BHT-412-MM-6

MAINTENANCE MANUAL
VOLUME 6
MAIN ROTOR/MAIN ROTOR
DRIVE SYSTEM
NOTICE
The instructions set forth in this manual, as supplemented or modified by Alert
Service Bulletins (ASB) and other directions issued by Bell Helicopter Textron, Inc.
and Airworthiness Directives (AD) issued by the Federal Aviation Administration,
shall be strictly followed.

Bell Helicopter
COPYRIGHT NOTICE A Subsidiary of Textron Inc.

COPYRIGHT 2001 POST OFFICE BOX 482 *FORT WORTH, TEXAS 76101
BELL ® HELICOPTER INC.
AND BELL HELICOPTER TEXTRON INC.
A DIVISION OF TEXTRON CANADA LTD.

REVISION 5-16 FEBRUARY 2001

 PROPRIETARY RIGHTS NOTICE

These data, excluding Chapter 4, Airworthiness Limitations, are proprietary to

Bell Helicopter Textron Inc. Disclosure, reproduction, or use of these data for
any purpose other than helicopter operation and/or maintenance is forbidden
without prior written authorization from Bell Helicopter Textron Inc.

Additional copies of this publication may be obtained by contacting:

Commercial Publication Distribution Center
Bell Helicopter Textron Inc.
P.O. Box 482
Fort Worth, Texas 76101-0482

PN Rev. 2
 Bell Helicopter BHT-412-MM-6

CHAPTER 62 - MAIN ROTOR

CONTENTS - MAINTENANCE PROCEDURES

Paragraph Chapter/Section Page

Number Title Number Number

MAIN ROTOR

62-1 Main Rotor Hub and Blades ............................................ 62-00-00 3

62-2 Main Rotor Blades ............................................................ 62-00-00 3
62-3 Removal ............ ........................................ 62-00-00 3
62-4 Cleaning............................................................... 62-00-00 4
62-5 Inspection ............................................................ 62-00-00 5
62-6 Repair.................................................................. 62-00-00 8
62-7 Installation............................................................ 62-00-00 8
62-8 Main Rotor Hub .......................................................... 62-00-00 9
62-9 Removal............................................................... 62-00-00 10
62-10 Cleaning............................................................... 62-00-00 18
62-11 Inspection ........................................ .... 62-00-00 18
62-12 Repair ................................................................. 62-00-00 18
62-13 Installation............................................................ 62-00-00 18

MAIN ROTOR CONTROLS

62-14 Main Rotor Controls.......................................................... 62-00-00 23

62-15 Swashplate and Support Assembly ........................... 62-00-00 23
62-16 Removal............................................................... 62-00-00 23
62-17 Cleaning............................................................... 62-00-00 23
62-18 Inspection ........................................ .... 62-00-00 23
62-19 Repair.................................................................. 62-00-00 23
62-20 Installation............................................................ 62-00-00 25
62-21 Main Rotor Pitch Link Assemblies.............................. 62-00-00 26
62-22 Removal............................................................... 62-00-00 26
62-23 Cleaning............................................................... 62-00-00 26
62-24 Inspection ............................................................ 62-00-00 26
62-25 Repair.................................................................. 62-00-00 26
62-26 Installation............................................................ 62-00-00 29
62-27 Hub and Sleeve Assembly ......................................... 62-00-00 32
62-28 Inspection of Teflon Lined Bearings (Installed) ... 62-00-00 33
62-29 Removal............................................................... 62-00-00 33
62-30 Cleaning............................................................... 62-00-00 38
62-31 Inspection ............................................................ 62-00-00 38
62-32 Repair.................................................................. 62-00-00 38
62-33 Installation............................................................ 62-00-00 38
62-34 Rephasing Levers ........................................ .... 62-00-00 41
62-35 Removal............................................................... 62-00-00 41
62-36 Installation............................................................ 62-00-00 41
62-37 Drive Link Assembly................................................... 62-00-00 42
62-38 Removal............................................................... 62-00-00 42
62-39 Installation............................................................ 62-00-00 45
62-40 Swashplate Link Assembly ........................................ 62-00-00 45
62-41 Removal............................................................... 62-00-00 45

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BHT-412-MM-6 Bell Helicopter

CONTENTS - MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

62-42 Installation ........................................................... 62-00-00 49

62-43 Collective Pitch Drive Plate Set.................................. 62-00-00 51
62-44 Removal .............................................................. 62-00-00 51
62-45 Installation ........................................................... 62-00-00 53
62-46 Collective Lever Assembly ........................................ 62-00-00 53
62-47 Removal .............................................................. 62-00-00 53
62-48 Cleaning .............................................................. 62-00-00 55
62-49 Inspection ............................................................ 62-00-00 55
62-50 Repair.................................................................. 62-00-00 55
62-51 Installation (Helicopters with Collective Lever
Pins 412-010-422-101 Installed) ......................... 62-00-00 55
62-52 Installation (Helicopters with Collective Lever
Pins 412-010-422-103 Installed) ......................... 62-00-00 56

FIGURES

Figure Page
Number Title Number

62-1 Main Rotor Blade Installation...................................................................... 6

62-2 M ain R oto r B lade ........................................................................................ 7
62-3 M ain R oto r H ub ......................................................................................... 11
62-4 Main Rotor Hub Stand - Tool Application................................................. 17
62-5 Swashplate and Support ............................................................................ 24
62-6 Main Rotor Pitch Link ................................................................................ 27
62-7 Main Rotor Pitch Link Assembly Initial Dimensions.................................... 30
62-8 Main Rotor Pitch Link Assembly................................................................. 31
62-9 Swashplate Link and Drive Link Bearings - Work Aid ............................. 34
62-10 Hub and Sleeve Assembly Teflon Bearing Inspection................................ 35
62-11 Hub and Sleeve ......................................................................................... 36
62-12 Collective Drive Plate Set - Damage Limits ............................................. 39
62-13 Rephasing Lever Installation ...................................................................... 43
62 -14 Drive Link .................................................................................................... 44
62-15 Swashplate Link ........................................................................................ 46
62-16 Collective Pitch Drive Plate Set.................................................................. 52
62-17 Collective Lever ......................................................................................... 54

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 Bell Helicopter BHT-412-MM-6

MAIN ROTOR

62-1. MAIN ROTOR HUB AND BLADES
The main rotor hub and blade consists of the hub, four
main rotor blades and four pitch horns. Each main
rotor blade is connected to hub by either two fixed
diameter bolts or one fixed diameter bolt on leading
edge side of rotor blade and an expandable bolt on
trailing edge side of rotor blade. The purpose of
expandable bolts (when used) is to facilitate removal
of bolts when rotor blades are folded. The main rotor
droop restraint assembly attaches to lower damper
bridges and to attach lugs of lower cone seat, (four
places) and will minimize yoke flexing during static
rotor blade droop.
NOTE
Use of expandable rotor blade bolt instead
of standard rotor blade retention bolt is
optional.
missing, apply new marking prior to removal (Chapter
11).
... ...
CAUTION
USE HOIST WITH MINIMUM CAPACITY
OF 1000 POUNDS (454 KILOGRAMS).
2. Attach sling (4) to hoist with minimum capacity of
1000 pounds (454 kilograms). Position hoist directly
over center of gravity of rotor blade to be removed.
Attach sling straps around rotor blade. Take up slack
with hoist.
CAUTION

62-2. MAIN ROTOR BLADES MAIN ROTOR BLADES AND HUB

COMPONENTS ARE COLOR CODED.
The main rotor blades are constructed of fiberglass AFTER EXPANDABLE BOLT (10 FIGURE
with a honeycomb core, stainless steel tip cap and 62-1) IS ADJUSTED AT INITIAL
outboard abrasion strip, and a titanium inboard INSTALLATION, IT SHALL BE KEPT WITH
abrasion strip. The glass fiber spar is made up of four SAME ROTOR BLADE AND HUB
spar caps and a nose block, constructed of spanwise SPINDLE, OR EXPANDABLE BOLT
oriented unidirectional glass fibers, all bonded SHALL BE READJUSTED.
between inner and outer glass fiber torque wraps. The
rotor blades are covered with fiberglass skins.
NOTE
62-3. Removal
For helicopters with expandable rotor blade
SPECIAL TOOLS REQUIRED bolts installed, accomplish following steps
3. and 4. For helicopters with standard rotor
blade bolts installed in both rotor blade
NUMBER NOMENCLATURE spindle holes, accomplish step 4. for both
T101626 Sling bolts
T101266 Blade Bolt Tool 3. Remove safety lock hair pin (12) from lower end
of expandable bolt (10). Cut and remove lockwire.

NOTE 4. Raise bolt handle (9) to reduce diameter of bolt

Removal procedure for main rotor blade (3,
figure 62-1) is given. Removal procedure
for the other three rotor blades is the same.
1. Inspect rotor blade (3, figure 62-1) and spindle (1)
for color code markings. If color code markings are
(10). Remove bolt (10).
5. Remove plug (8) and lock (7) from lower end of
rotor blade bolt (2). Remove nut (6) and washer (5).
Remove rotor blade bolt (2) using rotor blade bolt tool
(13).

62-00-00
Rev. 5 Page 3
6. Slide rotor blade (3) from spindle (1). Lower rotor
blade and place in a suitable blade rack.
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
C-305 Aliphatic Naphtha
C-318 Cleaning Compound
C-412 Wax
NAPHTHA/NAPHTHALENE IS
COMBUSTIBLE; DO NOT USE IT NEAR
WELDING AREAS, NEAR FLAMES, OR
ON HOT SURFACES. AVOID
PROLONGED OR REPEATED CONTACT
WITH LIQUID. CONTACT OF SKIN WITH
LIQUID CAN CAUSE IRRITATION.
INHALATION OF VAPORS CAN CAUSE
IRRITATION, GIDDINESS, AND
DROWSINESS. IF LIQUID CONTACTS
EYES, FLUSH EYES THOROUGHLY
WITH WATER. IF THERE IS ANY
PROLONGED SKIN CONTACT, WASH
CONTACTED AREA WITH SOAP AND
WATER. IF VAPORS CAUSE
DROWSINESS, GO TO FRESH AIR.
REMOVE SOLVENT-SATURATED
CLOTHING. IF LIQUID IS SWALLOWED,
DO NOT TRY TO VOMIT. IN ALL CASES
GET IMMEDIATE MEDICAL ATTENTION.
WHEN HANDLING LIQUID IN AN
AIR-EXHAUSTED, PARTIALLY COVERED
TANK, WEAR APPROVED GLOVES.
WHEN HANDLING LIQUID IN AN OPEN,
UNEXHAUSTED CONTAINER, WEAR
APPROVED RUBBER GLOVES AND
GOGGLES. IF CONTACT WITH VAPOR IS
LIKELY, WEAR AN APPROVED
RESPIRATOR. DISPOSE OF LIQUID-
SOAKED RAGS IN APPROVED METAL
CONTAINER. METAL CONTAINERS OF
62-00-00
Page 4 Rev. 5
LIQUID MUST BE GROUNDED TO
MAINTAIN ELECTRICAL CONTINUITY.
DRYCLEANING SOLVENT IS
OPEN FLAMES, NEAR WELDING AREAS,
OR ON HOT SURFACES. PROLONGED
CONTACT OF SKIN WITH LIQUID CAN
CAUSE SKIN IRRITATION. REPEATED
INHALATION OF VAPOR CAN IRRITATE
NOSE AND THROAT AND CAN CAUSE
WATER. REMOVE SOLVENT-
SATURATED CLOTHING. IF VAPORS
CAUSE DIZZINESS, GO TO FRESH AIR.
IN ALL CASES GET IMMEDIATE
MEDICAL ATTENTION. WHEN
HANDLING LIQUID OR WHEN APPLYING
IT IN AN AIR-EXHAUSTED, PARTIALLY
COVERED TANK, WEAR APPROVED
WEAR APPROVED RESPIRATOR AND
GOGGLES.
1. Wipe main rotor blades with cloth damp with
aliphatic naphtha (C-305) or solvent (C-304).
WARNING
AIRCRAFT CLEANING COMPOUND IS
FLAMMABLE AND IS TOXIC TO THE
SKIN BY ABSORPTION AND TO THE
LIVER AND KIDNEYS. IT CAN CAUSE
IRRITATION OF THE EYES AND
RESPIRATORY SYSTEM, SKIN
IRRITATION AND HEADACHE.
THOROUGHLY WASH SKIN AREA WITH
WATER AND IMMEDIATELY FLUSH
EYES WITH WATER FOR 15 MINUTES. IF
INGESTED, DO NOT INDUCE VOMITING.
IN ALL CASES GET IMMEDIATE
MEDICAL ATTENTION. WHEN WORKING
WITH CLEANING COMPOUND, WEAR
APPROVED CHEMICAL CARTRIDGE
RESPIRATOR, RUBBER GLOVES,
SAFETY GOGGLES, AND PROTECTIVE
CLOTHING. KEEP AWAY FROM HEAT
AND OPEN FLAMES. USE IN A WELL-
VENTILATED AREA.
 Bell Helicopter
2. Wash rotor blades with a mild solution of cleaning
compound (C-318) and water. Rinse rotor blades with
clean water and wipe dry with clean cloths.
CAUTION ]
... ............
DO NOT USE SILICONE TYPE WAXES.
DO NOT USE SILICONE TYPE WAXES.
SILICONE WAXES MAY INTERFERE
WITH FUTURE REPAIRS OR
REFINISHING.
NOTE
Waxing is not required for blades P/N 412-
I
015-300-109 and sub. or for any blade
finished with polyurethane paint.
3. Coat rotor blades with wax (C-412).
62-5. Inspection
1. Inspect leading edge abrasion strip (3, figure 62-
2) and splice covers (4 and 9) as follows:
a. Return main rotor blade to Bell Helicopter
Textron for replacement of leading edge abrasion strip
under the following conditions:
(1) Leading edge deformation due to
abrasion.
(2) Edge voids deeper than 0.50 in. (12.7
millimeters).
(3) Holes, cracks or tears.
b. Nicks, scratches or sharp dents not exceeding
0.010 in. (0.254 mm) are acceptable if polished
smooth. Non-sharp dents not exceeding 0.015 in.
(0.381 mm) are acceptable. If damage exceeds
inspection requirements replace abrasion strip (3) and/
or splice covers (4 or 9).
2. Inspect fretting pads (8) for cracks and adhesive
voids. If cracks are found or edge voids are in excess
of 0.25 in. (6.35 mm), notify Bell Helicopter Support
Representative.
BHT-412-MM-6
NOTE
Some main rotor blades are equipped with
only one trim tab (outboard).
3. Inspect inboard and outboard trim tabs (6 and 7)
and tip assembly (5) for damage, debonding or
corrosion (BHT-412-CR&O).
4. Inspect rotor blade bolt retention bushings (1)
(BHT-412-CR&O)
5. Inspect main rotor blade bonded assembly (2) as
follows:
a. Inspect for cracks. If crack(s) are found notify
Bell Helicopter Support Representative.
b. Nicks, scratches, gouges or dents on
fiberglass surfaces are acceptable without repair
provided fibers are not broken or cause delamination.
If fibers are broken or delaminations develop, refer to
BHT-412-CR&O manual.
c. Scratches, gouges or nicks that penetrate one
more layers of upper and lower skins (11 and 13),
or more layers of upper and lower skins (11 and 13),
but do not damage core (14) may be repaired (BHT-
412-CR&O).
d. Holes in skin outboard of station 90.0 may be
repaired (BHT-412-CR&O).
e. Nicks or notches in extreme trailing edge strip
(12) of blade less than 0.120 in. (3.04 mm) in depth
are acceptable if polished out over distance of at least
2.0 in. (50.8 mm) each side of nick or notch.
f. Nicks or scratches in erosion shield (10, detail
A) are acceptable provided there is no penetration.
Excessive damage requires erosion shield
replacement at BHT authorized repair station.
NOTE
A void is defined as any unbonded area.
Many sub-definitions of voids are often
used, such as lack of adhesive, gas pocket,
misfit, etc. This manual makes no
distinction among these sub-definitions, but
groups all such unbonded areas under the
general term, void. Inspect for voids using a
small steel tapping hammer similar to BHT
tool number T-75449-2 on all surfaces.
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BHT-412-MM-6 Bell Helicopter

NOTE
MINIMUM CAPACITY FOR HOIST

TORQUE 200 TO 250

LOCKWIRE (C-405)

NOTE

blade folding use blade bolt

VIEW A-A (2), washer (5), nut (6), lock
(7), and plug (8) in lieu of
DETAIL B expandable bolt (10).

