applying the appropriate RIN adjustment factor Refer to ASB 206L 94 99 Rev B dated 10 August 2001 A new component will begin with an accumulated RIN of zero that will be increased as lifts and takeoffs are performed Operator will record number of lifts and takeoffs torque events and increase accumulated RIN accordingly When maximum ...

Page 32: ...ate of manufacturing Dispose of time expired squib in accordance with local regulations Part of squib assembly 29022971 and approved alternate for squib 30908 Retire squib no later than 15 years after date of manufacturing Dispose of time expired squib in accordance with local regulations Storage life of cutter assembly Y 1265 11 1 in original sealed container is set at 60 months Service life is 3...

Page 33: ...er Left Attachment Fitting 206 032 409 001 110 hours NOTES Inspection limitation for the part number listed applies to all successive dash numbers for that component unless otherwise specified You must do an inspection of the tailboom upper left attachment fitting 206 032 409 001 every 110 flight hours Refer to ASB 206L 09 158 for a listing of affected tailbooms Refer to Figure 4 1 for inspection ...

Page 34: ...TION PROCEDURE 1 Inspect upper left attachment fitting for cracks mechanical damage corrosion damage loose rivets and general condition 2 Refer to ASB 206L 09 158 for wear damage and repair limits 3 Repair fitting in accordance with ASB 206L 09 158 4 Replace cracked or damaged fitting or loose rivets in accordance with ASB 206L 09 158 5 If a crack is found contact Product Support Engineering DETAI...

Page 35: ... 2 5 00 00 27 5 18 100 Hour Airframe Progressive Inspection Event No 3 5 00 00 33 5 19 100 Hour Airframe Progressive Inspection Event No 4 5 00 00 37 5 20 100 Hour Airframe Periodic Inspection 5 00 00 45 5 21 300 Hour Airframe Progressive Inspection Event No 1 5 00 00 47 5 22 300 Hour Airframe Progressive Inspection Event No 2 5 00 00 51 5 23 300 Hour Airframe Progressive Inspection Event No 3 5 0...

Page 36: ...9 5 50 Hard Landing 5 00 00 141 5 51 Sudden Stoppage Acceleration Main Rotor 5 00 00 147 5 52 Sudden Stoppage Acceleration Tail Rotor 5 00 00 153 5 53 Overspeed Main Rotor 114 or Greater 5 00 00 157 5 54 Overtorque 5 00 00 161 5 55 Engine Compressor Stall or Surge 5 00 00 167 5 56 Lightning Strike 5 00 00 175 5 57 Engine Overtemp 5 00 00 181 COMPONENT OVERHAUL SCHEDULE 5 58 Component Overhaul Sche...

Page 37: ...licopter 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 the Maintenance Manual Chapter 5 or a Technical Bulletin Every calendar and hourly inspection is a thorough visual inspection to determine the airworthiness of the helicopter and the components Qualified persons mus...

Page 38: ...component overhaul inspections a Scheduled inspections must occur at specified operating intervals The intervals may be in operating time hours cycles torque events RIN calendar days months years or other assigned units This makes sure that the helicopter is airworthy b Special inspections are of a temporary nature or of a special interval that is not consistent with the scheduled inspections c Co...

Page 39: ...egular basis to prevent non scheduled maintenance Operating time Actual flight or calendar time that must be recorded in the Historical Service Records or in the helicopter logs The operating time is specified as Time in service flight time The measured time that starts the moment the helicopter leaves the ground and continues until it touches the ground at the next point of landing The time when ...

Page 40: ...plicable for those operators whose governing aviation authority requires to specifically approve the inspection and overhaul tolerance If approval of the inspection and overhaul tolerance is required by the applicable governing aviation authority this is the responsibility of the owner operator Refer to the Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 for inspection and overhau...

Page 41: ...ximum of 300 hours operating time 6 months calendar time whichever is less 2250 HOUR 60 MONTH INSPECTION DUE AT MAXIMUM ALLOWED TOLERANCE INSPECTION CARRIED OUT AT NEXT 2250 HOUR 60 MONTH INSPECTION DUE AT 3400 Hours August 31 2010 10 of 2250 hours 225 hours or 10 of 60 months 6 months 3400 Hours February 15 2011 within 10 calendar tolerance 5650 Hours February 29 2016 5650 Hours February 29 2016 ...

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Page 43: ...essive inspections are divided into separate events of similar workload Table 5 1 Table 5 2 and Figure 5 1 NOTE All conditions of Table 5 3 must be met to utilize the 300 hour airframe progressive inspection Depending on the helicopter configuration you have the option to either use the 100 hour airframe progressive inspection program or the 300 hour airframe progressive inspection program To dete...

Page 44: ...tion to performing the 300 hour airframe progressive inspection program you also need to perform and record the following scheduled inspections NOTE Helicopters completing the 300 hour airframe progressive inspection program also need to accomplish the 100 hour inspection 100 hour inspection 1200 hour inspection As required by manufacturer Weekly inspection 12 month inspection 12 months of compone...

Page 45: ...y inspection 12 month inspection 12 months of component operation 24 month inspection 60 month inspection 300 hour or 12 month inspection 600 hour or 12 month inspection 1200 hours of component operation 1500 hours of component operation 2250 hours or 60 months of component operation 3000 hours of component operation 5 14 300 HOUR AIRFRAME PERIODIC INSPECTION PROGRAM Do a 300 Hour Airframe Periodi...

Page 46: ...hour airframe periodic inspection program do a complete 100 hour airframe periodic inspection To change from a 100 hour airframe periodic inspection program to a 100 hour airframe progressive inspection program do a complete 100 hour airframe periodic inspection To change from a 300 hour airframe progressive inspection program to a 300 hour airframe periodic inspection program do a complete 300 ho...

Page 47: ...9 is an acceptable alternate provided ASB 206L 97 108 is accomplished X X X X X Tail Rotor Hub Assembly 206 011 810 153 TB 206L 09 239 X X X X X Tailboom Attachment Fittings and Longeron Assembly 206 031 314 157A or 206 031 314 217B TB 206L 07 226 or PSE Instructions X X X X X Forward Engine Mount Fittings 206 031 629 103 BHT 206 SRM X X X X X Tailboom Assembly 206 033 004 175 177 or equivalent wi...

Page 48: ...s for 206 040 387 101 X X X X X Tail Rotor Gearbox Assembly 206 040 402 111 TB 206L 99 197 206 040 402 101 107 are acceptable fielded substitutes for 206 040 402 111 X X X X X Oil Cooler Blower Impeller 206 061 432 109 ASB 206L 86 40 X X X X X Main Driveshaft Assembly KAflex 206 340 300 105 ASB 206L 01 123 TB 206L 01 204 206 340 300 105M is an acceptable fielded substitute for 206 340 300 105 X X ...

Page 49: ...airframe progressive inspection program or the 300 hour airframe periodic inspection program the helicopter must have all of the parts listed installed or subsequent part numbers to those listed based on configuration eligibility requirements 3 If the helicopter does not have all of the parts listed in this table installed the helicopter is limited to either the 100 hour airframe progressive inspe...

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Page 51: ... 8 ZONE 9 ZONE 4 ZONE 5 ZONE 6 ZONE 2 Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Zone 7 Zone 8 Zone 9 Zone 10 Main rotor hub and blade assembly Tail rotor hub and blade assembly Forward top deck Power plant Aft top deck Tailboom Cabin interior Foward fuselage Aft fuselage Landing gear 25 FEB 2011 Rev 13 Page 15 16 ...

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Page 53: ...TEM Chapter 11 PLACARDS AND MARKINGS 1 Examine the placards decals and markings Make sure they are readable correctly applied and in agreement with the applicable configuration of your helicopter Chapter 62 MAIN ROTOR SYSTEM 1 Verify main rotor flap restraint for freedom of movement and for condition and security 2 Examine static stops and mast for evidence of mast bumping 3 Remove main rotor blad...

Page 54: ...2 Nm Examine for misalignment of anti slippage marks 11 Examine main rotor yoke for corrosion or mechanical damage as follows BHT 206L CR O a Examine fillet radius of both yoke spindles inboard of wear sleeves for evidence of corrosion If corrosion is visible remove with fine abrasive pad C 407 If corrosion cannot be removed with pads or is extensive disassemble hub for inspection and repair NOTE ...

Page 55: ...RKINGS 1 Examine the placards decals and markings Make sure they are readable correctly applied and in agreement with the applicable configuration of your helicopter Chapter 64 TAIL ROTOR ASSEMBLY 1 Clean tail rotor blades to maintain visibility of warning stripes BHT 206L CR O 2 Examine the following tail rotor hub assembly components for condition and security of attachment a Yoke b Pitch horns ...

Page 56: ...b Rubber bumper c Static stop d Nut e Balance wheel ZONE 3 FORWARD DECK Chapter 11 PLACARDS AND MARKINGS 1 Examine the placards decals and markings Make sure they are readable correctly applied and in agreement with the applicable configuration of your helicopter AIRFRAME FORWARD DECK Chapter 71 1 Open and examine forward fairing for condition and security 2 Remove and examine transmission cowling...

Page 57: ...dition and security Chapter 67 CONTROLS 1 Examine the following flight control components for signs of interference corrosion wear mechanical damage and security a Control tubes b Links c Rod and bearings d Bellcranks e Bellcrank supports f Attaching bolts and nuts 2 Inspect main rotor pitch links with a 3X magnifying glass for damage corrosion and cracks Give particular attention to swaged ends a...

Page 58: ... ring to check duplex bearing for condition Bearing must be smooth and show no evidence of roughness binding dragging or looseness 7 Examine pivot sleeve slot sidewalls for wear or deterioration 8 Examine pivot sleeve bearings for wear deterioration and evidence of excessive axial play between pivot sleeve and swashplate support 9 Examine collar set bushings for cracks and damage 10 Examine swashp...

Page 59: ...on 3 Examine hydraulic reservoir for leaks and general condition 4 Examine servo actuators for leaks condition and security 5 Examine servo actuator support for condition Chapter 67 6 Verify linkage pivot bolts on hydraulic servo actuators for freedom of rotation and security 7 Examine hydraulic filter red indicator button two locations Button should not be extended Chapter 12 8 Verify fluid level...

Page 60: ...for condition and security Stop mount bushings for wear g All pylon support elastomeric components for evidence of deterioration h All pylon support hardware for security of attachment 2 Examine transmission assembly for condition and security 3 Examine transmission assembly for evidence of oil leakage 4 Examine all fluid lines for chafing damage and evidence of leakage 5 Examine transmission oil ...

Page 61: ...d transmission for chafing general condition and security GROUND RUN CAUTION GROUND RUN OF HELICOPTER TO BE ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY Chapter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surr...

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Page 63: ...amine the placards decals and markings Ensure they are readable correctly applied and in agreement with the applicable configuration of your helicopter AIRFRAME POWER PLANT AREA Chapter 71 1 Examine firewalls for condition and security 2 Examine engine pan area for evidence of loose fasteners and damage Restore cracked or missing sealant form engine pan 3 Examine engine pan drains Make sure that t...

Page 64: ...l leaks 5 Examine all flexible and rigid lines for condition and security a Pay particular attention for chafing damage and kinked lines 6 Examine exhaust stack for condition and security 7 Examine all engine mounted accessories for condition and security Chapter 75 8 Examine the engine anti ice solenoid valve for condition and security Chapter 76 9 Inspect fuel control lever bolt hole and bolt fo...

Page 65: ...the 40 mark on the quadrant e Verify control linkage for excessive looseness lost motion and binding 14 Verify operation of engine N2 control as follows a Position N2 governor actuator to full DECREASE extended b Lift collective stick full up c Position N2 governor actuator to full INCREASE retracted d Verify for clearance between governor stop and lever stop arm e Lower collective stick full down...

Page 66: ...er 96 ELECTRICAL 1 Examine all electrical components wires cables and connectors in the power plant area for chafing general condition and security 2 Verify illumination of airframe fuel filter caution light by depressing differential switch press to test button on filter head ZONE 5 AFT TOP DECK PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Ensure they are readable c...

Page 67: ...tamination 6 Examine oil tank supports for condition and security Chapter 71 7 Examine the oil cooler seals bonded inside the aft fairing for condition 8 Examine external scavenge oil filter system STC if installed for condition and security DRIVETRAIN Chapter 65 1 Examine the blower impeller for condition 2 Examine oil cooler blower impeller shaft for condition 3 Examine oil cooler blower hanger ...

Page 68: ...ter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surrounding area is clear BHT 206L4 FM 1 4 Start the helicopter and conduct ground run at 100 NR to check for leaks and ensure all systems are operational an...

Page 69: ... _________________________ ZONE 6 TAILBOOM Chapter 11 PLACARDS AND MARKINGS 1 Examine the placards decals and markings Ensure they are readable correctly applied and in agreement with the applicable configuration of your helicopter TAILBOOM STRUCTURE Chapter 53 1 Remove and examine tail rotor driveshaft cover and fasteners for condition and security 2 Remove and examine tail rotor gearbox fairings...

Page 70: ...ound stabilizer of left side for integrity of sealant Reseal as required 7 Examine horizontal stabilizer for condition and security Verify security of all attachment bolts 8 Examine elevators for condition security and side play 9 Examine auxiliary finlets for condition and security 10 Examine vertical fin assembly for condition and security 11 Inspect the vertical fin attachment support for condi...

Page 71: ...attention for cracks at the gearbox attachment holes Chapter 65 2 Examine tail rotor gearbox for oil leaks condition and security 3 Examine gearbox oil for evidence of contamination 4 Examine tail rotor output shaft for condition Chapter 65 5 Examine the tail rotor gearbox chip detector for accumulated material Chapter 96 6 Perform operational check of the tail rotor gearbox chip detector Chapter ...

Page 72: ...Chapter 97 3 Examine antennas for condition and security GROUND RUN CAUTION GROUND RUN OF HELICOPTER TO BE ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY Chapter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surro...

Page 73: ...acards decals and markings Ensure they are readable correctly applied and in agreement with the applicable configuration of your helicopter BHT 206L4 FM 1 INSTRUMENTS 1 Examine instruments and instrument panel for condition security and for correct markings EQUIPMENT AND FURNISHINGS Chapter 53 1 Examine the cabin floor for condition Chapter 25 2 Examine the seat assemblies for condition and securi...

Page 74: ...ion and security Examine copilot collective control stick if installed 2 Examine the cyclic control stick for condition and security Examine copilot cyclic control stick if installed 3 Examine the anti torque control pedals for condition and security Examine copilot anti torque control pedals if installed Chapter 96 ELECTRICAL 1 Verify operation of cockpit map reading light 2 Verify operation of a...