1. Spindle 8. Plug (AN814-4L)

2. Blade bolt 9. Bolt handle
3. Blade 10. Expandable bolt
4. Sling (T101626) 11. Adjustment nut
5. Washer (206-010-154-3) 12. Safety lock hair pin
6. Nut 13. Blade bolt tool (T101266)
7. Lock

412-M-62-1

Figure 62-1. Main Rotor Blade Installation

62-00-00
Page 6 Rev. 5
 STATION STATION

1 Blade bolt retention bushings

2. Main rotor blade bonded assembly
3. Abrasion strip MAIN ROTOR BLADE

5. Tip assembly (412-015-300-101)

6. Outboard trim tab

8. Fretting pad
9. Splice cover (outboard)
10. Erosion shield
11. Upper skin
12. Trailing edge strip
13. Lower skin
14. Core
15. Spar

SECTION A-A

Figure 62-2. Main Rotor Blade

62-00-00
Rev. 5 Page 7
6. Inspect for voids under leading edge abrasion 62-7. Installation
strips (3) and skin of main rotor blade bonded
assembly (2). If any voids are found, refer to BHT-412- MATERIALS REQUIRED
CR&O manual for limitation and authorized repair.

Refer to BHT-ALL-SPM for specifications and source.

7. Inspect paint condition. Refer to BHT-412-CR&O
for refinish procedures. NUMBER NOMENCLATURE

C-102 Corrosion Preventive

62-6. Repair Compound

MATERIALS REQUIRED C-405 Lockwire

Refer to BHT-ALL-SPM for specifications and source. SPECIAL TOOLS REQUIRED

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

C-411 Steel Wool T101626 Sling
C-423 Abrasive Cloth or Paper T101266 Blade Bolt Tool

1. Polish out all acceptable nicks and scratches on

leading edge abrasion strip (3, figure 62-2), using 180 .... ....
grit or finer abrasive cloth or paper (C-423). Polish to a CAUTION

remove the nicks or scratches. The use of steel wool

USE HOIST WITH A MINIMUM CAPACITY
acceptable. Acceptable dents need not be filled or
faired.
MAIN ROTOR BLADES AND HUB
COMPONENTS ARE COLOR CODED.
2. Repair rotor blade bolt retention bushings (1) AFTER EXPANDABLE BOLT (10, FIGURE
(BHT-412-CR&O). 62-1) IS ADJUSTED AT INITIAL
INSTALLATION, IT SHALL BE KEPT WITH
THE SAME ROTOR BLADE AND HUB

painted surfaces immediately surrounding polished

areas.
NOTE
... When replacing main rotor blade assembly

assembly (412-015-300-101), blades shall

0.10 in. (2.54 mm) with 200 grit or finer abrasive cloth installed in pairs and i same yoke and
be
be installed in pairs and in same yoke and
(50.8
(50.8 mm)
mm) each
each side.
side. spindle of hub and blade assembly.

1. Attach sling (4, figure 62-1) to a suitable hoist and

5. Fill all acceptable edge voids (BHT-412-CR&O). position directly over center of blade (3).

6. Touch up finish of repaired areas (BHT-412- 2. Attach straps of sling (4) around blade (3). Hoist
CR&O). and align blade with hub.

62-00-00
Page 8 Rev. 5
 Bell Helicopter
3. Guide blade (3) into spindle (1) per color code
and align bolt holes.
4. Apply corrosion preventive compound (C-102) to
mating surfaces of blade bolts (2) and (if being used)
expandable bolts (10).
WARNING
STANDARD BLADE BOLTS MAY BE
INSTALLED IN LIEU OF EXPANDABLE
BOLTS IN BLADE TRAILING EDGE BOLT
HOLE. HOWEVER, STANDARD AND
EXPANDABLE BLADE BOLTS SHALL
NOT BE INTERMIXED ON SAME HUB.
5. Install rotor blade bolt (2) through spindle (1) and
rotor blade (3) in leading edge bolt hole. Use blade
bolt tool (T101266) to install bolt (2). Do not install nut
(6) at this time. If standard bolt is being installed in aft
hole, repeat procedure for trailing edge bolt.
CAUTION
..................
EXPANDABLE BOLT (10), BLADE (3) AND
SPINDLE ARE COLOR CODED.
EXPANDABLE BOLT (10) AND ROTOR
BLADE (3) SHALL BE INSTALLED IN
SAME SPINDLE FROM WHICH
REMOVED. IF FOR ANY REASON
EXPANDABLE BOLT (10), ROTOR BLADE
(3) AND SPINDLE COMBINATION ARE
CHANGED, EXPANDABLE BOLT (10)
SHALL BE ADJUSTED AS DESCRIBED
BELOW. ~The
6. For helicopters with expandable bolt installed in
aft blade hole, accomplish the following:
a. Raise bolt handle (9) on expandable bolt (10).
b. Install expandable bolt (10) in spindle (1) and
blade (3) in trailing edge hole with handle positioned
as shown in view A-A.
c. Push down on bolt handle (9). Force required
to push handle down should be 50 to 75 pounds (222
to 334 N) measured at end of handle. If force is within
BHT-412-MM-6
limits, latch spring clip of bolt handle (9) on core pin of
expandable bolt (10).
d. Install safety lock hair pin (12) to hold bolt
handle (9) in down position. If force required to push
handle down is not within limits, accomplish the
following step.
e. Adjust expandable bolt (10) only if force
required to latch bolt handle (9) is not within 50 to 75
pounds (222 to 334 N) measured at end of handle.
Install expandable bolt (10) in correct spindle (1) and
blade (3) combination. Adjust adjustment nut (11) in
increments and push bolt handle (9) down until force
required is within limits noted above. When
expandable bolt (10) is adjusted within limits, install
safety lock hair pin (12) to hold handle (9) in down
position.
7. For standard blade bolts, accomplish the
following:
a. Install washer (5) and nut (6).
b. Torque nut (6) 70 to 90 foot-pounds (95 to 122
N-m).
. Install lock (7) on nut (6) and install plug (8) to
secure lock (7) on nut (6).
d. Torque plug (8) 200 to 250 in.-lbs. (22.60 to
28.25 N-m). Secure plug (8) to lock (7) using lockwire
(C-405)
38. After all four main rotor blades are installed, track
main rotor blades (Chapter 18) and perform functional
check flight BHT-412-FM.
62-8. MAIN ROTOR HUB
main rotor hub consists of two titanium yokes,
each of which mounts two steel spindles in
elastomeric bearings and elastomeric dampers. Each
spindle has two spindle lugs for mounting a rotor
blade. Rotor blade pitch control is achieved by means
of a pitch horn attached to inboard end of each
spindle. The opposite end of each pitch horn is
attached to a pitch link. The pitch links are attached to
the rotating controls. The main rotor hub is attached to
mast by a procedure which does not require
application of large torque values to hub retaining nut.
The cap assembly, which secures main rotor hub to
mast, is threaded onto mast and is also bolted to hub
with eight bolts.
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BHT-412-MM-6 Bell Helicopter

62-9. Removal 7. Install three jackscrews (T101308) in lower cone

(11) of main rotor hub (5) where sealant was removed.
SPECIAL TOOLS REQUIRED If jackscrew set (T101308) is not available, use three
1/4 X 28 UNF threaded bolts approximately 2.5 in.
(63.5 mm) long. Tighten jackscrews (or bolts) evenly
NUMBER NOMENCLATURE and push lower cone (11) out of lower cone seat of
main rotor hub (5).
T101626 Sling Assembly

SWE 13875 Transportation Stand 8. Remove sealant from joint between cap assembly
SWE 13875-30 Adapter (3) and main rotor hub (5) with sharp plastic scraper.

T101263-105 Adapter
(Part of T101263-101)
NAS6208-9 Bolt
Part of T101263-101) 10. Remove bolts (1) and washers (2).

214-782-003-1 Support Assembly .

11. Remove cap assembly (3).
T101308 Jackscrew

1. Inspect main rotor hub, main rotor blades, and NOTE

pitch links for color code markings. If any color code
markings (dots) are missing, apply new markings
(Chapter 11).
Cap assembly (3) consists of two major
parts, upper cap and nut which threads onto
mast. After eight bolts (1) and bead of
sealant is removed, cap assembly (3) can
be removed with a wrench attached to flat
area at top of cap assembly.

3. Remove bolt (13, figure 62-3) and washers (14)
securing pitch link (19) to pitch horn (15). Secure pitch
link (19) to main rotor mast (8). Disconnect remaining
three pitch links (19). Secure pitch links (19) to main
rotor mast (8).
12. Place sling (T101626) (2, figure 62-4) on a hoist
with minimum capacity of 1000 pounds (454 kg). Hoist
sling (2) into position above main rotor hub (1).
Position sling straps around main rotor hub (1) as
shown on figure 62-4.

4. Cut and remove lockwire from bolts (9). 13. Check that adapter (6, figure 62-4) with support
assembly (5), adapter (4), and bolt (3) are installed on
5. Remove bolts (9) and washers (10). maintenance transport stand (7).

CAUTION
....................
WHEN REMOVING SEALANT FROM
HUB, USE PLASTIC OR BRASS TOOLS
ONLY.
6. Remove sealant from threaded holes in lower
cone (11) of main rotor hub (5) adjacent to where bolts
(9) were removed. Remove sealant with plastic or
brass tools to prevent damage to rotor hub.
NOTE
If adapter (6) with support (5), adapter (4)
and bolt (3) are installed on maintenance
transport stand (7), proceed to step 14. If
not installed, perform steps 13. and 14.
14. Install adapter (6) on maintenance transport
stand (7).
15. Install adapter (4) on support assembly (5) and
secure with bolt (3).

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 Bell Helicopter BHT-412-MM-6

1A TORQUE 250 TO 260 IN-LB

TORQUE 25 FT LB (28.4 TO 29.3 N-m)
(34 N-m) LOCKWIRE (C-447)

(14.2 TO 15.2 N-m)

LOCKWIRE (C-405)
1. Bolt 11. Lower cone
2. Washer (140-007-30S20A30) 12. Upper cone seat
3. Cap assembly 13. Bolt
17 TORQUE 100 TO 4. Upper cone 14. Steel washer
16 140 IN-LB 5. Main rotor hub 15. Pitch horn
15 (11.30 TO 15.82 N-m) 13 6. Blade bolt 16.
7 Steel washer

11 7,Refer toRDETAIL D for torquing Instruction.

3. Refer to DETAIL C for droop restraint rigging dimensions.

DETAIL A NAS1149C0532R washer between nut (17) and washer (16)

(post ASB 412-98-92). 412M-623-1

Figure 62-3. Main Rotor Hub (Sheet 1 of 6)

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BHT-412-MM-6 Bell Helicopter

20
21 LOCKWIRE (C-405)
BOLT HEADS TOGETHER

25 TO 28 FT-LB / / /
(33.90 TO 37.96 N-m)
TORQUE

37 TO 42 FT-LB 47

(2.82 TO 3.95 N-m)

(5.65 TO 7.91 N-m) 45 \ < 38

41
DETAIL B
After Installation of
412-704-114-101 kit and
412 S/N 33101 and sub.

20. Damper bridge 36. Clevis

21. Bolt 37. Washer (AN960-716)
22. Washer (AN960-616) 38. Bolt
23. Cotter pin 39. Bolt
24. Nut 40. Washer (MS9482-10)
25. Washer (412-018-064-101) 41. Bolt
26. Washer (140-00733S40C4) 42. Washer (AN960-516)
27. Race 43. Arm
28. Lower cone seat 44. Weight
29. Nut 45. Nut
30. Bolt 46. Nut
31. Bolt 47. Cotter pin
32. Clevis 48. Bolt
33. Nut 49. Washer (MS9482-11)
34. Bushing (412-018-062-109) 50. Cam
35. Nut
412-M-62-3-2

Figure 62-3. Main Rotor Hub (Sheet 2)

62-00-00
Page 12 Rev. 5
 Bell Helicopter BHT-412-MM-6

LOWER DETENT POSITION

FLEXURE SHOWN IN STATIC

DROOP POSITION WITH DROOP
RESTRAINT ENGAGED
FOUR PLACES
(ARM AND WEIGHT REMOVED FOR CLARITY)
DETAIL C

NOTES
1. Droop restraint arm length (dimension A)
to be adjusted with weight, brackets and
associated hardware removed per rigging
procedures.

2. Dimension B is to be set per rigging

instructions following setting of arm
length (dimension A) and prior to
reinstallatlon of weight, brackets and
associated hardware. For each restraint
arm, dimension B is to be measured on
both leading and trailing edge clevis tangs
and measured difference is to be 0.030
inch (0.762 mm) maximum.

3. Pivot stop rigging dimension to be set

after adjusting (dimension A) per rigging
procedures.

412-M-62-3-3

Figure 62-3. Main Rotor Hub (Sheet 3)

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Rev. 5 Page 13
BHT-412-MM-6 Bell Helicopter

NO.3

Torque upper cap assembly bolts In 50

inch-pound (5.6 N-m) Increments. Retorque
all bolts following the numbered sequence
until final torque of 250 to 260 inch-pound
(28.2 to 29.4 N-m) Is accomplished.

NO. 6 NO. 8

DETAIL D NO. 4
UPPER CONE
TORQUE SEQUENCE

Torque lower cone bolts In 40 inch-pound

NO. 3 (4.5 N-m) ncrements. Retorque all bolts
I NO. 8 following the numbered sequence until
final torque of 125 to 135 inch-pound
(14.1 to 15.3 N-m) Is reached.

DETAIL E NO. 5
TORQUE SEQUENCE

412-M-62-3-4

Figure 62-3. Main Rotor Hub (Sheet 4)

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 Bell Helicopter BHT-412-MM-6

Apply corrosion preventive compound (C-101).

Apply corrosion preventive compound (C-102) on faying surfaces.

Seal all around using sealant (C-396).

Small passageway must remain at lower cone split to vent space

between mast and hub.

VENT PER NOTE

412-M-62-35

Figure 62-3. Main Rotor Hub (Sheet 5)

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BHT-412-MM-6 Bell Helicopter

MAST NUT

412-M-62-3-6

62-00-00
Page 16 Rev. 5
 Bell Helicopter BHT-412-MM-6

1. Main rotor hub assembly

2. Sling (T101626)
3. Bolt (NAS6208-9) (Part of T101263-101)
4. Adapter (T101263-105) (Part of T101263-101)
5. Support assembly (214-782-003-1)
6. Adapter SWE 13875-30
7. Maintenance transportation stand SWE 13875 412-M24

Figure 62-4. Main Rotor Hub Stand - Tool Application

62-00-00
Rev. 5 Page 17
16. Hoist main rotor assembly (1) approximately 2.0 SPECIAL TOOLS REQUIRED
in. (50 mm) and remove upper cone (4, figure 62-3).
NUMBER NOMENCLATURE
17. Hoist main rotor hub (5) clear of main rotor mast
(8). T101626 Sling Assembly

18. Align main rotor hub assembly (1, figure 62-4)

with adapter (4) and lower main rotor hub assembly (1) 1. Place sling assembly (T101626) (2, figure 62-4)
into position on maintenance transport stand (7). on a hoist with minimum capacity of 1000 pounds (454
kg) or more.
19. Remove sling (2) from main rotor hub assembly
(1). 2. Hoist sling (2) into position above main rotor hub
assembly (1).
62-10. Cleaning
3. Position sling (2) straps around hub as shown on
MATERIALS REQUIRED figure
figure 62-4.
62-4.