Page 75: ... with the applicable configuration of your helicopter FUSELAGE Chapter 53 1 Examine forward fuselage for condition Chapter 52 2 Examine all cabin doors for condition and security Give special attention to the following a Hinges b Seals c Latches for proper adjustment positive locking and wear d Windows e Handles Chapter 95 3 Drain moisture from pitot and static piping installation Chapter 53 4 Exa...

Page 76: ...ition Restore sealant as necessary Chapter 96 ELECTRICAL AND AVIONICS 1 Examine all visible electrical components wires cables and connectors in the area of the forward fuselage for chafing and general condition and security 2 Examine battery and vent tubes for condition and security 3 Perform operational test of the battery temperature indicating system 4 Verify operation of litter door open warn...

Page 77: ...condition and freedom from obstructions Applicable Service Instruction 6 Examine heater and or air conditioning inlets and outlets for cleanliness and absence of obstructions if installed Chapter 53 7 Examine baggage compartment door seal and latches for operation condition and security Chapter 96 8 Verify operation of the baggage door ajar caution light if installed FUSELAGE INTERIOR Chapter 53 1...

Page 78: ...t fittings on fuselage aft bulkhead and tailboom forward bulkhead for cracks Give special attention to the tailboom attachment fittings intercostals and bolts and to fasteners between the intercostal Particular attention must be given to inspection of the upper left fitting refer to Chapter 4 Inspection Limitations Schedule CONTROLS Chapter 67 1 Examine the anti torque control system components fo...

Page 79: ...installed for condition and security 4 Examine fairings if installed for condition and security 5 Examine crosstube riveted or clamped supports for condition and security Give particular attention to the sealant joints around supports Restore sealant C 251 and paint finish as required 6 Examine crosstubes for corrosion and damage Give particular attention to areas where equipment is mounted Repair...

Page 80: ...s have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surrounding area is clear BHT 206L4 FM 1 4 Start the helicopter and conduct ground run at 100 NR to check for leaks and ensure all systems are operational and parameters are within Flight Manual limitations C...

Page 81: ...____________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ 1 Do this inspection every 100 hours of operation or every 12 calendar months Chapter 5 Paragraph 5 16 through paragraph 5 19 2 Do all four events of the 100 hour progressiv...

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Page 83: ...TEM Chapter 11 PLACARDS AND MARKINGS 1 Examine the placards decals and markings Make sure they are readable correctly applied and in agreement with the applicable configuration of your helicopter Chapter 62 MAIN ROTOR SYSTEM 1 Verify main rotor flap restraint for freedom of movement and for condition and security 2 Examine static stops and mast for evidence of mast bumping 3 Remove main rotor blad...

Page 84: ...amine fillet radius of both yoke spindles inboard of wear sleeves for evidence of corrosion If corrosion is visible remove with fine abrasive pad C 407 If corrosion cannot be removed with pads or is extensive disassemble hub for inspection and repair NOTE If the main rotor hub must be disassembled omit remaining steps b Examine entire yoke centre section inboard and outboard surfaces for damage c ...

Page 85: ...plicable configuration of your helicopter Chapter 64 TAIL ROTOR ASSEMBLY 1 Clean tail rotor blades to maintain visibility of warning stripes BHT 206L CR O 2 Examine the following tail rotor hub assembly components for condition and security of attachment a Yoke b Pitch horns c Trunnion and trunnion caps d Counterweight hardware Chapter 64 3 Examine tail rotor blades as follows a Tip block rivets f...

Page 86: ...ring ground run GROUND RUN CAUTION GROUND RUN OF HELICOPTER TO BE ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY Chapter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surrounding area is clear BHT 206L4 FM 1 4 Sta...

Page 87: ...DECK Chapter 11 PLACARDS AND MARKINGS 1 Examine the placards decals and markings Make sure they are readable correctly applied and in agreement with the applicable configuration of your helicopter AIRFRAME FORWARD DECK Chapter 71 1 Open and examine forward fairing for condition and security 2 Remove and examine transmission cowling for condition 3 Examine all fairing and cowling latches and or fas...

Page 88: ...ports f Attaching bolts and nuts 2 Inspect main rotor pitch links with a 3X magnifying glass for damage corrosion and cracks Give particular attention to swaged ends at jam nut or inserts Chapter 76 3 Examine N2 control linkages on forward deck for condition and security Pay particular attention to the jackshaft assembly for damage or evidence or twisting 4 Verify all control tubes and bellcranks ...

Page 89: ... evidence of excessive axial play between pivot sleeve and swashplate support 9 Examine collar set bushings for cracks and damage 10 Examine swashplate support and uniball surfaces for condition 11 Examine collective lever to sleeve assembly pins and bushings for condition 12 Examine inner ring for condition Examine for evidence of contact with sleeve assembly 13 Examine outer ring for condition 1...

Page 90: ...ar Chapter 12 4 Lubricate hydraulic pump shaft splines and rotor tachometer splines 5 Examine hydraulic reservoir for leaks and general condition 6 Examine servo actuators for leaks condition and security 7 Examine servo actuator support for condition Chapter 67 8 Verify linkage pivot bolts on hydraulic servo actuators for freedom of rotation and security 9 Examine hydraulic filter red indicator b...

Page 91: ...for wear g All pylon support elastomeric components for evidence of deterioration h All pylon support hardware for security of attachment 2 Examine transmission assembly for condition and security 3 Examine transmission assembly for evidence of oil leakage 4 Examine all fluid lines for chafing damage and evidence of leakage 5 Examine transmission oil for evidence of contamination 6 Examine transmi...

Page 92: ... forward deck and transmission for chafing general condition and security GROUND RUN CAUTION GROUND RUN OF HELICOPTER TO BE ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY Chapter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground r...

Page 93: ...cals and markings Ensure they are readable correctly applied and in agreement with the applicable configuration of your helicopter AIRFRAME POWER PLANT AREA Chapter 71 1 Examine firewalls for condition and security Chapter 53 2 Examine engine cowlings and doors for condition and security Using a bright light and mirror inspect exposed upper and lower edges of the joints between aluminium longerons...

Page 94: ...and Maintenance Manual Chapter 71 2 Examine engine inlet bellmouth for obstruction and general condition 3 Examine engine compartment hardware for security of attachment 4 Examine engine for evidence of fuel or oil leaks 5 Examine all flexible and rigid lines for condition and security a Pay particular attention for chafing damage and kinked lines 6 Examine exhaust stack for condition and security...

Page 95: ...el limit NOTE If dual controls are installed it is permissible for pointer to be 0 078 inch 1 98 mm below 40 mark when copilot twist grip is used d Rotate throttle grip to idle detent fuel control pointer should be no more than 0 01 inch 0 25 mm below the 40 mark on the quadrant e Verify control linkage for excessive looseness lost motion and binding 15 Verify operation of engine N2 control as fol...

Page 96: ... step does not apply to helicopters equipped with fuel filter assembly 222 366 621 103 a Remove outlet port fitting from filter head b Pass a 0 020 inch 0 50 mm wire through the bleed hole in outlet port side of filter head to ensure hole is not obstructed 2 Replace airframe fuel filter element Chapter 28 3 Purge airframe and engine fuel system as follows a Turn both fuel boost pumps ON b Depress ...

Page 97: ...e splines on starter generator shaft and engine gear shaft DRIVETRAIN Chapter 63 1 Examine freewheel assembly for condition leaks and security Chapter 63 Chapter 96 2 Examine the freewheel unit chip detector for accumulated material Perform operational check of freewheel unit chip detector Refer to transmission chip detector caution system Chapter 65 3 Examine forward short shaft steel disc pack c...

Page 98: ...NLY Chapter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surrounding area is clear BHT 206L4 FM 1 4 Start the helicopter and conduct ground run at 100 NR for a minimum of 2 minutes to check for leaks and en...

Page 99: ..._ ZONE 5 AFT TOP DECK PLACARDS AND MARKINGS Chapter 11 1 Examine the placards decals and markings Ensure they are readable correctly applied and in agreement with the applicable configuration of your helicopter AIRFRAME AFT TOP DECK Chapter 71 1 Remove and examine aft fairing and attachment fasteners for condition and security 2 Examine fairing retainer for condition 3 Examine exterior of aft deck...

Page 100: ... Using dye penetrant methods inspect oil cooler blower impeller 206 061 432 031 for cracks Give particular attention to the mounting flange where individual blades attach 3 Examine oil cooler blower impeller shaft for condition 4 Examine oil cooler blower hanger bearings and brackets for grease leakage and evidence of overheating 5 Lubricate oil cooler blower hanger bearings Chapter 12 Chapter 65 ...

Page 101: ...move and examine tail rotor driveshaft cover and fasteners for condition and security 2 Remove and examine tail rotor gearbox fairings for condition 3 Examine anti chafing adhesive tape C 460 on tailboom for condition Replace worn or damaged tape as required NOTE In the event that cracks are found contact Bell Helicopter Textron Product Support Engineering 4 Examine entire tailboom for the followi...

Page 102: ...achment bolts 8 Examine elevators for condition security and side play 9 Examine auxiliary finlets for condition and security 10 Examine vertical fin assembly for condition and security 11 Inspect the vertical fin attachment support for condition and damage Pay particular attention to the vertical fin attachment points 12 Examine for open tailboom drains on lower tailboom skin and clear any obstru...

Page 103: ...l rotor gearbox for oil leaks condition and security 3 Examine gearbox oil for evidence of contamination 4 Examine tail rotor output shaft for condition 5 Torque check tail rotor gearbox retaining nuts 50 to 70 inch pounds 5 6 to 7 9 Nm 6 Examine the tail rotor gearbox chip detector for accumulated material Chapter 96 7 Perform operational check of the tail rotor gearbox chip detector Chapter 64 T...

Page 104: ...Chapter 97 3 Examine antennas for condition and security GROUND RUN CAUTION GROUND RUN OF HELICOPTER TO BE ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY Chapter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surro...

Page 105: ...S 1 Examine the placards decals and markings Ensure they are readable correctly applied and in agreement with the applicable configuration of your helicopter BHT 206L4 FM 1 INSTRUMENTS 1 Examine instruments and instrument panel for condition security and for correct markings AIRFRAME Chapter 25 1 Remove cabin overhead upholstery hat bin soundproofing blanket aft vertical tunnel covers and roll ove...

Page 106: ...sive looseness and security of attachment Chapter 95 c Oil lines for leakage condition and security Chapter 53 d Roof beam interface with vertical tunnel for cracks corrosion and loose fasteners e Vertical tunnel stiffening angles at roof beam interface for cracks condition and loose fasteners Chapter 25 and Chapter 53 9 Remove crew seat cushions and panels and examine the following Chapter 67 and...

Page 107: ...rity Chapter 52 6 Verify sliding windows for safety and smoothness of sliding Chapter 21 7 Examine the ventilation system for condition and security 8 Verify nose vents for proper operation absence of obstructions or debris and open drains Chapter 95 9 Verify for proper operation of the fuel valve switch guard Chapter 26 10 Inspect cabin fire extinguisher for condition security and proper charge C...

Page 108: ...MAY RESULT IN SERIOUS BURNS 3 Verify operation of the pitot tube heating system 4 Verify operation of defog blowers 5 Verify operation of ENGINE OUT and LOW ROTOR RPM audio and mute switch if installed 6 Verify illumination of all caution panel annunciator light segments by depressing test switch or each individual light segment as applicable 7 Verify instrument lighting and dimming capabilities Z...

Page 109: ...ent door door seal and attachment for condition and security Chapter 52 6 Examine components in battery compartment for condition and security Chapter 32 7 Examine cabin entry steps if installed for condition and security Chapter 52 8 Examine windshields and skylights for condition Chapter 53 9 Examine upper fuselage for evidence of water leaks 10 Examine lower fuselage for indication of fuel leak...

Page 110: ...If battery was removed clean mounting area prior to installing serviceable battery 6 Verify operation of litter door open warning light 7 Verify operation of landing lights 8 Verify operation of lower fuselage mounted position lights if installed 9 Examine antennas for condition and security GROUND RUN CAUTION GROUND RUN OF HELICOPTER TO BE ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY Chapter 12 1 Mak...

Page 111: ...ound run at 100 NR to check for leaks and ensure all systems are operational and parameters are within Flight Manual limitations Chapter 96 5 Check the voltage regulator setting Adjust as required PROGRESSIVE INSPECTIONS 5 25 300 HOUR AIRFRAME PROGRESSIVE INSPECTION EVENT NO 5 CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 25 FEB 2011 Rev 13 Page 75 76 ...

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Page 113: ... decals and markings Make sure they are readable correctly applied and in agreement with the applicable configuration of your helicopter FUSELAGE EXTERIOR Chapter 53 1 Examine aft fuselage for dents cracks corrosion delamination loose or missing rivets and condition 2 Examine aft fuselage for indications of fuel or oil leaks Chapter 28 3 Examine the fuel cap for condition and security Chapter 96 4...

Page 114: ...mine interface between longerons and engine pan structure for cracks corrosion distortion and loose fasteners e Inspect engine mount attachment structure for condition 3 Remove fuel shutoff valve access panel a Examine structure for cracks and corrosion Chapter 28 b Examine fuel system components for leaks and general condition Chapter 96 c Examine wires and connectors for condition CONTROLS Chapt...

Page 115: ...opter Chapter 32 CROSSTUBES 1 Examine crosstube retaining straps cushions and attaching hardware for condition and security 2 Examine fuselage attachment fittings for condition and security 3 Examine electrical bonding strips if installed for condition and security 4 Examine fairings if installed for condition and security 5 Examine crosstube riveted or clamped supports for condition and security ...

Page 116: ...urity GROUND RUN CAUTION GROUND RUN OF HELICOPTER TO BE ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY Chapter 12 1 Make sure applicable servicing requirements have been carried out 2 Check oil level of transmission hydraulic tank engine and rail rotor gearbox prior to running helicopter 3 Make sure that helicopter is ready for ground run and that surrounding area is clear BHT 206L4 FM 1 4 Start the hel...

Page 117: ...____________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ 1 Do this inspection every 300 hours of operation or every 12 calendar months Chapter 5 Paragraph 5 21 through paragraph 5 26 2 Do all six events of the 300 hour progressive...