Refer to BHT-ALL-SPM for specifications and source. 4. Hoist main rotor hub assembly (1) clear of
adapter (4).
NUMBER NOMENCLATURE

C-304 Solvent

CAUTION

304).
ENSURE CORROSION PREVENTIVE
62-11. Inspection COMPOUND DOES NOT COME IN
CONTACT WITH TEFLON OF CONE OR

refer to BHT-412-CR&O manual.

62-12. Repair
For detailed repair procedures of main rotor hub
components, refer to BHT-412-CR&O manual.
62-13. Installation
5. Apply a thin coat of corrosion preventive
compound (C-102) to mating surfaces of main rotor
mast (8, figure 62-3) lower cone (11), main rotor hub
(5), upper cone (4), and cap assembly (3).
6. Apply corrosion preventive compound (C-101) to
main rotor mast (8) and splined plate splines.

MATERIALS REQUIRED 7. Position lower cone (11) on main rotor mast (8)
with beveled side up.
Refer to BHT-ALL-SPM for specifications and source. with beveled side

NUMBER NOMENCLATURE 8. Hoist main rotor hub (5) into position above main
rotor mast (8).
C-101 Corrosion Preventive
Compound
9. Align master tooth of splined plate in main rotor
C-102 Corrosion Preventive hub (5) with master tooth of main rotor mast (8)
Compound splines.
C-396 Sealant
C-405 Lockwire 10. Carefully lower main rotor hub (5) onto main rotor
mast (8) until the upper cone seat (12) is supported by
C-447 Lockwire splines on main rotor mast.

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Page 18 Rev. 5
 Bell Helicopter
11. Remove sling (2, figure 62-4) from main rotor hub
(5, figure 62-3).
12. Install lower cone (11)(11) which was previously
coated with corrosion preventive compound, on main
rotor mast (8) with beveled side down.
13. Apply a thin coat of corrosion preventive
compound (C-102) under the heads and to the shanks
of bolts (9).
14. Slide upper cone (4) into position and install bolts
(9) with washers (10) under bolt heads. Do not torque
bolts (9) at this time.
15. Install cap assembly (3) on main rotor mast (8),
and torque cap assembly to approximately 25 foot-
pounds (33.8 N-m) to ensure cone is seated.
16. Loosen cap assembly until holes in cap assembly
flange are aligned with threaded holes in upper cone
seat (12). If cap assembly has been loosened less
than half the distance between holes, loosen one
additional hole for installation of bolts (1).
17. Apply a bead of sealant (C-396) around cap
assembly (3) where cap assembly joins main rotor hub
(5).
18. Apply a thin coat of corrosion preventive
eight bolts (1).
19. Install eight bolts (1) with washers (2) under bolt
heads, and torque bolts (1) in sequence and steps
(detail D).
20. Secure bolts (1) in pairs using lockwire (C-447).
21. Apply a thin coat of corrosion preventive
compound (C-101) to head of bolts (1).
22. Check torque of bolts (1) after every flight during
rotor smoothing process until torque is maintained.
23. Torque bolts (9) in sequence and steps (detail E),
and secure bolt heads in pairs using lockwire (C-405).
24. Apply a thin coat of corrosion preventive
compound (C-101) to head of bolts (9) and washers.
BHT-412-MM-6
25. Check torque of bolts (9) after every flight during
rotor smoothing process until torque is maintained.
26. Fill threaded holes in lower cone seat of main
rotor hub (5) in area above bolts (9). area at lower
cone (11) to main rotor mast (8) interface, and gap
396).
NOTE
Small passageway must remain open at
lower cone split to vent space between
mast and hub.
27. Position pitch link (19) in pitch hom (15).
28. Coat bolt (13) with corrosion preventive
compound (C-102).
29. Install bolt (13), washer(14), washer(16), and nut
(17) with head of bolt (13) in direction of rotation.
NOTE
Verify that the thickness of the pitch horn
(15) and two washers (14 and 16) exceeds
the spindle length of the bolt (13). If not,
add one NAS1149C0532R washer between
nut (17) and washer (16).
30. Torque nut (17) 100 to 140 in.-Ibs. (11.30 to 15.82
N-m). Install cotter pin (18).
31. Repeat steps 27, 28, and 29 for installation of
remaining pitch links.
NOTE
Main rotor hub can remain on maintenance
transportation stand (1, figure 62-4) or be
installed on helicopter for accomplishment
of rigging procedures.
32. Install main rotor blades (paragraph 62-7).
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BHT-412-MM-6 Bell Helicopter

a. Manually hold droop restraint arm to position

. . ................ 7/16 in. holes of outboard clevis (36) into outboard
CAUTION radius of cam (50) lower detent. Using bolt, verify bolt
.- ...................
--- .. will install freely through both clevis tangs while
PROPER RIGGING IS EXTREMELY passing through lower detent of cam window. If bolt
IMPORTANT AND MUST BE does not pass through, turn clevis as necessary, until

CONDITIONS. MAIN ROTOR BLADE

MOVEMENT, SUCH AS CAUSED BY b. Manually stabilize forward blade at tip during
WIND MUST BE MINIMIZED. IT IS steps (c) and (d). Do not support blade.
RECOMMENDED THE FOLLOWING
RIGGING PROCEDURES BE c. Lengthen arm by turning clevis (36) outward in
PERFORMED IN A HANGER WITH MAIN one-half turn increments (installing bolt each time) until
ROTOR HUB AND BLADE ASSEMBLY first instance occurs where bolt will not freely install.
EITHER ON HELICOPTER OR This establishes "length baseline".
INSTALLED ON MAINTENANCE
TRANSPORTATION STAND (1, FIGURE d. Turn clevis inward one half turn from "length
62-4) WITH BLADE TIPS baseline". Bolt should install freely. With bolt loosely in
UNSUPPORTED. IF MAINTENANCE place, attempt to swing droop restraint arm upward
TRANSPORTATION STAND (1) IS USED, into upper portion of cam window. If bolt hits cam
DISREGARD REFERENCES IN RIGGING window surface and arm is restrained in cam lower
PROCEDURE REGARDING BLADE detent, length adjustment is correct. If bolt clears cam
POSITION RELATIVE TO HELICOPTER. window surface and arm swings up freely, turn clevis
OUTDOOR RIGGING MAY BE outwardone-halfturn.
PERFORMED PROVIDING WIND
VELOCITY IS FIVE (5) KNOTS OR LESS.
e. Square up clevis (36) with cam (50) by
33. Manually rotate rotor until blade corresponding to pushing clevis upward until both clevis tangs are in
first droop restraint arm to be rigged is pointing forward contact with the cam mounting flange.
over nose of helicopter. Rigging procedure is to be
performed while blade is at normal static droop. f. Torque nut (35) 375 to 400 in.-lbs. (42.36 to
45.19 N-m).
34. Cut and remove lockwire from bolt (30).
38. Adjust pivot adjusting bolt (30) to achieve
35. Loosen nut (29, figure 62-3) on pivot adjusting dimension B, 0.60 to 0.70 in. (measured from face of
bolt (30) and turn bolt inward until it bottoms; do not cam plate mounting flange to outboard upper corner of
torque nut. each clevis tang) (figure 62-3, detail C). Dimension B
on same clevis may vary 0.030 in. (0.762 mm)
(35). maximum leading edge side to trailing edge side.
36. Cutlockwire
36. Cut and remove lockwire from nut
and remove
from nut (35).

37. Adjust droop37. Adjust droop

restraint
restraint arm
arm length (dimension A,
length (dimension A, 39. Torque nut (29) 50 to 70 in.-lbs. (5.65 to 7.91 N-
figure 62-3, detail C) as follows: m).

40. Recheck Dimension B. Repeat step 33., if

CAUTION

REQUIRES THAT DIMENSION A BE

ESTABLISHED USING BOLT (38) 42. Install weight (44) to arms (43); secure with bolt
WITHOUT BUSHING (34) INSTALLED TO (41), washers (42) and nut (45). Bolt head must be
OBTAIN LENGTH BASELINE. installed in direction of rotation.

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Page 20 Rev. 5
 Bell Helicopter
NOTE
It may be necessary to raise blade slightly
to allow installation of bolt (38) through
43. Install bushing (34) inside cam (50).
44. Position arms (43) on clevis (36) and align arms
with bolt holes on clevis.
45. Position clevis (36) to align bolt holes in flange of
clevis with bushing (34) in cam (50).
NOTE
direction of rotation.
46. Install bolt (38) with washer (37) under head of
bolt through arm (43), clevis (36), bushing (34) in cam
(50), and through arm (43).
47. Install washers (37) and nuts (46) on bolt (38).
48. Install bolts (39) with two washers (40) under
each head of bolts through arm (43) into clevis (36).
49. Torque nut (46) 37 to 42 ft.-lbs. (50 to 70 N-m).
Install cotter pin (47).
50. Torque bolts (39) 25 to 35 in.-lbs. (2.82 to 3.95 N-
m). Secure with lockwire (C-405) to arm (43).
BHT-412-MM-6
51. Torque nut (45) 50 to 70 in.-lbs. (5.65 to 7.91 N-
m).
arm to fall into lower detent of cam window.
53. Repeat steps 33. through 43. for remaining droop
restraint arms.
NOTE
of main rotor droop restraint, have an
observer visually verify all droop restraint
arms disengage prior to RPM reaching idle.
Normal disengagement occurs at 80 to 100
RPM (25 to 30 percent Nr). Arm
disengagement may be observed by using
a fixed reference point (cowling surface,
etc.) to gage droop restraint arm position as
RPM increases, or a strobe light of
sufficient intensity may be used. A
noticeable vibration will be detectable at
idle if arm disengagement does not occur
during application of collective with neutral
cyclic. If vibration occurs, shut down
helicopter and verify droop restraint arm
rigging by repeating steps 33. though 44.
54. Ensure main rotor rigging is within limits (Chapter
67).
62-00-00
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 Bell Helicopter
MAIN ROTOR CONTROLS
62-14. MAIN ROTOR CONTROLS
The two major assemblies of main rotor controls are
hub and sleeve assembly and swashplate and support
assembly. The four pitch links, four rephasing levers, Carefully
one drive link, three swashplate links and collective
lever, are also included in main rotor control
installation. The function of main rotor controls is to
transmit cyclic and collective input forces to the main 62.
rotor hub and blade assembly by means of the hub
and sleeve, swashplate and support, and
interconnecting links and tubes.
62-15. SWASHPLATE AND SUPPORT ASSEMBLY
The swashplate and support assembly consists of the
outer rotating ring mounted through a duplex bearing
set on the inner non-rotating ring. The inner ring is
connected to the swashplate support by a gimbal ring
assembly. Servo actuator control tubes connect to two
trunnions on the inner ring assembly to tilt the ring in
the desired direction. The outer ring assembly tilts with
the inner ring assembly, but rotates independently with
the rotating controls.
62-16. Removal
1. Remove main rotor hub and blade assemblies
(paragraph 62-3).
2. Remove hub and sleeve assembly (paragraph
62-29).
3. Remove cotter pin (9, figure 62-5), nut (8),
washers (7 and 6), bolt (3) with washer (4) from clevis
(5) and separate clevis (5) from trunnion (2).
4. Remove cotter pin (17) and remove nut (16) and
washers (14 and 15) from bolt (12).
5. Remove bolt (12) and washer (13) from clevis
(11) and separate clevis (11) from trunnion (10).
6. Remove cotter pin (26) and remove nut (25) and
washers (24 and 23) from bolt (21).
7. Remove bolt (21) and washer (22) from clevis
(20) and separate clevis (20) from trunnion (27).
I BHT-412-MM-6
8. Remove lockwire from bolts (19) and remove
bolts (19) and washers (18).
remove swashplate and support
assembly (1) from transmission.
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-304 Solvent
NOTE
Do not allow solvent to saturate trunnion
bearings, gimbal ring bearings or thrust
bearings, gimbal ring bearings or thrust
bearing in swashplate inner ring.
Clean swashplate and support assembly (1, figure 62-
5) with clean cloth damp with solvent (C-304).
62-18.
62-18. Inspection
NOTE
If records or physical appearance indicate
swashplate and support assembly has
been involved in an accident or incident,
refer to Chapter 5 for inspection
requirements.
Refer to BHT-412-CR&O manual for instructions to
inspect swashplate and support assembly.
inspect swashplate and support assembly.
62-19. Repair
Refer to BHT-412-CR&O manual for repair limits and
procedures.
62-00-00
Rev. 5 Page 23
BHT-412-MM-6 Bell Helicopter

26

24
23

211

1. Swashplate and support 10. Trunion 19. Bolt

2. Trunnlon 11. Clevis 20. Clevis
3. Bolt 12. Bolt 21. Bolt
4. Washer (thick) 13. Washer (thick) 22. Washer (thick)
5. Clevis 14. Washer (thick) 23. Washer (thick)
6. Washer (thick) 15. Washer (thin) 24. Washer (thin)
7. Washer (thin) 16. Nut 25. Nut
8. Nut 17. Cotter pin 26. Cotter pin
9. Cotter pin 18. Washer (thick) 27. Trunnion

412-M-625

Figure 62-5. Swashplate and Support

62-00-00
Page 24 Rev. 5
 Bell Helicopter BHT-412-MM-6

62-20. Installation 8. Apply a thin coat of corrosion preventive

compound (C-102) under the head and to shank of bolt
MATERIALS REQUIRED (3).

Referto BHT-ALL-SPM for specifications and source. 9. Install bolt (3) with washer (4) under bolt head.

NUMBER NOMENCLATURE 10. Install nut (8) with washers (6 and 7) as required to
C-101 Corrosion Preventive attain proper thread engagement for cotter pin (9).
Compound Install cotter pin (9).
C-102
C-102 Corrosion
Corrosion Preventive
Preventive 11. Apply a thin coat of corrosion preventive
Compound compound (C-101) to the head of bolt (3), washer (4),
C-405 Lockwire nut (8) with washers (6 and 7), and cotter pin (9).

12. Position clevis (11) on trunnion (10).

NOTE
A thin coat of corrosion preventive
compound (C-102) should be applied to
shanks and under bolt heads of all rotating
control bolts prior to installation.
A thin coat of corrosion preventive
compound (C-101) should be applied to all
rotating control nuts, washers, and bolt
heads after installation.
1. Carefully lower swashplate and support assembly
(1, figure 62-5) over mast and position on mast bearing
plate on top of transmission.
2. Apply a thin coat of corrosion preventive
compound (C-102) under the heads and to shanks of
bolts (19).
13. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of bolt
(13).
14. Install bolt (12) with washer (13) under bolt head.
15. Install nut (16) with washers (14 and 15) as
required to attain proper thread engagement for cotter
pin (17). Install cotter pin (17).
16. Apply a thin coat of corrosion preventive
compound (C-101) to the head of bolt (12), washer
(13), nut (16) with washers (14 and 15), and cotter pin
(17).
17. Position clevis (20) on trunnion (27).