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Page 119: ...______________________________________ SIGNATURE _______________ _________________________ NOTE 100 hour inspection must be accomplished when using the 300 hour airframe progressive inspection program or the 300 hour airframe periodic inspection program MAIN ROTOR 1 Torque check pillow block retention hardware 84 to 107 inch pounds 9 4 to 12 Nm Examine for misalignment of anti slippage marks TAILB...

Page 120: ...en to inspection of the upper left fitting refer to Chapter 4 Inspection Limitations Schedule 4 Make sure the area is clean and visually examine all visible sections of the upper left longeron between aft fuselage frame at STA 204 92 and frame at STA 231 486 for general condition corrosion and cracks a If corrosion or a defect is found submit details to Product Support Engineering for evaluation a...

Page 121: ... of operation the 300 hour inspection must be accomplished in conjunction with the 100 hour airframe progressive inspection program or the 100 hour airframe periodic inspection program FORWARD FUSELAGE CABIN INTERIOR Chapter 25 1 Remove cabin overhead upholstery hat bin soundproofing blanket aft vertical tunnel covers and roll over bulkhead access panels Chapter 53 2 Remove roof beam access panels...

Page 122: ...for binding excessive looseness and security of attachment Chapter 95 c Oil lines for leakage condition and security Chapter 53 d Roof beam interface with vertical tunnel for cracks corrosion and loose fasteners e Vertical tunnel stiffening angles at roof beam interface for cracks condition and loose fasteners Chapter 25 and Chapter 53 9 Remove crew seat cushions and panels and examine the followi...

Page 123: ...required Chapter 96 ELECTRICAL 1 Remove battery and recondition in accordance with BHT ALL SPM and manufacturer s service manual FUSELAGE Chapter 52 1 Inspect latches on crew doors for correct adjustment 2 Inspect latches on passenger doors and baggage door for correct adjustment PYLON AREA SWASHPLATE ASSEMBLY Chapter 62 1 Verify and adjust swashplate tilt friction as required 2 Value must be betw...

Page 124: ...Rolls Royce Operation and Maintenance Manual Chapter 95 2 Perform operational check of turbine outlet temperature system Chapter 95 and Chapter 12 3 Examine N1 and N2 tachometer generator shaft splines and gearbox adapter splines for condition Clean and lubricate shaft splines Chapter 28 FUEL SYSTEM 1 Inspect airframe fuel filter head as follows NOTE The following step does not apply to helicopter...

Page 125: ... purged from fuel filter head and check for fuel leaks during ground run STARTER GENERATOR Chapter 71 1 Remove starter generator Examine mounting pad and clamp for condition Chapter 96 2 Examine commutator for wear Replace starter generator if not smooth and bright or if showing excessive wear 3 Inspect brushes for wear Chapter 71 4 Examine cooling duct and retention clamp for condition and securi...

Page 126: ...ks Check wiring and plumbing for security and condition g Inspect aft passenger rear bulkhead for indication of screw contact or cracks in area of hat bin attachment anchor nuts 2 Inspect aft passenger rear bulkhead for distortion in area of hat bin attachment anchor nuts DRIVETRAIN Chapter 65 and Chapter 12 1 Examine forward short shaft steel splined adapters for excessive wear and lubricate BHT ...

Page 127: ...uts 50 to 70 inch pounds 5 6 to 7 9 Nm TAIL ROTOR HUB AND BLADE ASSEMBLY Chapter 64 1 Check dynamic balance of tail rotor hub and blade assembly 2 Adjust as required SCHEDULED INSPECTIONS 5 29 300 HOUR INSPECTION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 25 FEB 2011 Rev 13 Page 91 92 ...

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Page 129: ...ed every 1200 flight hours Chapter 67 CYCLIC CONTROL STICK Chapter 67 1 Open right crew door to gain access to pilot cyclic control stick Remove cyclic control stick BHT 206L CR O 2 Clean lower 4 inches of removed cyclic stick tube and inspect 3 Visually inspect cyclic stick tube for cracks using a 3X magnifying glass Pay particular attention to the area adjacent to the two slots in the tube where...

Page 130: ... corrosion damage Bore damage is not to exceed 0 002 inch 0 051 mm for 1 4 of the circumference Limit of one repair per bore Repair or replace lever assembly as required 8 For cyclic stick tubes considered serviceable polish out any acceptable damage using 400 to 600 grit abrasive paper C 423 9 Thoroughly clean cyclic stick tube with water and mild detergent to completely remove residual penetrant...

Page 131: ... and support 2 Gain access to inside of tailboom from right side Using a bright light perform inspection of skin on inside surface of left side of tailboom for cracks a Inspect skin in area where doubler is attached b Inspect each rivet location for signs of loose or working rivets and for cracks that start at rivet holes 3 Using a 10X magnifying glass perform a visual inspection of external left ...

Page 132: ...be for wear and corrosion and nylatron sleeve for debonding at five areas where tube contacts tailboom fairleads as follows a To gain access to control tube remove tail rotor gearbox fairing and access panel on right side of aft fuselage adjacent to tailboom b Remove bolt at forward end of control tube At the bellcrank disconnect the small control rod coming from pitch change mechanism Remove bolt...

Page 133: ...m at any point or if wear extends more than half way around tube regardless of depth scrap control tube d Inspect tube for corrosion Pay particular attention to bond line at nylatron sleeves Chapter 67 3 Install and connect control tubes and bellcrank in tailbone Reinstall tail rotor gearbox fairing and access panel on right side of aft fuselage SCHEDULED INSPECTIONS 5 30 1200 HOUR INSPECTION CONT...

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Page 135: ...FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ ENGINE Rolls Royce 250 C30 Series Operations and Maintenance Manual 14W2 Perform engine inspection requirements 25 FEB 2011 Rev 13 Page 99 10...

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Page 137: ...HUB AND BLADES Preventive maintenance NOTE The following procedures shall be accomplished as frequently as deemed necessary when operating in rain corrosive salt laden air or other adverse environmental conditions The following preventive maintenance procedures for the main rotor hub and blades and tail rotor hub and blades are recommended to prevent corrosion and extend their life The inspection ...

Page 138: ... Apply a light coat of preservative oil C 125 to all hub and blade surfaces Flood areas between main rotor hub grip tangs and blades latch bolts to grips and yoke fillet areas just inboard of pitch horn to ensure complete coverage SCHEDULED INSPECTIONS 5 32 WEEKLY INSPECTION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 139: ...______________ SIGNATURE _______________ _________________________ GENERAL 1 Ensure that a 100 or 300 hour airframe progressive inspection all four or six events as applicable or the 100 or 300 hour airframe periodic inspection has been completed in the last 12 calendar month period 2 Perform a dynamic balance of the main rotor hub and blade assembly FUEL SYSTEM Chapter 96 1 Check operation of low...

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Page 141: ...____________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 62 BHT 206A B L Series CR O MAIN ROTOR MAST 1 Inspect mast assembly as follows a Remove mast nut flap restraint kit and cap plug With the help of a bright light inspect internal surface internal diameter of mast for corrosion and condition of protective coating b Install cap ...

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Page 143: ...ipe dry 3 Visually inspect bolts nuts for corrosion and thread damage Replace any bolts nuts that have damaged threads detectable wear and or corrosion pitting 4 Apply a coating of corrosion preventive compound C 104 to all bolt shanks prior to installation Do not apply corrosion preventive compound to bolt threads 5 Install flight control bolts and attaching hardware Torque nuts and install new c...

Page 144: ...st pump assemblies and inspect fuel cell interiors for debris water contamination and fungus growth 2 Remove clean and inspect fuel manifold assembly 3 Remove clean and inspect inline fuel filters and check valves SCHEDULED INSPECTIONS 5 35 24 MONTH INSPECTION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 145: ...BHT 206L4 MM 1 5 00 00 7 NOV 2014 Rev 20 Page 109 Export Classification C ECCN EAR99 Figure 5 2 Inspection of Main Rotor Flight Control Bolts Nuts Sheet 1 of 2 ...

Page 146: ...BHT 206L4 MM 1 5 00 00 Page 110 Rev 20 7 NOV 2014 Export Classification C ECCN EAR99 Figure 5 2 Inspection of Main Rotor Flight Control Bolts Nuts Sheet 2 of 2 ...

Page 147: ...________ BHT 206L4 MM BHT 206L CR O FREEWHEEL ASSEMBLY NOTE This inspection applies to helicopters equipped with freewheel assembly 406 040 500 143 or subsequent Do this inspection if an overhaul of the applicable freewheel assembly has not been accomplished in the last 60 months 1 Remove the freewheel assembly 2 Disassemble the freewheel assembly NOTE Do not do a non destructive inspection It is ...

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Page 149: ...NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ NOTE This inspection is only applicable when conducting the 100 hour airframe progressive or 100 hour airframe periodic inspection program BHT ELEC SPM BATTERY Remove battery and recondition according to the BHT ELEC SPM and manufacturer s service manual ...

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Page 151: ...___ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 96 ELECTRICAL 1 Perform operational test of internal battery overtemperature switches Chapter 63 2 Remove rotor tachometer generator a Remove examine and lubricate the rotor tachometer generator internal driv...

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Page 153: ...________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ BHT 206L CR O MAIN ROTOR HUB ASSEMBLY 1 lnspect yoke and trunnion bearing surfaces for brinelling 2 lnspect yoke latch bolts strap pins strap fittings trunnion pillow blocks grips and pitch horns for corrosion 3 Visually ...

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Page 155: ...L TIME _______________________________________ SIGNATURE _______________ _________________________ Chapter 63 BHT 206A B L Series CR O MAIN ROTOR MAST 1 Remove disassemble and clean main rotor mast 2 Inspect main rotor mast as follows a Visually inspect mast splines for burrs nicks cracks and wear Indication of wear requires an over pins dimensional check b Visually inspect mast inner and outer su...

Page 156: ... for debris and metal contamination BHT 206L CR O 4 Remove the transmission top case the planetary assembly and the sun gear 5 Visually examine all removed components for condition 6 Insert a mirror between the spiral bevel gear edge and the lower case and use a bright light to examine the spiral bevel gear input pinion gears and surrounding areas for condition 7 Reassemble the transmission Chapte...

Page 157: ...6 040 004 115 and subsequent that have been operating with DOD PRF 85734 oil since new or since last overhaul TB 206L 04 213 If the transmission has been operated with MIL PRF 7808 oil the 1500 Hours Of Component Operation scheduled inspection applies Chapter 63 1 If installed on the helicopter remove the transmission assembly 2 Remove the mast and swashplate assembly from the transmission assembl...

Page 158: ... into the transmission assembly 9 Apply sealant primer and paint to the required areas 10 Install the transmission assembly into the helicopter Chapter 12 11 Service the transmission with oil DOD PRF 85734 SCHEDULED INSPECTIONS 5 41 2250 HOURS OR 60 MONTHS OF COMPONENT OPERATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 159: ...x bearing 206 040 410 005 101 or subsequent replacement at 3000 hours 1 Perform backlash check of the gearbox prior to disassembly Backlash shall be 0 003 to 0 011 inch 0 08 to 0 28 mm and shall not vary more than 0 002 inch 0 05 mm when measured at three different locations Record backlash for later reference NOTE If this inspection is being done in conjunction with replacement of bearing 206 040...

Page 160: ...ay obscure level or color of oil Inspect oil level indicator for discoloration peeling paint or evidence of a plastic film on painted side Remove plastic film if present 8 Reassemble gearbox Exercise caution when inserting input pinion assembly if previously removed to ensure proper gear mesh with spiral bevel gear 9 Check gearbox backlash Measured values shall be within 0 001 inch 0 03 mm of thos...

Page 161: ...pecial inspections on the helicopter paragraph 5 44 through paragraph 5 48 After fuel system maintenance and or component change 1 to 5 hours after each installation 3 to 8 hours after each installation 10 to 25 hours after each installation 100 hours after each installation 25 FEB 2011 Rev 13 Page 125 126 ...

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Page 163: ...NOTE Installation and removal of a fuel boost pump cartridge fuel quantity probe or fuel drain valve does not require this inspection If fuel system maintenance and or component change removal is performed at a site remote from an adequate maintenance facility accomplish step 1 substep c through substep e and step 3 or step 2 and step 3 as applicable prior to flight Upon return to an adequate main...

Page 164: ...nge removal fuel pressure transducer fuel valve scheduled fuel component change removal fuel line or hose ground run helicopter and check for air or fuel leaks and for proper operation as follows BHT 206L4 FM 1 a Perform normal engine start and run up checks b Set throttle to full open and operate engine at 100 N2 for a minimum of 2 minutes with both fuel pumps OFF If flameout or power loss occurs...

Page 165: ... and Maintenance Manual 14W2 c Purge air from fuel system and accomplish pneumatic leak check SPECIAL INSPECTIONS 5 44 AFTER FUEL SYSTEM MAINTENANCE AND OR COMPONENT CHANGE CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 25 FEB 2011 Rev 13 Page 129 130 ...

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Page 167: ... FACILITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR Chapter 62 Torque check main rotor mast nut 250 to 275 foot pounds 339 0 to 372 Nm until the torque is stabilized TB 206L 07 223 ...

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Page 169: ...ITY _________________ _________________________ HELICOPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ MAIN ROTOR BHT 206L CR O Torque check pillow block retention bolts nuts 84 to 107 inch pounds 9 4 to 12 Nm Check for misalignment of anti slippage...

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Page 171: ...7 to 142 N If not within limits adjust to 15 to 32 pounds 67 to 142 N Check tilt friction every 10 to 25 hours until it is stabilized Chapter 65 DISC PACK COUPLING Torque check disc pack coupling attaching hardware as follows 1 Apply the minimum torque required for the fasteners If the fasteners do not move the check is completed Check torque seal C 049 and apply as required 2 If the fastener s mo...

Page 172: ...OTOR GEARBOX Torque check tail rotor gearbox retaining nuts 50 to 70 inch pounds 5 6 to 7 9 Nm Repeat every 10 to 25 hours until torque has stabilized SPECIAL INSPECTIONS 5 47 10 TO 25 HOURS AFTER EACH INSTALLATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 173: ...______________ _________________________ POWER PLANT Chapter 71 1 Torque check engine mount attachment hardware at engine and airframe attachment points 2 If fastener is improperly torqued a Check nuts tare torque and bolt threads and shanks for damage b Check engine mounts and supporting structure for damage c Install new fastener if required and apply torque Recheck torque at next 100 hours TAIL...