3. Install bolts (19) with washers (18) under bolt 18. Apply a thin coat of corrosion preventive
heads. Torque bolts (19) 130 to 140 in.-lbs. (14.69 to compound (C-102) under the head and to shank of bolt
15.82 N-m). (21).

4. Secure bolts (19) in pairs using lockwire (C-405). 19. Install bolt (21) with washer (22) under bolt head.

5. Apply a thin coat of corrosion preventive 20. Install nut (25) with washers (23 and 24) as
compound (C-101) to the heads of bolts (19) and required to attain proper thread engagement for cotter
washers (18). pin (26). Install cotter pin (26).

6. Install hub and sleeve assembly (paragraph 62- 21. Apply a thin coat of corrosion preventive
33). compound (C-101) to the head of bolt (21), washer
(22), nuts (25) with washers (23) and (24), and cotter
7. Position clevis (5) on trunnion (2). pin (26).

62-00-00
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BHT-412-MM-6 Bell Helicopter

62-21. MAIN ROTOR PITCH LINK ASSEMBLIES 62-23. Cleaning

The pitch links are composed of a tube, two swaged MATERIALS REQUIRED
inserts, two adjustable rod end bearings with lock nuts,
a nameplate and decal. The pitch link assemblies
connect the semi-circular pitch horn on the blade Refer to BHT-ALL-SPM for specifications and source.
spindle to the rephasing levers on hub and sleeve.
NUMBER NOMENCLATURE
62-22. Removal

1. Removal of pitch link with elastomeric lower rod

end bearing.
NOTE
a. With boost off, center cyclic and pull collective Do not immerse rod end bearing (8 and 14,
up as high as possible. figure 62-6) in solvent (C-304).

b. Remove lockwire from bolt (21, figure 62-6) 1. Wipe pitch link (12) with clean cloth damp with
and remove bolt (21) with washer (22) from rephasing solvent (C-304).
lever (23).

c. Remove cotter pin (20A), nut (20), washer 2. Dry with filtered, compressed air.
(19), and bushing (18) from bolt (16).
62-24. Inspection
d. Remove bolt (16) with washer (17) and
bushing (18) from rephrasing lever (23). 1. Inspect pitch link assemblies (12, 15, 24, and 25,
figure 62-6) for damage in accordance with BHT-412-
e. Remove cotter pin (10A), nut (10), and washer CR&O manual.
(9) from bolt (6).
2. Inspect bushings (18) for cracks and damage
f. Remove bolt (6) with washer (7) and separate (BHT-412-CR&O).
pitch link (12) from pitch horn (5) and rephasing lever
(23).
3. Inspect bolts (6, 16, and 21) for thread damage
g. Repeat steps a. through d. to remove distortion and corrosion.
remaining pitch links.
4. Inspect rod end bearings (8 and 14) for wear
2. Removal of pitch link with uniball teflon lined (BHT-412-CR&O).
bearing.
62-25. Repair
a. With boost off, center cyclic and pull collective
up as high as possible. MATERIALS REQUIRED

b. Remove cotter pin (28, detail B), nut (29), bolt

(16), washer (32), long bushing (30), bracket (31), and Refer to BHT-ALL-SPM for specifications and source.
short bushing (33) from rephasing lever (23).
NUMBER NOMENCLATURE
c. Remove cotter pin (10A), nut (10), washers (9 C-100 Chemical Film Material
and 7), bolt (6), and separate pitch link (12) from pitch
horn (5) and rephasing lever (23). C-102 Corrosion Preventive
Compound
d. Repeat steps a. through c. to remove the C-210 Paint
remaining pitch links.

62-00-00
Page 26 Rev. 5
26

TORQUE 30 TO 40 IN-LB
(3.39 TO 4.52 N-m)
LOCKWIRE (C-405)

1. Main rotor hub 10A. Cotter pin 20. Nut

2. Pitch horn (upper yoke) 11. Nut 20A. Cotter pin
3. Pitch horn (lower yoke) 12. Pitch link 2. Bolt
4. Pitch horn (lower yoke) 13. Nut 22. Steel washer
5. Pitch horn (upper yoke) 14. Rod end bearing 23. Rephasing lever
6. Bolt 15. Pitch link 24. Pitch link
7. Steel washer 16. Bolt 25. Pitch link
8. Rod end bearing 17. Washer (140-007-25S-20C4) 26. Upper yoke
9. Steel washer 18. Bushing 27. Lower yoke
10. Nut 19. Thin steel washer

NOTE:

Verity that the thickness of pitch horn (5) and two washers
(7 and 9) exceeds the grip length of the bolt (6). If not, add one
NAS1149C0532R washer between nut (10) and washer (9)
(post ASB 412-982).
412-M-62-6-1
Figure 62-6. Main Rotor Pitch Link (Sheet 1 of 2)

62-00-00
Rev. 5 Page 27
BHT-412-MM-6 Bell Helicopter

SERRATED
FACE

DETAIL A
ELASTOMERIC ROD END
BEARING UNI-BALL ROD END
BEARING
(4 PLACES)

29. Nut
30. Long bushing

B 32. Washer

34. Anti-rotation pin

LOOKING DOWN ON REPHASING

LEVER

412--62-6-2

Figure 62-6. Main Rotor Pitch Link (Sheet 2)

62-00-00
Page 28 Rev. 5
 Bell Helicopter
NOTE
Repair is restricted to polishing out damage
and replacing rod end bearings, decal, and
nameplates.
1. Polish out mechanical and corrosion damage
within limits (BHT-412-CR&O).
2. Apply chemical film material (C-100) to all bare
aluminum areas (BHT-ALL-SPM).
3. Apply paint (C-210) to areas where metal is
exposed (BHT-ALL-SPM).
4. Touch up paint to match existing finish (BHT-ALL-
SPM).
5. Replace rod end bearing (1 and 8, figure 62-8) if
rod end bearings are worn beyond limits (BHT-412-
CR&O) as follows:
a. Loosen nut (2) and remove rod end bearing
(1) from tube (9).
b. Remove nut (2) from rod end bearing (1).
c. Apply light coat of corrosion preventive
compound (C-102) to threads of new rod end bearing.
d. Install nut (2) on rod end bearing (1).
e. Install rod end bearing (1) on tube (9).
f. Repeat steps 5.a. through 5.e. to replace
opposite rod end bearing (8).
g. Adjust pitch link to initial setting dimension
(figure 62-7).
h. Tighten nut (2, figure 62-8) enough to hold set
dimensions. Do not torque nut at this time.
BHT-412-MM-6
62-26. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-101 Corrosion Preventive
Compound
Corrosion Prev
C-102 Corrosion Preventive
Compound
C-405 Lockwire
NOTE
The two shorter pitch links (15 and 24,
figure 62-6) are installed on pitch horns (3
and 4) of lower yoke (27). The longer pitch
links (12 and 25) are installed on pitch
horns (2 and 5) and can be identified for
installation in correct position by color code
markings or pitch link tube dimensions
(figure 62-7).
A thin coat of corrosion preventive
compound (C-102) should be applied to
shanks and under bolt heads of all rotating
control bolts prior to installation.
A thin coat of corrosion preventive
compound (C-101) should be applied to all
rotating control nuts, washers, and bolt
heads after their installation.
1. If not previously accomplished, adjust pitch link to
initial setting dimensions (figure 62-7).
NOTE
Steps 2.a. through 2.c. are required for
pitch links with lower elastomeric rod ends
only.
2. Select pitch link to be installed by color code or
pitch link tube dimension. Refer to NOTE preceding
step 1. above. During installation of pitch links, ensure
links are installed such that any elastomeric bearing
has zero torsional preload at flat pitch when
swashplate is level with respect to mast. This may be
accomplished as follows:
62-00-00
Rev. 5 Page 29
BHT-412-MM-6 Bell Helicopter

A
B
6.09 INCH 5.52 INCH
6.03 5.46

DIMENSIONS DIMENSIONS METRIC

PITCH LINK FOR B A
A B A B

21.010 INCH 16.64 INCH 533.65 mm 422.65 mm

UPPER YOKE 20.990 INCH 16.61 INCH 533.146 mm 421.89 mm

19.125 INCH 14.985 INCH 485.775 mm 380.619 mm

LOWER YOKE 19.105 INCH 15.015 INCH 485.267 mm 381.381 mm

NOTE:

A After initial setting: Exposed threads on rod end bearings (dimensions "C" and "D")
must be equal within two threads.
After installation and rigging: Maximum exposed threads shall not exceed eleven at
dimensions "C" and eight at dimension "D".

412-M-62-7

Figure 62-7. Main Rotor Pitch Link Assembly Initial Dimensions

62-00-00
Page 30 Rev. 5
 Bell Helicopter BHT-412-MM-6

1. Rod end bearing 4. Name plate 7. Nut

2. Nut 5. Decal 8. Rod end bearing
3. Insert 6. Insert 9. Tube

412-M-62-8

Figure 62-8. Main Rotor Pitch Link Assembly

a. Center cyclic to maintain swashplate level in b. Position upper end of pitch link (12, figure 62-
respect to mast. 6) in pitch horn (5).

b. Lower collective lever until down stop is c. Apply a thin coat of corrosion preventive
contacted. compound (C-102) under the head and to shank of
bolt (6).

c. Rotate rotor until lower link of control system
in which link (swashplate link or pitch link) is being
installed is directly forward of mast and over center
line of helicopter (within ±10°). All links of control
system shall be installed in this manner to ensure any
cyclic input to swashplate will not be a significant
factor.
3. To install pitch link with elastomeric bearing
proceed as follows:
a. Install link so elastomeric bearing is within one
serration of being parallel to mast.
NOTE
d. Install bolt (6), washer (7 and 9), and nut (10).
NOTE
Verify that the thickness of the pitch horn (5)
and two washers (7 and 9) exceeds the
spindle length of the bolt (6). If not, add one
NAS1149C0532R washer between nut (10)
and washer (9).
e. Torque nut (10) 100 to 140 in.-lbs. (11.30 to
15.82 N-). nstal cotter pin (1A).
f. Apply a thin coat of corrosion preventive
compound (C-101) to the head of bolt (6) and washer
(7), washer (9), nut (10), and cotter pin (10A).

All bolts installed in rotating controls are to g. Position rod end bearing (14) on rephasing
be installed with heads in direction of lever (23) with serrated face of lower rod end bearing
rotation. facing bushing (18) as shown on detail A.

62-00-00
Rev. 5 Page 31
BHT-412-MM-6 Bell Helicopter
h. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (16).
i. Install bolt (16) with washer (17) under bolt
head.
j. Install bushing (18), washer (19) and nut (20).
Do not torque nut (20) at this time.
k. Ensure serrations of bushing (18) and rod end
bearing (14) are properly engaged.
bearing (14)
I. Install bolt (21) and washer (22), and torque
bolt (21) 30 to 40 in.-lbs. (3.39 to 4.52 N-m).
m. Secure bolt (21) to bushing (18) with lockwire
(C-405).
n. Torque nut (20) 165 to 200 in.-lbs. (18.64 to
22.50 N-m). Install cotter pin (20A).
o. Apply a thin coat of corrosion preventive
compound (C-101) to head of bolt (16), washer (17),
washer (19), nut (20), cotter pin (20A), washer (22),
and bolt (21).
4. To install pitch link with uniball teflon lined
bearing.
NOTE
All bolts in rotating controls are to be
installed with heads in direction of rotation.
a. Position upper end of pitch link (12, figure 62-
6) in pitch horn (5).
b. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
c. Install bolt (6), washer (7 and 9), and nut (10).
d. Torque nut (10) 100 to 140 in.-lbs. (11.30 to
15.82 N-m). Install cotter pin (10A).
e. Apply a thin coat of corrosion preventive
compound (C-101) to the head of bolt (6) and washer
(7), washer (9), nut (10), and cotter pin (10A).
62-00-00
Page 32 Rev. 5
f. Install short bushing (33) into inside flange of
bracket (31). Detail B (pitch link lower end).
g. Position bracket (31) at end of rephasing lever
(23) arm in alignment with rod end (14) and anti-
rotation pin (34).
h. Install long bushing (30) into side of bracket
(31) with head of bushing opposite direction of rotation
as shown in detail B.
Apply a thin coat of corrosion preventive
i. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (16).
j. Install washer (32) under head of bolt (16).
Push bolt (16) through bushings in bracket (31), rod
end (14), and rephasing lever (23).
k. Install nut (29).
I. Torque nut (29) 165 to 200 in.-lbs. (18.64 to
22.60 N-m). Install cotter pin (28).
5. Repeat steps 3. or 4., as applicable, to install
remaining pitch links.
6. Center rod end bearing (8) in pitch horn clevis (5).
7. Torque nut (11) 120 to 150 in.-lbs. (13.56 to 16.95
N-m).
8. Secure nut (11) to insert (3, figure 62-8) with |
lockwire (C-405).
9. Center rod end bearing (14, figure 62-6) in
rephasing lever clevis (23).
10. Torque nut (13) 120 to 150 in.-lbs. (13.65 to 16.95
N-m).
12. Repeat steps 1. through 10. to install remaining
12. Repeat steps 1. through 10. to install remaining
pitch links.
62-27. HUB AND SLEEVE ASSEMBLY
The hub and sleeve assembly consists of four
rephasing levers and a rotating hub splined to mast
and mounted through ball bearings on upper end of
 Bell Helicopter
non-rotating collective sleeve. The collective hub and
sleeve operates between the swashplate and support
assembly and mast, and is actuated by collective lever
attached to lower end. The inboard ends of rephasing
levers are connected to the hub. Prior to S/N 33108,
one rephasing lever is connected to the drive link and
three rephasing levers are connected to swashplate
links. On S/N 33108 and subsequent, or prior to S/N
33108 modified by T.B. 412-86-52, the rephasing
levers are connected to two drive links and two
swashplate links. The outboard ends of rephasing
levers are connected to pitch horns by four pitch links
which transmit collective and cyclic control motions to
the main rotor hub and blade assembly.
62-28. Inspection of Teflon Lined Bearings
1. Fabricate work aid as shown on figure 62-9,
Detail A.
Detail A.
NOTE
Inspection procedure is typical for all four
pitch change links.
2. Hook work aid (2, figure 62-10) on pitch horn (3)
andto
and pull down pullrelieve
to down loading.
relieve loading. Pitch change link
Pitch change link
loading occurs from main rotor elastomeric bearings.
3. Grasp pitch link (4) and move in a direction to
permit a check for axial looseness of the pitch link rod
end bearings (teflon lined) (1 and 9). Maximum
acceptable axial wear in pitch link rod end bearings
(teflon lined) (1 and 9) is 0.015 in. (0.381 mm).
4. Grasp swashplate link (8) and attempt to move
axially.
axially. Maximum
Maximum acceptable
acceptable axial
axial wear
wear in
in swashplate
swashplate
5. Grasp drive link (5) and attempt to move axially.
Maximum acceptable axial wear in drive link rod end
bearing (teflon lined) (6) is 0.015 in. (0.381 mm).
6. Replace pitch link rod end bearings (1 and 9)
exceeding maximum acceptable wear (BHT-412-
CR&O).
7. Replace swashplate link rod end bearing (7)
exceeding maximum acceptable in swashplate link rod
end bearing (BHT-412-CR&O).
BHT-412-MM-6
8. Replace drive link rod end bearing (6) exceeding
maximum acceptable wear (BHT-412-CR&O).
62-29. Removal
1. Remove main rotor hub and blade assemblies
(paragraphs 62-3 and 62-9).
2. Cut and remove lockwire from dust boot (3, figure
62-11). Remove dust boot (3) and spacer (2) from
mast (1).
3. Prior to removal of hub and sleeve assembly,
measure spline wear on collective pitch drive plate set
(4) (paragraph 62-31).
rephasing levers (6, 7, 31, and 32) (paragraph 62-22).
5. Cut and remove lockwire from bolt (23) and
5. Cutbolt
and(23)remove lockwire
remove with washer (24).from bolt (23) and
6. Remove cotter pin (26), nut (27), washer (25),
bolt (20), washer (21) and anti-torque bushing (22).
7. Separate swashplate link (30) from outer ring
(28).
8. Repeat steps 5., 6., and 7. to disconnect opposite
swashplate link (30A) and (37), if installed.
9. Remove cotter pin (12), nut (13), and safety
washer (11). Separate rephrasing lever drive link (8)
from outer ring (28).
10. Remove washer (15) from stud on outer ring (28).
11. Remove cotter pin (35, detail B), nut (36) and
safety washer (34). Separate swashplate link (37) from
outer ring (28). Repeat for opposite swashplate link, if
installed
13. Cut and remove lockwire from bolt (16) and
remove bolt (16), washer (17), collective lever pin (18),
shim (19), and if installed, shim (19A).
14. Index shim (19) for reinstallation in same location.
collective lever pin (18) on collective levers.
16. Cut and remove lockwire from four screws (10)
and remove four screws (10) and remove bearing and
liner (9).
62-00-00
Rev. 5 Page 33
BHT-412-MM-6 Bell Helicopter

BOLT - 0.25 INCH (6.35 mm) X 2.5 INCHES (63.50 mm)

WASHER - 0.25 INCH (6.35 mm) X 1.25 INCHES (31.75 mm)
HOSE - 0.25 INCH (6.35 mm) I.D. X 1.375 INCH (34.93 mm)
NUT - COMMON

.1.0 INCH (25.4 mm) STEEL TUBE

~~~~31
---------------- INCHES
(787.40 mm)
DETAIL A

SEE DETAIL A

...................
...-
;::..,<,r....\.
......

Page .4 . Iev.

Figure 62-9. Swashplate Link and Drive Link Bearings Work Aid

62-00-00
 Bell Helicopter BHT-412-MM-6

1. Pitch link rod end bearing (teflon lined)

2. Work aid
3. Pitch horn
4. Pitch link
5. Drive link
6. Drive link bearing (teflon lined)
7. Swashplate link rod end bearing
(teflon lined) (on lower end of
swashplate link)
8. Swashplate link
9. Pitch link rod end
bearing (teflon lined)

412-M-62-10

Figure 62-10. Hub and Sleeve Assembly Teflon Bearing Inspection

62-00-00
Rev. 5 Page 35
BHT-412-MM-6 Bell Helicopter

SEE DETAIL B

31 . 30A
6
7

30 - 29 - 9 11
11
12

480 TO 690 IN-LB

(54.2 TO 77.9 N-m)
28 . TORQUE
SEE DETAIL A 20 TO 25 IN-LB
(2.2 TO 2.82 N-m)

(18.64 TO 22.60 N-m) 27

26, ,J,

25

TORQUE 15
30 TO 40 IN-LB ¢
(3.39 TO 4.52 N-n) 23 i^ (

62-00-00 30 TO 40 IN-LB
(3.39 TO 4.52 N-m)
412-M-62-11-1

Figure 62-11. Hub and Sleeve (Sheet 1 of 2)

62-00-00
Page 36 Rev. 5
 32-

20

480 TO 690 IN-LB

25A 35
27 26 TORQUE
165 TO 200 IN-LB

LOOKING DOWN ON SWASHPLATE

LOWER END OF LINK
DETAIL A

1. Mast
2. Spacer
3. Dust boot
4. Collective pitch drive plate set
5. Pitch link
6. Rephasing lever
7. Rephasing lever
8. Rephasing lever drive link
9. Bearing and liner DETAIL B
10. Screw
11. Safety washer 25. Steel washer S/N 33001 through
12. Cotter pin 25A. Interrupter bracket 33107 not modified
13. Nut 26. Cotter pin by T.B. 412-86-52
14. Collective lever 27. Nut
15. Washer (140-009D41S60) 28. Outer ring
16. Bolt 29. Collective sleeve
17. Steel washer 30. Swashplate link (412-010-406-111)
18. Collective lever pin 30A. Swashplate link
19. Shim 31. Rephasing lever
20. Bolt 32. Rephasing lever
21. Washer (140-007-25S-20C4) 33. Washer (140-009D41S60)
22. Anti-torque bushing 34. Safety washer
22A. Bushing 35. Cotter pin
23. Bolt 36. Nut
24. Steel washer 37. Swashplate link (412-010-406-113)

412M-62-11-2

Figure 62-11. Hub and Sleeve (Sheet 2)

62-00-00
Rev. 5 Page 37
BHT-412-MM-6 Bell Helicopter

17. Repeat step 16. to remove opposite bearing and
liner (9).
18. Remove collective pitch drive plate set (4)
(paragraph 62-43).
19. Carefully lift hub and sleeve assembly from
swashplate.
3. Inspect spacer (2) for damage and deterioration.
4. Measure spline wear on collective drive plate set
(7, figure 62-12).
5. Inspect safety washers (11 and 34, figure 62-11)
for distortion and cracks. Superficial damage is
acceptable without repair.

62-30. Cleaning 6. Hold collective sleeve (29) and rotate hub. Check
bearing set by feel for looseness and/or binding. If
MATERIALS REQUIRED looseness and/or binding is detected, inspect in
accordance with procedures contained in BHT-412-
Refer to BHT-ALL-SPM for specifications and source. CR&O manual.

NUMBER NOMENCLATURE 7. Inspect anti-torque bushing (22, figure 62-11) for

damage or distortion and wear which would prevent
C-304 Solvent locking rod end bearing.

8. For remainder of hub and sleeve components,

----.-- .--
-------- inspect in accordance with procedures contained in
CAUTION BHT-412-CR&O manual.

DO NOT IMMERSE HUB AND SLEEVE 62-32. Repair

ASSEMBLY IN SOLVENT.
1. Clean hub and sleeve assembly with clean cloth
damp with solvent (C-304).
2. Dry with filtered, compressed air.
62-31. Inspection
NOTE
If records or physical appearance indicate
hub and sleeve assembly has been
involved in an accident or incident, refer to
Chapter 5 for inspection requirements.
NOTE
Repair of hub and sleeve assembly is
restricted to polishing out mechanical and
corrosion damage and installation of new
parts such as bearing and liner assembly,
drive link assembly, swashplate link
assembly, and rephasing lever drive
assembly. Refer to BHT-412-CR&O manual
for mechanical and corrosion damage limits
and repair procedures and limits.
62-33. Installation
MATERIALS REQUIRED

1. Inspect hub and sleeve assembly teflon lined rod

end bearings (installed) as required by Chapter 5 and Refer to BHT-ALL-SPM for specifications and source.
figure 62-7. figure 62-7. NUMBER NOMENCLATURE

2. Inspect boot (3, figure 62-11) for tears, cracks, C-001 Grease
and deterioration.
C-101 Corrosion Preventive
Compound
NOTE C-102 Corrosion Preventive
The hub and sleeve assembly must be Compound
installed on main rotor mast to accomplish C
the following step.Lockwire
62-00-00
Page 38 Rev. 5
 Bell Helicopter BHT-412-MM-6

1. Mast
2. Magnet
3. Dial indicator
4. Indicator probe
5. Bolt
6. Hub assembly
NOTES 7. Drive plate set
NOTES:

Attach dial indicator (3) to mast (1) with

magnet (2). Position indicator probe (4) in
contact with a flat of bolt (5) (Flange
attaching bolt). Move hub (6) back and forth.
in plane of rotation and measure amount of
play.

Maximum acceptable radial play allowed

between mast (1) and plate set drive (7) is
0.040 inch (1.01 mm).
412-M-62-12

Figure 62-12. Collective Drive Plate Set- Damage Limits

62-00-00
Rev. 5 Page 39
BHT-412-MM-6 Bell Helicopter
NOTE
A thin coat of corrosion preventive
compound (C-102) should be applied to
shanks and under bolt heads of all rotating
control bolts prior to installation.
A thin coat of corrosion preventive
compound (C-101) should be applied to all
rotating control nuts, washers, and bolt
heads after there installation.
1. Apply grease (C-001) to splines of mast and
collective pitch drive plate set (4, figure 62-11).
2. Install collective pitch drive plate set (4) if not
previously accomplished (paragraph 62-45).
3. Carefully position hub and sleeve assembly on
mast (1).
mast (1) and lower hub and sleeve assembly into
swashplate.
5. Install washer (15) on stud of outer ring (28) and
position rephrasing lever drive link (8) on swashplate
outer ring (28).
6. Install safety washer (11), with raised lip toward
drive link bearing, and nut (13).
7. Torque nut (13) 480 to 690 in.-lbs. (54.2 to 77.9
N-m). Install cotter pin (12).
8. If second drive link is installed, repeat steps 5, 6,
and 7, then proceed to step 13 or 14, as required.
9. Install washer (33) on stud of outer ring (28).
10. Position swashplate link (37) on outer ring (28).
11. Install safety washer (34), with raised lip toward
swashplate link bearing, and nut (36).
12. Torque nut (36) 480 to 690 in.-lbs. (54.2 to 77.9
N-m). Install cotter pin (35).
13. To install swashplate link assembly with
elastomeric bearings, proceed as follows:
62-00-00
Page 40 Rev. 5
a. Position swashplate link (30) on outer ring (28)
with serrated face of rod end bearing toward anti-
torque bushing (22) (detail A).
b. Install anti-torque bushing (22) with serrated
face of bushing in contact with serrated face of rod end
bearing (detail A).
c. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (20).
d. Install bolt (20) with washer (21) under head of
bolt.
e. Install washer (25) and nut (27) on bolt (20).
Do not torque nut (27) at this time.
f. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (23).
g. Install bolt (23) with washer (24) under head of
bolt.
h. Torque bolt (23) 30 to 40 in.-lbs. (3.39 to 4.52
N-m).
i. Secure bolt (23) to bushing (22) using lockwire
(C-405).
j. Torque nut (27) 165 to 200 in.-lbs. (18.64 to
22.60 N-m). Install cotter pin (26).
k. Apply a thin coat of corrosion preventive
compound (C-101) to nut (27), to head of bolt (20) and
washer (21), and to head of bolt (23) and washer (24).
14. To install swashplate link assembly with uniball
teflon lined bearing, proceed as follows:
a.
a. Install
Install lower
lower end
end ofof swashplate link (30)
seashplate link (30) with
with
head of bolt (20) in direction of rotation.
b. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to the shank of
bolt (20).
c. Install washer (21) under bolt head (20).
d. Slide bushing (22A) into swashplate outer ring
(28).
 Bell Helicopter BHT-412-MM-6

e. Install bolt (20) with washer (10) through
bushing (22A), swashplate link (30), and outer ring
(28).
f. Install interrupter bracket (25A) and nut (27).
g. Torque nut (27) 165 to 200 in.-lbs. (18.64 to
22.60 N-m) and secure with cotter pin (26).
15. Repeat steps 13a. through 13k. to install
remaining swashplate link.
16. Position bearing and liner (9) on collective sleeve
(29) and install four screws (10).
17. Torque screws (10) evenly 20 to 25 in.-lbs. (2.26
to 2.82 N-m).
18. Secure screws (10) together in pairs using
lockwire (C-405).
19. Repeat steps 16. through 18. to install opposite
bearing and liner (9).
20. Install pin (18) (paragraph 62-51 or paragraph 62-
52).
21. Install dust boot (3) and spacer (2).
1. Remove rephasing lever (2, figure 62-13) with
swashplate (3) link attached as follows:
a. Remove pitch link (1) with uniball or
elastomeric rod end bearings from rephasing lever (2)
(paragraph 62-22).
b. Remove swashplate link (3) with uniball or
elastomeric rod ends from rephasing lever (2)
(paragraph 62-41).
c. Remove cotter pin (4), nut (5), washer (6), bolt
(7), washer (8), and washers (9). Discard cotter pin (4).
d. Lift rephasing lever (3) from hub (10).
e. Repeat step 1 for remaining rephasing levers
with swashplate links attached.
2. Remove rephasing lever (11) with drive link (12)
as follows:
a. Remove pitch link (13) with uniball or
elastomeric rod end bearings from rephasing lever (11)
(paragraph 62-22).
b. Remove drive link (12) from rephasing lever
(11) (paragraph 62-38).

22. Secure boot to mast (1) and collective pitch drive c. Remove cotter pin (14), nut (15), washer (16),
plate set (4) using lockwire (C-405). bolt (17), washer (18), and washers (19).

23. Lubricate hub and sleeve assembly (Chapter 12). d. Lift rephasing lever (11) from hub (20).

24. Confirm control rigging is within limits (Chapter e. Repeat step 2 for remaining drive link, if
67). installed.

62-34. REPHASING LEVERS 62-36. Installation

62-35. Removal MATERIALS REQUIRED

NOTE Refer to BHT-ALL-SPM for specifications and source.

Prior to S/N 33108, one rephasing lever is NUMBER NOMENCLATURE
connected to the drive link and three
rephasing levers are connected to C-101 Corrosion Preventive
swashplate links. On S/N 33108 and Compound
subsequent, the rephasing levers are
connected to two drive links and two C-102 Corrosion Preventive
swashplate links. Compound

62-00-00
Rev. 5 Page 41
BHT-412-MM-6 Bell Helicopter
WARNING
IT IS POSSIBLE TO INSTALL REPHASING
LEVER (2) INVERTED. ENSURE
REPHASING LEVER (2) IS INSTALLED
ON HUB (10) WITH SHORT ARM FOR
ATTACHMENT OF SWASHPLATE LINK
(3) ON SIDE IN DIRECTION OF
ROTATION OF MAST WHICH WILL
AFFECT FLIGHT CONTROL RIGGING.
NOTE
Prior to S/N 33108, one rephasing lever is
connected to the drive link and three
rephasing levers are connected to
swashplate links. On S/N 33108 and
subsequent, the rephasing levers are
connected to two drive links and two
swashplate links.
1. Install rephasing lever (2) with swashplate link as
follows:
a. Position lever (2, figure 62-13) on hub (10)
with washers (9).
b. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (7)
c. Install bolt (7) with washer (8) under bolt head.
d. Install
(6) and nut
washer
(467).
e. Torque nut (4) 24 to 34 ft.-lbs. (32.54 to 46.10
N-m). Install cotter pin (5).
f. Apply a thin coat of corrosion preventive
compound (C-101) on nut (4) and washer (6) and to
g2(2) (paragraph
62-42).nd
h. Install pitch link (1) on rephasing lever (2)
(paragraph 62-26).
i. Repeat step 1 for remaining rephasing levers
(11) with swashplate links (3) installed.
62-00-00
Page 42 Rev. 5
WARNING
IT IS POSSIBLE TO INSTALL REPHASING
LEVER (11) INVERTED. ENSURE
REPHASING LEVER (11) IS INSTALLED
ON HUB (20) WITH SHORT ARM FOR
ATTACHMENT OF DRIVE LINK (12) ON
SIDE IN DIRECTION OF ROTATION OF
MAST.
2. Install rephasing lever (11) with drive link (12) as
follows:
a. Position rephasing lever (11) on hub (20) with
washers (19).
b. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (17)
c. Install bolt (17) with washer (18) under bolt
head.
d. Install washer (16) and nut (14).
e. Torque nut 24 to 34 ft.-lbs. (32.54 to 46.10 N-
m). Install cotter pin (14).
f. Apply a thin coat of corrosion preventive
compound (C-101) on nut (14) and washer (16) and to
head of bolt 7) and washer (18).
62-37. DRIVE LINK ASSEMBLY
62-38.
62-38 Removal
Removal
Remove cotter pin (19, figure 62-14), nut (18),
1. Remove cotter pin (19, figure 62-14), nut (18),
and safety washer (17).
2. Remove cotter pin (12), nut (13), washers (14, 15,
23, and 2), spacer (16), and bolt (1).
3. Remove cotter pin (4), nut (5), washers (6, 9, 10,
and 7), spacer (11), and bolt (8).
4. Remove drive link (20).
 DETAIL A
1. Pitch link 11. Rephaslng lever
2. Rephasing lever 12. Drive link
3. Swashplate link 13. Pitch link
4. Cotter pin 14. Cotter pin A NOTES:
65. Nut 15.Washer
Nut Effective helicopters S/N 33108 and subsequent and helicopters

9. Washer 19. Washer 4 Torque 1/2 inch bolts 24 to 34 ft-lb (33 to 46 N-m).
10. Hub 120. Hub Torque 3/8 Inch bolts 165 to 200 In-lb (18.64 to 22.60 N-m).

412-M-62-13

62-00-00
Rev. 5
Rev. 5 Page 43
Page 43
BHT-412-MM-6 Bell Helicopter

TORQUE 6
165 TO 200 IN-LB
(18.64 TO 22.60 Nm) 5

7 8

22
18 TORQUE
(54.2 TO 77.9 Nm)

21

NOTE
Helicopters serial no. 33108 and subsequent and helicopters
modified by TB412-86-52 use washer P/N 412-010-423-103

Not used on helicopters serial no. 33108 and

subsequent and helicopters modified by TB412-86-52

1. Bolt 13. Nut

2. Washer (140-007-25S20C4) 14. Washer (140-009D25S72)
3. Rephasing lever 15. Drive washer (412010-423-101)
4. Cotter pin 16. Spacer
5. Nut 17. Safety washer
6. Washer (140-009D-25S40) 18. Nut
7. Washer (140-007-25S36C4) 19. Cotter pin
8. Bolt 20. Drive link
9. Drive washer (412-010-423-101) 21. Washer (140-009D-41S60)
10. Drive washer (412-010-423-101) 22. Stud
11. Spacer (412-010-418-101) 23. Drive washer (412-010-423-101)
12. Cotter pin
412-M-62-14

Figure 62-14. Drive Link

62-00-00
Page 44 Rev. 5
 Bell Helicopter
62-39. Installation
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-101 Corrosion Preventive
Compound
C-102 Corrosion Preventive
Compound
NOTE
A thin coat of corrosion preventive
compound (C-102) should be applied to
shanks and under bolt heads of all rotating
control bolts prior to installation.
A thin coat of corrosion preventive
compound (C-101) should be applied to all
rotating control nuts, washers, and bolt
heads after their installation.
1. Position washer (21, figure 62-14) on stud (22).
2. Position drive link (20) on stud (22).
3. Install washer (17), with raised lip toward drive
link (20). Install nut (18). Do not torque nut at this time.
4. Apply a thin coat corrosion preventive compound
(C-102) under the head and to shank of bolt (8).
5. Assemble spacer (11), washer (9), washer (10) (if
applicable) on drive link bearing and install bolt (8) with
washer (7) under bolt head.
6. Install washer (6) and nut (5). Do not torque nut at
this time.
17. Apply a thin coat corrosion preventive compound
(C-102) under the head and to shank of bolt (1).
8. Assemble spacer (16), washer (23), washer (15)
on drive link bearing and install bolt (1) with washer (2)
under bolt head.
BHT-412-MM-6
9. Install washer (14) and nut (13). Torque nut (13)
165 to 200 in.-lbs. (18.64 to 22.60 N-m). Install cotter
pin (12).
10. Torque nut (5) 165 to 200 in.-lbs. (18.64 to 22.60
N-m). Install cotter pin (4).
11. Torque nut (18) 480 to 690 in.-lbs. (54.2 to 77.9
N-m). Install cotter pin (19).
12. Apply a thin coat of corrosion preventive
compound (C-101) on head of bolt (8 and 1), nut (13)
and washer (14), nut (5) and washer (6), and nut (18)
and washer (17).
13. Confirm control rigging is within limits (Chapter
67).
62-40. SWASHPLATE LINK ASSEMBLY
62-41. Removal
NOTE
To maintain track and balance, it is
recommended that swashplate links are
removed one at a time.
Prior to S/N 33108, three rephasing levers are
connected to swashplate links. On S/N 33108 and
subsequent, only two swashplate links are required.
1. Remove swashplate link with elastomerc rod end
bearings as follows:
a. Cut and remove lockwire from bolt (7, figure
62-15) and remove bolt (7) and washer (6).
b. Cut and remove lockwire from bolt (12) and
remove bolt (12) and washer (13).
c. Remove cotter pin (16), nut (15), washer (14),
bolt (9)washer (10) and anti-torque ushig (11).