Page 174: ... torque and replace as required Recheck torque at next 100 hours 2 Torque check transmission top case stud nuts 130 to 160 inch pounds 15 to 18 Nm BHT ALL SPM 3 Touch up paint finish as required SPECIAL INSPECTIONS 5 48 100 HOURS AFTER EACH INSTALLATION CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 175: ... inspections paragraph 5 50 through paragraph 5 57 of the helicopter after the following Hard landing Sudden stoppage acceleration Main rotor Sudden stoppage acceleration Tail rotor Overspeed Main rotor 114 or greater Overtorque Engine compressor stall or surge Lightning strike Engine overtemp 25 FEB 2011 Rev 13 Page 139 140 ...

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Page 177: ... may be retained in service for continued usage If on a hard landing either main rotor blade comes in contact with the ground tailboom or other foreign object both main rotor blades are to be regarded as having been involved in a sudden stoppage and must be returned to a Bell Helicopter Textron approved blade repair station for inspection The airframe landing skids and crosstubes will deform and y...

Page 178: ...major stresses and damage to components 4 Remove all cowlings and fairings necessary to perform a complete visual inspection Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 5 Engine Refer to the Rolls Royce Maintenance Manual for inspection instructions 6 Check for leaks in the hydraulic system interference or binding of hydraulic actuator and controls and for satisfactory operati...

Page 179: ...connecting control tubes and scrap all connecting control bolts BHT ALL SPM c Inspect all bearings for smoothness and axial and radial play 8 Inspect structure with a 10X magnifying glass around the transmission mounting points Particular attention should be given to the transmission restraint system and transmission mount stops for sheared bolts damaged drag pins and supports 9 lnspect transmissi...

Page 180: ... hub assembly in accordance with the Conditional Inspection criteria b Transmission assembly c Main driveshaft assembly Remove and examine the driveshaft for deformation and cracks If deformation or cracks are found discard the driveshaft d Transmission restraint e Remove main rotor blades and send to a Bell Helicopter Textron approved blade repair facility for evaluation 17 lnspect engine mounts ...

Page 181: ...emove and overhaul the following components a Main rotor hub assembly in accordance with the Conditional Inspection criteria b Swashplate and support assembly with drive collar link and lever c All control tubes d Main rotor pitch link assemblies e Transmission and mast assembly f Freewheel assembly g Tail rotor driveshaft assembly h Tail rotor gearbox i Tail rotor hub and blade assembly j Transmi...

Page 182: ...CCN EAR99 BHT 206L4 FM 1 24 Provided no visual damage is found start engine and check main rotor for evidence of 1 rev vibration and lateral balance while at flat pitch CONDITIONAL INSPECTIONS 5 50 HARD LANDING CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER ...

Page 183: ...tion or acceleration of the drive system whether caused by seizure within the drive system sudden freewheel clutch engagement or impact of the main rotor with the ground or with a foreign object of sufficient inertia to cause rapid deceleration NOTE Components removed from helicopter for evaluation following a sudden stoppage acceleration shall be evaluated as an interrelated group Removal records...

Page 184: ...during main rotor sudden stoppage acceleration the main rotor hub assembly must be considered unserviceable and scrapped BHT 206L CR O a Main rotor hub assembly in accordance with the Conditional Inspection criteria NOTE If main rotor mast was severed during a main rotor sudden stoppage acceleration with the engine operating the main rotor mast has sustained torsional yielding b Mast assembly BHT ...

Page 185: ...etected by measuring the offset between the mast splines above and below the main rotor trunnion split cone groove using either of the following methods i Sliding a 0 1600 inch 4 06 mm diameter measuring pin across the upper and lower spline ii Sliding a straight edge across the upper and lower unworn face of the spline coast side of the spline BHT 206L CR O c Transmission assembly d Swashplate as...

Page 186: ... shall be considered unserviceable and scrapped Inspect remaining hanger assemblies adapters and disc couplings according to step l and step m Inspect hanger attachment points for cracks and distortion k Inspect tail rotor driveshafts for out of roundness and distortion or bowing exceeding the limits specified If any defect is detected scrap all bonded tail rotor driveshafts l lnspect steel tail r...

Page 187: ...ch 0 381 mm d Structural failure or distortion of any coupling disc bolts e Structural failure or distortion exceeding the specified limits of the tail rotor driveshaft steel or aluminum adapters Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 5 Refer to the Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 for sudden stoppage inspection requirements CONDITIONAL INS...

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Page 189: ... acceleration of the drive system whether caused by seizure within the helicopter drive system sudden freewheel clutch engagement or by contact of tail rotor blade s with the ground water or with a foreign object of sufficient inertia to cause rapid deceleration CAUTION DAMAGE TO TAIL ROTOR BLADE ASSEMBLY COULD BE PRESENT ALTHOUGH IT MAY NOT BE READILY DETECTED BY STANDARD VISUAL DIMENSIONAL AND M...

Page 190: ...ks 6 lnspect tail rotor hanger supports for cracks and distortion BHT 206L CR O NOTE If tail rotor driveshaft failed as a result of torsional overload ALL hangers driveshafts adapters impeller and disc couplings shall be considered unserviceable and scrapped Inspect hanger attachment points for cracks and distortion Ensure airworthiness of tail rotor gearbox by conducting a major overhaul If a tai...

Page 191: ...nt method of inspection 9 Inspect the four tailboom attachment points for cracks distortion damage and security Check torque on nuts of tailboom attachment bolts 10 lnspect tailboom internally for cracks distortion and loose or missing rivets Check external skin of tailboom for cracks paying particular attention to area of horizontal stabilizer and attachment points of vertical fin 11 Inspect hori...

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Page 193: ...D MAIN ROTOR 114 OR GREATER NOTE Components removed from a helicopter for evaluation following an overspeed shall be evaluated as an interrelated group Removal records accompanying each component shall cross reference part and serial numbers of other drive system components removed for evaluation For main rotor overspeeds above 107 and up to 114 visually inspect main rotor blades and tail rotor bl...

Page 194: ... to a Bell Helicopter Textron approved major overhaul facility for evaluation 4 If main rotor blades pass the previous inspection they are acceptable for continued service c Tail rotor blades 1 If one of the tail rotor blades of a pair has been damaged badly enough that metal has been torn or any bond plies have separated then both blades and tail rotor hub must be scrapped 2 If contour of a blade...

Page 195: ... SPM f Inspect oil cooler fan impeller for visible distortion or cracks of the brazed vane joints using dye penetrant inspection method Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 2 Engine Refer to the Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 CONDITIONAL INSPECTIONS 5 53 OVERSPEED MAIN ROTOR 114 OR GREATER CONT DATA REFERENCE INSPECTION TASK DESCRIPTION...

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Page 197: ..._______ NOTE Torque Indicator Reference 100 71 4 PSI 110 78 5 PSI 120 85 7 PSI OVERTORQUE 110 TO 120 NOTE Components removed from a helicopter for evaluation following an overtorque shall be evaluated as an interrelated group Removal records accompanying each component shall cross reference part and serial numbers of other drive system components removed for evaluation NOTE If overtorque above 100...

Page 198: ...ub blades and attachments b Examine the transmission electric chip detectors for accumulated material c Remove and examine the engine to transmission driveshaft for deformation and cracks If deformation cracks or other damage is found discard the driveshaft CAUTION A QUALIFIED PERSON MUST BE AT THE HELICOPTER CONTROLS DURING THE FOLLOWING PROCEDURE BHT 206L4 FM 1 d Start engine and check main roto...