bolt (9), washer (10) and anti-torque bushing (11).
d. Remove cotter pin (2), nut (3), washer (1), bolt
(18), washer (21), and anti-torque bushing (5).
e. Remove swashplate link assembly (19).
f. Repeat steps a. through e. to remove opposite
swashplate link assembly.
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BHT-412-MM-6 Bell Helicopter

SEE DETAIL B OR C

TORQUE 165 TO
200 IN-LBS
(18.64 TO

TORQUE 30 TO 40 IN-LBS

11. Anti-torque bushing

12. Bolt

18. Bolt
19. Swashplate link assembly

20. Rod end bearing

21. Washer (140-007-25S20C4)

NOTES:

shown in detail A.
412-M-62-15-1

Figure 62-15. Swashplate Link (Sheet 1 of 3)

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Page 46 Rev. 5
 Bell Helicopter BHT-412-MM-6

TORQUE 165 TO
200 IN-LB
(18.64 TO 22.60 Nm)

TORQUE 480

25. Bolt
26. Outer ring

29. Cotter pin

30. Nut
31. Bolt

35. Steelwasher
36. Cotter pin

DETAIL B
412-M-62-1-2

Figure 62-15. Swashplate Link (Sheet 2)

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BHT-412-MM-6 Bell Helicopter

LOOKING DOWN ON I^ IN-LBS

(2 PLACES)
DETAIL C DETAIL D
12 PLACES)

39. Long bushing, 412-010-461-105

41. Washer. 140-007-25S40C4

42. Nut, MS14144L6
43. Cotter pin, MS24665-302

LOOKING DOWN ON SWASHPLATE 49. Nut, MS14144L6

LOWER END OF LINK 50. Cotter pin, MS24665-302

DETAIL E 412-M-62-15-3

Figure 62-15. Swashplate Link (Sheet 3)

62-00-00
Page 48 Rev. 5
 Bell Helicopter BHT-412-MM-6

. 2. Remove swashplate link with uniball teflon lined

bearing as follows:
62-42. Installation

MATERIALS REQUIRED
a. Remove cotter pin (50, detail E), nut (49),
interrupter bracket (48), bolt (9), bushing (47), and
washer (10). Discard cotter pin (50). Refer to BHT-ALL-SPM for specifications and source.

b. Remove cotter pin (43, detail D), nut (42), NUMBER NOMENCLATURE
washer (41), short bushing (44), long bushing (39), and C-101 Corrosion Preventive
bracket (40). Compound

c. Remove swashplate link assembly (45). C-102 Corrosion Preventive

Compound
d. Repeat steps a. through c. to remove opposite C-405 Lockwire
swashplate link assembly.

3. Remove third swashplate link (prior to S/N 33108

only) as follows:
NOTE
Steps a. and b. are for swashplate links with
elastomeric rod end bearings installed. For
swashplate links with uniball rod end
bearings, perform step 2.b. from above in
lieu of steps a. and b.
a. Cut and remove lockwire from bolt (25) and
remove bolt (25) and washer (24).
b. Remove cotter pin (36), nut (37), washer (35),
bolt (31) with washer (34) under bolt head, and anti-
torque bushing (23).
NOTE
A thin coat of corrosion preventive
compound (C-102) should be applied to
shanks and under bolt heads of all rotating
control bolts prior to installation.
A thin coat of corrosion preventive
compound (C-101) should be applied to all
rotating control nuts, washers, and bolt
heads after installation.
1. If swashplate link assembly (19 or 32, figure 62-
15) is to be installed in same position it was removed
from without changing dimensions, proceed to step 3.

c. Remove cotter pin (29) from nut (30) and

remove nut (30) with safety washer (28).
CAUTION
d. Remove swashplate link assembly (32).
IF NEW OR REPLACEMENT LINK
e. Remove washer (27) from stud of outer ring ASSEMBLY IS BEING INSTALLED,
(26). COMPLIANCE WITH INSTRUCTIONS IN
STEP 2. IS MANDATORY TO ENSURE
ADEQUATE ROD END BEARING THREAD
ENGAGEMENT IS MAINTAINED.

2. If new or replacement swashplate link assembly

(19 or 32) is to be installed, adjust link to dimensions
outlined in BHT-412-CR&O manual.

3. To install swashplate link assembly with

elastomeric bearing proceed as follows:

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BHT-412-MM-6 Bell Helicopter
a. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (7).
b. Position bushing (5) in rephrasing lever driver
(4) and loosely install bolt (7) with washer (6).
c. Position swashplate link (19) 90° + 5 ° to
centerline of rephasing lever driver (4).
d. Ensure serrations of anti-torque bushing (5)
and swashplate link assembly (19) are properly
engaged.
e. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (18).
f. Install bolt (18) with washer (21) under bolt
head and washer (1) and nut (3). Do not torque at this
time.
g. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (12).
h. Position anti-torque bushing (11) in outer ring
(8) and loosely install bolt (12) and washer (13).
i. Position swashplate link driver (19) in outer
ring (8).
j. Ensure serrations of bushing (11) and link (19)
are properly engaged.
k. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (9).
I. Install bolt (9) with washer (10) under bolt
head, washer (14), and nut (15).
m. Torque nut (3) 165 to 200 in.-lbs. (18.64 to
22.60 N-m) and install cotter pin (2).
n. Torque bolt (7) 30 to 40 in.-lbs. (3.39 to 4.60
N-m). Secure bolt (7) to bushing (5) using lockwire (C-
405).
o. Torque nut (15) 165 to 200 in.-lbs. (18.64 to
22.60 N-m), and install cotter pin (16).
62-00-00
Page 50 Rev. 5
p. Torque bolt (12) 30 to 40 in.-lbs. (3.39 to 4.60
N-m). Secure bolt (12) to bushing (11) using lockwire
(C-405).
q. Apply a thin coat of corrosion preventive
compound (C-101) to nut (3) and washer (1), head of
bolt (7) and washer (6), nut (15) and washer (14), and
head of bolt (12) and washer (13).
r. Repeat steps a. through q. to install opposite
swashplate link assembly.
4. To install swashplate link with uniball teflon lined
bearing proceed as follows:
NOTE
The upper end of swashplate link assembly
(45) incorporating anti-rotation pin (46) rod
end must be installed first.
a. Position bracket (40) at end of rephasing lever
driver (4) arm in alignment with swashplate link (45)
anti-rotation pin (46).
NOTE
NOTE
Long bushing (39) passes through bracket
(40), rephasing lever driver (4) bushings,
and bottoms against swashplate link (45)
upper rod end.
b. Install long bushing (39) into side of bracket
(40) with head of bushing in direction of rotation
c. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (38).
d. Install bolt (38) with head in direction of
rotation through long bushing (39), swashplate link
(45) and short bushing (44). Install washer (41) and
nut (42) finger tight.
e. Install lower end of swashplate link (45) with
head of bolt (9) in direction of rotation.
f. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (9).
g. Install washer (10) under bolt head (9).
 h. Slide bushing (47) into swashplate outer ring
(8).
i. Apply a thin coat of corrosion preventive
compound (C-102) under the head and to shank of
bolt (9).
j. Install bolt (9) with washer (10) through
bushing (47), rod end (17), and swashplate outer ring
(8).
k. Install interrupter bracket (48) and nut (49).
I. Torque nut (49) 165 to 200 in.-lbs. (18.64 to
22.60 N-m) and secure with cotter pin (50).
m. Torque nut (42) 165 to 200 in.-lbs. (18.64 to
22.60 N-m) and secure with cotter pin (43).
n. Apply a thin coat of corrosion preventive
compound (C-101) to nut (49), head of bolt (9) and
washer (10), and nut (42) and washer (41).
5. Install third swashplate link (Prior to S/N 33108
only) as follows:
a. Install washer (27) on stud of outer ring (26).
b. Position swashplate link assembly (32) on
outer ring (26) and install safety washer (28) and nut
,,-~~~~~~~(30). ~bolts
(30).
c. Torque nut (30) 480 to 690 in.-lbs. (54.2 to
77.9 N-m) and install cotter pin (29).
NOTE
Steps d. through i. are for swashplate links
with elastomeric rod end bearings. For
swashplate links with uniball rod end
bearings, perform steps 4.a. through 4.d. in
lieu of steps d. through i.
d. Position anti-torque bushing (23) in rephasing
lever driver (22) and loosely install bolt (25) with
washer (24).
e. Position swashplate link assembly (32) 90 °
°
5 to centerline of rephasing lever driver (22).
f. Ensure serrations of bushing (23) and
swashplate link assembly (32) are properly engaged.
g. Install bolt (31) with washer (34) through rod
end bearing (33).
h. Install washer (35) and nut (37) on bolt (31).
i. Torque bolt (25) 30 to 40 in.-lbs. (3.39 to 4.60
N-m), and secure bolt (25) to bushing (23) using
lockwire (C-405).
j. Torque nut (37) 165 to 200 in.-lbs. (18.64 to
22.60 N-m) and install cotter pin (36).
COLLECTIVE PITCH DRIVE PLATE SET
62-43. COLLECTIVE PITCH DRIVE PLATE SET
62-44. Removal
NOTE
The collective pitch drive plate set is a serial
numbered, matched set.
1. Cut and remove lockwire from dust boot (2, figure
62-16) and remove dust boot (2) and spacer (1).
2. Remove eight nuts 10), aluminum washers (9),
(3), and aluminum washers (4).
3. Removedustbootflange (5).
LCAUTION
EXERCISE CARE WHEN REMOVING
PLATE SET HALVES (6 AND 11) OR SHIM
(7) TO PREVENT DAMAGE.
4. Remove plate set halves (6 and 11).
5. If collective pitch drive plate set is not to be
installed immediately, secure shim (7) to hub (8).
62-00-00
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BHT-412-MM-6 Bell Helicopter

1. Spacer
2. Dust boot
3. Bolt
SEE 4. Aluminum washer
DETAIL A 5. Dust boot flange
6. Plate set half
7. Shim

9. Aluminum washer
10. Nut
11. Plate set half

MASTER TOOTH

DETAIL A

Figure 62-16. Collective Pitch Drive Plate Set

62-00-00
Page 52 Rev. 5
 Bell Helicopter BHT-412-MM-6

62-45. Installation 4. Install bolts (3) with washers (4) under the heads
of bolts, washers (9), and nuts (10). Torque nuts (10)
MATERIALS REQUIRED 50 to 70 in.-lbs. (5.65 to 7.91 N-m).

Refer to BHT-ALL-SPM for specifications and source. 5. Apply a thin coat of corrosion preventive
compound (C-101) to nut (49), head of bolts (3) and
NUMBER NOMENCLATURE washers (4), and nuts (10) and washers (9).

C-101 Corrosion Preventive

Compound 6. Install boot (2) and spacer (1). Secure boot (2) to
mast (12) and boot flange (5) with lockwire (C-405).
C-102 Corrosion Preventive
Compound
62-46. COLLECTIVE LEVER ASSEMBLY
C-405 Lockwire
62-47. Removal

1. Remove cotter pin (12, figure 62-17), nut (13),

CAUTION washer (10), washer (11), bolt (7), washer (8) and
................... separate clevis (9) from trunnion (6). Discard cotter pin
SHIM (7, FIGURE 62-16) SHALL BE OF (12).
CORRECT THICKNESS TO GIVE 0.003
TO 0.005 IN. (0.076 TO 0.127 MM) PIN. ON 2. Cut and remove lockwire from bolt (17) and
HUB BEARINGS. IF SHIM (7) IS KNOWN remove bolt (17) and washer (18).
TO BE OF CORRECT THICKNESS,
PROCEED TO STEP 2. IF IT IS NOT
KNOWN WHETHER SHIM (7) IS OF
CORRECT THICKNESS, REFER TO BHT-
412-CR&O MANUAL TO ESTABLISH When removing shims (20 or 23), reinstall
SHIM THICKNESS. shims in the same location and order of
removal.

NOTE~3. Remove collective lever pin (19) and shims (20)

A thin coat of corrosion preventive or (23).
compound (C-102) should be applied to
shanks and under bolt heads of all rotating
control bolts prior
control bolts prior to
to installation.
installation. 4. Repeat 2. and 3. to remove opposite
collective leversteps
pin (19).
A thin coat of corrosion preventive
compound (C-101) should be applied to all
rotating control nuts, washers, and bolt NOTE
heads after there installation. When removing washers (3 and 15) and
spacers (4 and 16), reinstall in the same
1. Position plate set halves (6 and 11) on hub (8) location and order of removal.
and align as shown on detail A.
5. Remove cotter pin (1), nut (2), washer (3), bolt
2. Position dust boot flange (5) on plate set halves. (14), washer (15), spacers (4 and 16). Discard cotter
pin (1).
3. Apply a thin coat of corrosion preventive
compound (C-102) under the heads and to shanks of 6. Carefully remove collective lever assembly (5)
bolts (3). from support (22).

62-00-00
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BHT-412-MM-6 Bell Helicopter

DETAIL A

7. Bolt 19. Collective lever pin

8. Washer (AN960-C516) 20. Shim (helicopters not modified by TB 412.88-68)
9. Clevis 21. Bearing andliner
10. Washer (AN960-C516) 22. Support
11. Washer (AN960-C516L) 23. Shim (helicopters modified by TB 412-88-68)
12. Cotter pin DETAIL B

412-M62-17

Figure 62-17. Collective Lever

62-00-00
Page 54 Rev. 5
 Bell Helicopter BHT-412-MM-6

62-48. Cleaning 4. Touch up paint to match existing finish.

REQUIRED
MATERIALS REQUIRED 5. Replace trunnion which does not meet
requirements defined in BHT-412-CR&O manual.
Refer to BHT-ALL-SPM for specifications and source.
62-51. Installation (Helicopters with Collective
NUMBER NUMBERNOMENCLATURE Lever Pins 412-010-422-101 Installed)
C-304 Solvent MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications and source.

DO NOT IMMERSE COLLECTIVE LEVER C-309 Methyl-Ethyl-Ketone

ASSEMBLY IN SOLVENT. (MEK)
C-352 Sealant
1. Carefully clean collective lever (5, figure 62-17)
with clean cloth damp in solvent (C-304). C-405 Lockwire

2. Dry collective lever (5) with filtered, compressed

air. NOTE
If shims (20, figure 62-17) have been set
62-49. Inspection aside and are to be installed in same
location as removed, proceed to step 5. If
Inspect collective lever pins (19, figure 62-17) for new shims (20) are to be installed,
damage, cracks, and distortion. Damage in excess of accomplish steps 1. through 4.
superficial marks are not acceptable.
1. Position collective lever pin (19) on collective
62-50. Repair lever (5) and install washer (18) and bolt (17).
MATERIALS REQUIRED
2. Install opposite collective lever pin (19) in same
manner.
Refer to BHT-ALL-SPM for specifications and source.

NUMBER 3. Measure distance between shoulders on

NOMENCLATURE
NUMBER
NOMENCLATURE collective lever pins (19) and bearing and liners (21).
C-210 Paint Record dimension.

C-423 Abrasive Cloth or Paper 4. Measure outside dimension of bearing and liners
(21) and record dimension.
1. Polish out mechanical and corrosion damage with
fine to medium grades of abrasive cloth or paper (C- 5. Subtract value recorded in step 5. from dimension
423). Do not exceed limits defined in BHT-412-CR&O recorded in step 3. and record.
manual.
6. Prepare two shims (20) of equal thickness within
2. Apply chemical film material to all bare aluminum 0.005 in. (0.127 mm). Total thickness of two shims
~shall
areas. be equal to value recorded in step 5. plus up to
0.004 in. (0.1016 mm). This will result in 0.000 to
3. Apply paint (C-210) to areas where metal is 0.002 in. (0.000 to 0.050 mm) clamp up on each
exposed. bearing (21) when collective lever is installed.

62-00-00
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BHT-412-MM-6 Bell Helicopter
NOTE
It is possible to install collective lever (5,
figure 62-17) in inverted position. Ensure
collective lever (5) is installed with slotted
area for installation of trunnion (6) facing
down as illustrated.
7. Clean bores of lever, inside diameter of bearing
(21) and outside diameter of pins with MEK (C-309) or
equivalent.
8. Coat all faying surfaces of shims (20), pins (19),
lever bores, and bolts (17) with sealant (C-352).
9. Position collective lever pin (19) in each side of
collective lever (5). Position shim (20), indexed at time
of removal, or new shim prepared at step 6., on each
pin (19).
10. Carefully position collective lever (5), collective
lever pins (19) and shims (20) on swashplate support
assembly (22).
11. Install bolt (14) with washer (15) under bolt head,
then spacer (16). Install spacer (4), washer (3) and nut
(2).
12. Torque nut (2) 300 to 400 in.-lbs. (33.9 to 45.1 N-
m), and install cotter pin (1).
13. Ensure shim (20) is in position and insert pin (19)
into bearing (21).
NOTE
Steps d. through i. are for swashplate links
with elastomeric rod end bearings. For
swashplate links with uniball rod end
bearings, perform steps 4.a. through 4.d. in
lieu of steps d. through i.
14. Install bolt (17) with washer (18), and torque bolt
(17) 30 to 40 in.-lbs. (3.39 to 4.52 N-m).
15. Secure bolt (17) to pin (19) using lockwire (C-
405).
16. Install opposite collective lever pin (19) in same
manner.
62-00-00
Page 56 Rev. 5
17. Position clevis (9) on trunnion (6), and install bolt
(7) with washer (8) under bolt head.
18. Install nut (13) with washers (10 and 11) as
required to attain proper thread engagement for cotter
pin (12), and install cotter pin (12).
62-52. Installation (Helicopters with Collective
Lever Pins 412-010-422-103 Installed)
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-309 Methyl-Ethyl-Ketone
MEK
C-352 Sealant
C-405 Lockwire
NOTE
NOTE
It is possible to install collective lever (5,
figure 62-17) in inverted position. Ensure
collective lever (5) is installed with slotted
area for installation of trunnion (6) facing
down as illustrated.
1. Install collective lever (5, figure 62-17) on support
(22) as follows:
2. Install bolt (14) with washer (15) under bolt head,
and then install bushing (16).
3. Install bushing (4), washer (3), and nut (2) on bolt
(14).
4. Torque nut (2) 300 to 400 in.-lbs. (33.9 to 45.1 N-
m). Install cotter pin (1).
5. Position collective lever pins (19), without shims
(23), through either side of collective lever (5) into
bearing (21).
6. Install bolts (17) and washers (18) finger tight.
7. Measure distance between collective lever (5)
and hold down flange of collective lever pins (19).
Record dimension and remove collective lever pins.
 Bell Helicopter
8. Prepare two shims (23, detail B) of equal
thickness to within 0.005 in. (0.127 mm). Total
thickness of two shims shall be equal to value
recorded in step 7. minus up to 0.004 in. (0.1016 mm).
Maintaining these dimensions will result in a 0.000 to
0.002 in. (0.000 to 0.051 mm) clamp up on each
bearing when pins are installed,
9. Clean bores of lever, inside diameter of bearing
(21) and outside diameter of pins with MEK (C-309) or
equivalent.
11. Install shims (23) prepared in step 8. equally on
pins (19) and install pins in each side of collective
lever (5).
12. Ensure end of each pin is engaged in collective
lever sleeve bearings (21).
BHT-412-MM-6
NOTE
When installing bolt (17), ensure that the
bolt (17) has not bottomed out in the
collective lever or the spindle has become
thread bound. Either condition would result
in lower than specified torque on the pin
even though torque has been verified.
13. Install bolts (17) and washers (18).
15. Position clevis (9) on trunnion (6). Install bolt (7)
with washer (8) under bolt head.
16. Install nut (13) with washers (10 and 11) as
required to attain proper thread engagement for cotter
pin (12). Install cotter pin (12).
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 Bell Helicopter BHT-412-MM-6

CHAPTER 63 - MAIN ROTOR DRIVE SYSTEM

CONTENTS - MAINTENANCE PROCEDURES

Paragraph Chapter/Section Page

Number Title Number Number

MAIN ROTOR DRIVE SYSTEM

63-1 Main Rotor Drive ............................................................... 63-00-00 9

63-2 Metal Particle Contamination............................................ 63-00-00 9
63-3 Inspection ................................................................... 63-00-00 9
63-4 Identification ............................................................... 63-00-00 9

ENGINE-TO-TRANSMISSION (MAIN) DRIVESHAFT

63-5 Engine-to-Transmission (Main) Driveshaft ....................... 63-00-00 13

63-6 Troubleshooting ........... .................................................. 63-00-00 13
63-7 Maintenance............................................................... 63-00-00 13
63-8 Removal............................................................... 63-00-00 13
63-9 Cleaning............................................................... 63-00-00 13
63-10 Inspection ........................................ .... 63-00-00 13
63-11 Repair ........................................ .... 63-00-00 14
63-12 Lubrication ........................................................... 63-00-00 16
63-13 Installation............................................................ 63-00-00 16
63-14 Balancing ............................................................. 63-00-00 16
63-15 Engine-to-Driveshaft Curvic Coupling Adapter .......... 63-00-00 16
63-16 Removal............................................................... 63-00-00 16
63-17 Inspection ........................................ .... 63-00-00 18
63-18 Repair ........................................ .... 63-00-00 18
63-19 Installation............................................................ 63-00-00 18

MAIN ROTOR MAST

63-20 Main Rotor Mast ............................................................... 63-00-00 23

63-21 Maintenance............................................................... 63-00-00 23
63-22 Removal............................................................... 63-00-00 23
63-23 Cleaning............................................................... 63-00-00 24
63-24 Inspection and Repair.......................................... 63-00-00 24
63-25 Installation............................................................ 63-00-00 24
63-26 Torque Tube Assembly Alignment ............................. 63-00-00 28

TRANSMISSION

63-27 Transmission .................................................................... 63-00-00 31

63-28 Troubleshooting ......................................................... 63-00-00 31
63-29 Maintenance............................................................... 63-00-00 31
63-30 Removal............................................................... 63-00-00 31
63-31 Inspection ............................................................ 63-00-00 34
63-32 Build-up ...................................................................... 63-00-00 34
63-33 Installation............................................................ 63-00-00 43
63-34 Altemate Run-in Procedures ...................................... 63-00-00 44

63-00-00
Rev.5 Page 1
BHT-412-MM-6 Bell Helicopter

CONTENTS - MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

TRANSMISSION OIL SYSTEM COMPONENTS

63-35 Electric Chip Detectors ..................................................... 63-00-00 47

63-36 Mast Bearing Electric Chip Detector .......................... 63-00-00 47
63-37 Removal .............................................................. 63-00-00 47
63-38 Inspection ............................................................ 63-00-00 47
63-39 Cleaning .............................................................. 63-00-00 47
63-40 Installation ........................................................... 63-00-00 47
63-41 Main Input Gear Quill Electric Chip Detector ............. 63-00-00 47
63-42 Removal .............................................................. 63-00-00 48
63-43 Inspection ............................................................ 63-00-00 48
63-44 Cleaning .............................................................. 63-00-00 48
63-45 Installation ........................................................... 63-00-00 48
63-46 Sump Case Electrical Chip Detector.......................... 63-00-00 48
63-47 Removal .............................................................. 63-00-00 48
63-48 Inspection ............................................................ 63-00-00 49
63-49 Cleaning .............................................................. 63-00-00 49
63-50 Installation ........................................................... 63-00-00 50
63-51 Transmission Oil System Components ............................ 63-00-00 51
63-52 Planetary Oil Jets ....................................................... 63-00-00 51
63-53 Removal .............................................................. 63-00-00 51
63-54 Inspection ............................................................ 63-00-00 51
63-55 Cleaning .............................................................. 63-00-00 53
63-56 Repair.................................................................. 63-00-00 53
63-57 Installation ........................................................... 63-00-00 53
63-58 Oil Jet No. 1 ........................................ .... 63-00-00 54
63-59 Removal .............................................................. 63-00-00 54
63-60 Inspection ......................... ............................ 63-00-00 54
63-61 Cleaning .............................................................. 63-00-00 54
63-62 Repair .................................................................. 63-00-00 54
63-63 Installation ........................................................... 63-00-00 54
63-64 Oil Jet No. 2 ........................................ .... 63-00-00 55
63-65 Removal .............................................................. 63-00-00 55
63-66 Inspection ............................................................ 63-00-00 55
63-67 Cleaning .............................................................. 63-00-00 55
63-68 Repair.................................................... ............. 63-00-00 . 55
63-69 Installation ........................................................... 63-00-00 55
63-70 Oil Jet No. 3 ........................................ .... 63-00-00 55
63-71 Removal .............................................................. 63-00-00 55
63-72 Inspection ............................................................ 63-00-00 55
63-73 Cleaning ......... ... ........................................ 63-00-00 55
63-74 Repair.................................................................. 63-00-00 55
63-75 Installation ........................................................... 63-00-00 55
63-76 Oil Jet No. 4 ........................................ .... 63-00-00 58
63-77 Removal .............................................................. 63-00-00 58
63-78 Inspection ............................................................ 63-00-00 58
63-79 Cleaning ....................................... 63-00-00 58
63-80 Repair .................................. 63-00-00 58

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 CONTENTS - MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-81 Installation............................................................ 63-00-00 58

63-82 Oil Jet No. 5 ............................................................... 63-00-00 58
63-83 Removal............................................................... 63-00-00 58
63-84 Inspection ............................................................ 63-00-00 58
63-85 Cleaning............................................................... 63-00-00 58
63-86 Repair.................................................................. 63-00-00 58
63-87 Installation............................................................ 63-00-00 61
63-88 Oil Jet No. 6 ............................................................... 63-00-00 61
63-89 Removal............................................................... 63-00-00 61
63-90 Inspection ............................................................ 63-00-00 61
63-91 Cleaning............................................................... 63-00-00 61
63-92 Repair .................................................................. 63-00-00 61
63-93 Installation............................................................ 63-00-00 61
63-94 Oil Jet No. 7 ............................................................... 63-00-00 61
63-95 Removal............................................................... 63-00-00 61
63-96 Inspection ............................................................ 63-00-00 61
63-97 Cleaning............................................................... 63-00-00 61
63-98 Repair .................................................................. 63-00-00 62
63-99 Installation............................................................ 63-00-00 62
63-100 Oil Pressure Regulating Valve ................................... 63-00-00 62
63-101 Removal............................................................... 63-00-00 62
63-102 Cleaning............................................................... 63-00-00 64
63-103 Inspection ............................................................ 63-00-00 64
63-104 Repair .................................................................. 63-00-00 64
63-105 Installation............................................................ 63-00-00 64
63-106 Oil Temperature Manifold........................................... 63-00-00 64
63-107 Removal............................................................... 63-00-00 64
63-108 Installation............................................................ 63-00-00 67
63-109 Oil Pressure Transmitter ............................................ 63-00-00 67
63-110 Removal. ............................... ...................... 63-00-00 67
63-111 Inspection ........................................ 63-00-00 67
63-112 Installation............................................................ 63-00-00 67
63-113 Oil Pressure Switch................................................... 63-00-00 68
63-114 Removal............................................................... 63-00-00 68
63-115 Inspection ........................................ 63-00-00 68
63-116 Installation............................................................ 63-00-00 68
63-117 Oil Pressure Manifold.............................................. 63-00-00 68
63-118 Removal.............................................................. 63-00-00 68
63-119 Cleaning............................................................... 63-00-00 68
63-120 Inspection ........................................ 63-00-00 68
63-121 Repair.................................................................. 63-00-00 68
63-122 Installation............................................................ 63-00-00 70
63-123 Filler Neck, Scupper, and Mounting Bracket .............. 63-00-00 70
63-124 Removal............................................................... 63-00-00 70
63-125 Cleaning............................................................... 63-00-00 70
63-126 Inspection ............................................................ 63-00-00 70
63-127 Installation............................................................ 63-00-00 70
63-128 Oil Pump ................................................. 63-00-00 73
63-129 Removal............................................................... 63-00-00 73

63-00-00
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 CONTENTS - MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-130 Installation ........................................................... 63-00-00 73

63-131 Oil Pump Inlet Screen ................................................ 63-00-00 75
63-132 Removal .............................................................. 63-00-00 75
63-133 Inspection ............................................................ 63-00-00 75
63-134 Cleaning .............................................................. 63-00-00 75
63-135 Installation ........................................................... 63-00-00 75
63-136 Sump Internal Filter ................................................... 63-00-00 75
63-137 Removal .............................................................. 63-00-00 75
63-138 Inspection ............................................................ 63-00-00 77
63-139 Cleaning .............................................................. 63-00-00 77
63-140 Installation ........................................................... 63-00-00 77
63-141 Full Flow Debris Monitor ........................................... 63-00-00 79
63-142 Removal .............................................................. 63-00-00 79
63-143 Inspection ............................................................ 63-00-00 79
63-144 Cleaning .............................................................. 63-00-00 79
63-145 Installation ........................................................... 63-00-00 80
63-146 Sight Glasses ............................................................. 63-00-00 80
63-147 Removal .............................................................. 63-00-00 80
63-148 Cleaning .............................................................. 63-00-00 82
63-149 Inspection ............................................................ 63-00-00 82
63-150 Installation ........................................................... 63-00-00 82

TRANSMISSION OIL COOLING SYSTEM

63-151 Transmission Oil Cooling System ..................................... 63-00-00 87

63-152 External Oil Filter........................................................ 63-00-00 87
63-153 Removal ........................................ .... 63-00-00 87
63-154 Inspection ........................................ .... 63-00-00 87
63-155 Cleaning .............................................................. 63-00-00 87