Page 199: ...pport assemblies f Cabin roof shell and beam at transmission mount attachment points g Transmission restraint attachment at stop mounts support and cabin roof shell and beam h Transmission electric chip detectors i Tail rotor gearbox chip detector and gearbox attachments j Tail rotor hub blades and attachments OVERTORQUE ABOVE 120 NOTE Components removed from helicopter for evaluation following an...

Page 200: ...in Rotor Mast Remove and overhaul c Main Transmission Remove and overhaul Replace top case of main transmission and transmission link attachments During overhaul inspect gear patterns for shifting and scuffing d Main driveshaft Remove and visually inspect e Freewheel assembly Remove and overhaul Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 2 Refer to the Rolls Royce 250 C30 Ser...

Page 201: ...on mount attachment points g Transmission restraint attachment h Transmission electric chip detectors i Tail rotor gearbox chip detectors and gearbox attachments j Tail rotor hub blades and attachments CONDITIONAL INSPECTIONS 5 54 OVERTORQUE CONT DATA REFERENCE INSPECTION TASK DESCRIPTION INITIAL MECH OTHER 25 FEB 2011 Rev 13 Page 165 166 ...

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Page 203: ...vibration or a rapid rise in Turbine Outlet Temperature TOT depending on the severity of stall or surge When a stall or surge is suspected follow steps as dictated by reported conditions NOTE The components removed from the helicopter for evaluation following a compressor stall or surge shall be evaluated as a matched group The records accompanying each component shall cross reference part and ser...

Page 204: ...nce Manual for further maintenance action If no blockage is found do step 2 2 Remove the induction fairing and examine the compressor intake area as follows a Examine the compressor rotor for contamination If contamination is found perform a compressor wash Refer to applicable BHT 206L4 MM 9 Chapter 71 b Inspect compressor rotor for foreign object damage in accordance with the appropriate Rolls Ro...

Page 205: ...ved facility for overhaul 2 Examine the tail rotor driveshafts for condition and security of attachment 3 Examine the tail rotor disc pack couplings for cracks or gapping greater than 0 015 inch 0 38 mm 4 Examine the tail rotor steel driveshaft and adapters for structural failure or distortion exceeding specified limits 5 Examine the bond lines on all bonded tail rotor driveshaft adapters if insta...

Page 206: ...n approved facility for overhaul 2 Examine the tail rotor blade s for condition If any damage suspected to be related to the stall or surge is found remove the tail rotor blade s Make an entry on the Historical Service Record and attach a tag on the tail rotor blade s and write THIS BLADE WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL OR SURGE Send the tail rotor blade s assembly to a Bell...

Page 207: ...MBLY WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL SURGE Send the component to a Bell Helicopter Textron approved facility for overhaul 5 If no defects were detected on main rotor hub the main rotor hub is serviceable 6 If defects are detected in step 1 step 2 and step 4 through step 5 discard all bonded tail rotor driveshafts and perform a main rotor sudden stoppage inspection SPECIAL IN...

Page 208: ...defects were detected return the engine to transmission main driveshaft to service TRANSMISSION ASSEMBLY BHT 206L CR O 1 Remove the transmission input pinion and triplex bearing 2 Inspect the following gear teeth for scoring and other mechanical damage a Input pinion gear b Main input driven bevel gear 3 If any damage suspected to be related to the stall or surge is found make an entry on the Hist...

Page 209: ... Helicopter Textron approved facility for overhaul 4 If no defects were detected on the gears the tail rotor gearbox is serviceable Chapter 53 FUSELAGE 1 Examine the complete tailboom structure for distortion buckles cracks in the skin and sheared or loose rivets 2 Inspect tailboom attachment fittings for cracks 3 Inspect the vertical fin for condition and security of attachment Chapter 63 Chapter...

Page 210: ...storical Service Record and attach a tag and write THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL SURGE Send the component to a Bell Helicopter Textron approved facility for overhaul 3 If no metal particles were found the transmission assembly freewheel assembly and or tail rotor gearbox are serviceable CONDITIONAL INSPECTIONS 5 55 ENGINE COMPRESSOR STALL OR SURGE CONT DATA ...

Page 211: ...______________________ NOTE This inspection must be accomplished after helicopter is suspected of receiving a lightning strike LIGHTNING STRIKE NOTE In all of the following instances if significant damage has been found in any area inspection shall be expanded in those areas until it extends beyond the zone of damage Scrap any component that shows evidence of severe arc burns Because lightning beh...

Page 212: ...terrelated group Make entries in component records to cross reference part and serial numbers of other drive system components removed for evaluation a Inspect main rotor blades Blades that exhibit severe arcing shall be scrapped Blades that exhibit light to moderate arcing shall be returned to a Bell Helicopter Textron approved blade repair facility for evaluation 1 Inspect blades for signs of bu...

Page 213: ...arbox and return for overhaul State lightning strike as reason for removal h Check auxiliary fins for evidence of burning or debonding i lnspect tailboom fitting for indication of arcing burns around mounting points of tail rotor gearbox and vertical fin Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 j Inspect power plant assembly 3 If no indications of damage are found do the fo...

Page 214: ...ng strike as reason for removal c Remove transmission top case and inspect for entry and exit of lightning strike Special attention should be given to the planetary pinion and sun gear ring gear spiral bevel gear and quill pinion Check all bearings for smooth rotation and damage If evidence of arcing or burning is found or bearings do not rotate smoothly remove gearbox and return for overhaul stat...

Page 215: ...ations of damage are found and bearings rotate smoothly reassemble gearbox and return it to limited service After 5 hours remove chip detector and inspect for chips If no chip indications are found return gearbox to full service If chip indications are found return gearbox for overhaul State lightning strike as reason for removal f Inspect main driveshaft for evidence of arcing or burning BHT 206L...

Page 216: ...e the swashplate assembly and return to service h Inspect tailboom horizontal stabilizer auxiliary fins and vertical fin for evidence of arcing burning or debonding paying particular attention to area around the mounting points for the tail rotor driveshaft hangers and tail rotor gearbox Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 i Inspect power plant assembly CONDITIONAL INS...

Page 217: ...COPTER S N __________ _________________________ REGISTRY NO ____________ _________________________ TOTAL TIME _______________________________________ SIGNATURE _______________ _________________________ ENGINE OVERTEMP Inspect Rolls Royce250 C30P Series Operation and Maintenance Manual 14W2 Perform hot end inspection of power plant assembly if start or transient turbine outlet temperature limits ha...

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Page 219: ...ENTLY PARTS THAT HAVE BEEN USED ON MILITARY HELICOPTERS SHOULD NOT BE USED ON COMMERCIAL HELICOPTERS CAUTION OVERHAUL SCHEDULE FOR SOME KIT COMPONENTS AND OR PARTS IS NOT COVERED IN THIS SCHEDULE REFER TO APPLICABLE 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 ...

Page 220: ...0 hours Tail Rotor Gearbox 206 040 402 101 6000 hours HYDRAULIC SYSTEM Hydraulic Servo Actuators 206 076 062 101 3600 hours POWER PLANT Turboshaft Engine 250 C30P Refer to Rolls Royce 250 C30 Series Operation and Maintenance Manual 14W2 STARTER GENERATORS Starter Generator ALL 1000 hours NOTES The operating time specified for overhaul of any given part number listed applies to all successive dash ...