63-156 Installation ........................................ .... 63-00-00 87
63-157 Thermal Bypass Valve ............................................ 63-00-00 88
63-158 Removal ........................................ .... 63-00-00 88
63-159 Cleaning ........................................ .... 63-00-00 88
63-160 Installation ........................................ .... 63-00-00 88
63-161 Oil Drain Valves ........................................ .... 63-00-00 89
63-162 Removal ........................................ .... 63-00-00 89
63-163 Cleaning ........................................ .... 63-00-00 89
63-164 Inspection ........................................ .... 63-00-00 89
63-165 Installation ........................................ .... 63-00-00 89
63-166 Transmission Oil Cooler and Blower .......................... 63-00-00 91

TRANSMISSION QUILLS

63-167 Transmission Quills ........................................ .... 63-00-00 93

63-168 Main Input Quill ........................................ .... 63-00-00 93
63-169 Removal ........................................ .... 63-00-00 93
63-170 Cleaning .............................................................. 63-00-00 93
63-171 Inspection ............................................. .............. 63-00-00 93
63-172 Repair .................................................................. 63-00-00 94.

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 Bell Helicopter BHT-412-MM-6

CONTENTS - MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-173 Installation ............................................................ 63-00-00 94

63-174 Main Input Quill Magnetic Seal (412-040-111) .......... 63-00-00 97
63-175 Removal ............................................ 63-00-00 97
63-176 Cleaning ............................................ 63-00-00 98
63-177 Inspection ........................................ .... 63-00-00 98
63-178 Repair.................................................................. 63-00-00 98
63-179 Installation...........................................................
. 63-00-00 98
63-180 Main Input Quill Seal (28203-3655) ........................... 63-00-00 104
63-181 Removal ............................................ 63-00-00 104
63-182 Cleaning ............................................ 63-00-00 105
63-183 Inspection ........................................ .... 63-00-00 105
63-184 Repair ................................................................. 63-00-00 105
63-185 Installation ........................................ .... 63-00-00 105
63-186 No. 1 Hydraulic Pump Drive Quill............................... 63-00-00 108
63-187 Removal ............................................ 63-00-00 108
63-188 Cleaning ............................................ 63-00-00 108
63-189 Inspection ........................................ .... 63-00-00 108
63-190 Repair ............................................ 63-00-00 109
63-191 Installation ............................................ 63-00-00 109
63-192 No. 2 Hydraulic Pump Drive Quill............................... 63-00-00 110
63-193 Removal............................................................. 63-00-00 110
63-194 Cleaning ............................................ 63-00-00 110
63-195 Inspection ........................................ .... 63-00-00 110
63-196 Repair .. .......................................... 63-00-00 110
63-197 Installation ............................................ 63-00-00 112
63-198 Rotor Tachometer Generator . .................................... 63-00-00 112
63-199 Removal ................................ ...................... 63-00-00 112
63-200 Cleaning ............................................ 63-00-00 112
63-201 Inspection ........................................ .... 63-00-00 112
63-202 Repair .. .......................................... 63-00-00 114
63-203 Installation ............................................ 63-00-00 114
63-204 Tail Rotor Drive Quill .................................................. 63-00-00 115
63-205 Removal ............................................ 63-00-00 115
63-206 Inspection ........................................ .... 63-00-00 115
63-207 Cleaning ............................................ 63-00-00 116
63-208 Repair.................................................................. 63-00-00 117
63-209 Installation ............................................ 63-00-00 117
63-210 Rotor Brake Quill ............................................ 63-00-00 117
63-211 Removal ............................................................ 63-00-00 117
63-212 Cleaning ............................................ 63-00-00 118
63-213 Inspection ........................................ .... 63-00-00 118
63-214 Repair .................................................................. 63-00-00 118
63-215 Installation............................................................ 63-00-00 118

TRANSMISSION QUILL PORT COVERS

63-216 Transmission Quill Port Covers ........................................ 63-00-00 123

63-217 Removal ........................................ ... . 63-00-00 123
63-218 Installation . .................................................................63-00-00 123

63-00-00
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BHT-412-MM-6 Bell Helicopter

CONTENTS - MAINTENANCE PROCEDURES (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

TRANSMISSION MOUNTS

63-219 Transmission Mounts ........................................ .... 63-00-00 125

63-220 Aft Isolation Mount and Friction Dampers .................. 63-00-00 125
63-221 Removal ........................................ .... 63-00-00 125
63-222 Inspection (Transmission Mounts) ....................... 63-00-00 125
63-223 Inspection (Aft Mount Friction Dampers) ............. 63-00-00 125
63-224 Installation ........................................ .... 63-00-00 127
63-225 Forward Isolation Mounts .................................... 63-00-00 127
63-226 Inspection ........................................ .... 63-00-00 127
63-227 Installation ........................................ .... 63-00-00 127
63-228 Lift Link....................................................................... 63-00-00 127
63-229 Removal ........................................ .... 63-00-00 127
63-230 Cleaning ........................................ .... 63-00-00 130
63-231 Inspection and Repair.......................................... 63-00-00 130
63-232 Installation ........................................ .... 63-00-00 130
63-233 Lift Link Fitting ........................................ .... 63-00-00 130
63-234 Removal ........................................ .... 63-00-00 130
63-235 Cleaning ........................................ .... 63-00-00 132
63-236 Inspection and Repair.......................................... 63-00-00 132
63-237 Installation ........................................ .... 63-00-00 132

SERVICEABILITY CHECKS

63-238 Serviceability Checks - Transmission, Tail Rotor

Gearbox and Intermediate Gearbox ................................. 63-00-00 135
63-239 Transmission ............................................................ 63-00-00 135
63-240 Intermediate or Tail Rotor Gearbox ........................... 63-00-00 135

FIGURES

Figure Page
Number Title Number

63-1 Analysis of Drive System Chip Detector Debris ........................................ 10

63-2 Engine-to-Transmission (Main) Driveshaft ................................................. 15
63-3 Main Driveshaft - Damage Limits .............................................................. 19
63-4 Engine to Driveshaft Curvic Coupling Adapter ......................................... 21
63-5 Engine to Driveshaft Curvic Coupling Wrench Set - Tool Application ........ 21
63-6 Main Rotor M ast.........................................................................................25
63-7 Mast Driving Adapter to Transmission Top Case Dimension
Requirem e nts ............................................................................................. 27
63-8 T ransm ission .............................................................................................. 32
63-9 Transmission Removal and Installation .................................................... 35
63-10 Transmission Assembly ........................................... ............................ 37
63-11 Transmission Build-up ........................................ ................. 39
63-12 Mast Bearing Electric Chip Detector......................................................... 49
63-13 Electric Chip Detector (Typical) - Damage Limits ...................................... 50

63-00-00
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 Bell Helicopter BHT-412-MM-6

FIGURES (CONT)

Figure Page
Number Title Number

63-14 Main Input Gear Quill Electric Chip Detector ........................................... 51

63-15 Sump Case Electric Chip Detector ............................................................ 52
63-16 Sump Case Electric Chip Detector - Damage Limits .................................. 53
63-17 Planetary Oil Jet ......................................................................................... 54
63-18 Oil Jet N o. 1 ................................................................................................ 56
63-19 O il Jet N o. 2 ................................................................................................ 57
63-20 Oil Jet N o. 3 ................................................................................................ 59
63-21 Oil Jet N o. 4 ................................................................................................ 60
63-22 Oil Jet N o. 5................................................................................................ 62
63-23 Oil Jet N o. 6 ................................................................................................ 63
63-24 Oil Jet N o. 7 ................................................................................................ 65
63-25 Oil Pressure Regulator Valve ..................................................................... 66
63-26 Oil Temperature Manifold ........................................................................... 69
63-27 Oil Pressure Transmitter............................................................................. 71
63-28 Oil Pressure Switch .................................................................................... 72
63-29 Oil Pressure Manifold ................................................................................. 74
63-30 Filler Neck, Scupper, and Mounting Bracket .............................................. 76
63-31 Transmission Oil Pump ............................................................................. 78
63-32 Oil Pump Screen ....................................................................................... 79
63-33 Oil Pump Inlet Screen - Damage Limits...................................................... 80
63-34 Sump Intemal Filter (pre T.B. 412-91-94) .................................................. 81
63-35 Sump Internal Filter .................................................................................... 82
63-36 Sump Internal Filter - Damage Limits ......................................................... 83
63-37 Full Flow Debris Monitor ............................................................................. 84
63-38 Sight Glass ................................................................................................. 85
63-39 Transmission External Oil Filter.................................................................. 90
63-40 Thermal Oil Bypass Valve .......................................................................... 91
63-41 O il D rain Valve ............................................................................................ 92
63-42 M ain Input Q uill........................................................................................... 95
63-43 Main Input Quill Assembly .......................................................................... 97
63-44 Pusher Set, T101586-5, Application ........................................ ............ 99
63-45 Main Input Quill Magnetic Seal ................................................................... 101
63-46 Tool Application - Spline Wrench (T101306), Wrench Set (T101588),
and Extension Bar (L-122) ......................................................... 102
63-47 Main Input Quill Curvic Coupling Adapter and Magnetic Seal Assembly ... 103
63-48 Main Input Quill Seal (28203-3655) .......................................................... 106
63-49 No. 1 Hydraulic Pump Drive Quill ........................................ ................. 111
63-50 No. 1 Hydraulic Pump Drive Quill Assembly ............................................... 113
63-51 No. 2 Hydraulic Pump Drive Quill ........................................ ................. 114
63-52 Rotor Tachometer Generator ......................................................... 116
63-53 Tail Rotor Drive Quill ........................................ ................. 119
63-54 Rotor Brake Quill ........................................ ................. 121
63-55 Quill Port Covers ........................................ ................. 124
63-56 Transmission Aft Isolation Mounts and Friction Dampers .......................... 126
63-57 Isolation Mount Inspection Work Aid - Tool Application ............................. 128
63-58 Forward Isolation Mounts ............................................... .......... 129
63-59 Transmission Lift Link................................................................................. 131
63-60 Lift Link Fitting ............................................................................................ 133

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BHT-412-MM-6 Bell Helicopter

TABLES

Table Page
Number Title Number

63-1 Troubleshooting - Engine-to-Transmission (Main) Driveshaft.................. 14

63-2 Main Driveshaft TEMP-PLATE Condition and Corrective Action ............... 17

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Page 8 Rev. 5
 Bell Helicopter
MAIN ROTOR DRIVE SYSTEM
63-1. MAIN ROTOR DRIVE
This chapter contains maintenance instructions for the
drive system components which transmit power from
the engine to the main rotor assembly and to
transmission mounted accessories. This includes the
engine-to-transmission (main) driveshaft, transmission
and related components, and main rotor mast
assembly.
63-2. METAL PARTICLE CONTAMINATION
INSPECTION
63-3. INSPECTION
63-3.
Metal particles found in transmission oil, screens,
filters, or accumulated on chip detectors may indicate
impending failure of an internal part of the
transmission. The presence of metal particles is not
necessarily an indication the transmission, or
component part, is no longer serviceable (paragraph
63-238). The quantity, source, form, and type of metal,
together with the service history of the particular
component, must be taken into consideration. The
time accumulated since the gearbox was new or
overhauled, previous failures, and type of operation
are important factors in determining further
serviceability. The particles found may be steel,
aluminum, magnesium, or phenolic in various shapes
and quantities. Refer to figure 63-1 for disposition of
metal particle contaminated transmissions.
63-4. IDENTIFICATION
CAUTION
.. ............
WHEN PARTICLES FOUND ARE
READILY IDENTIFIABLE AS FRAGMENTS
OF TRANSMISSION PARTS SUCH AS
BHT-412-MM-6
GEARS, HARDWARE, BEARINGS,
LOCKWIRE, OR OTHER INTERNAL
COMPONENTS, REPLACE
TRANSMISSION, MAST ASSEMBLY, OIL
COOLER, AND EXTERNAL OIL FILTER
ELEMENTS. CLEAN AND THOROUGHLY
FLUSH ALL OIL LINES WITH OPERATING
OIL (CHAPTER 12).
Visual inspection of color and hardness may identify
particles. When a particle cannot be positively
identified by visual means, perform the following tests
with a permanent magnet, concentrated hydrochloric
acid and concentrated nitric acid.
1. STEEL. Isolate steel particles with a permanent
magnet.
2. ALUMINUM. Identify aluminum particles by
reaction to hydrochloric acid. When a particle of
aluminum is immersed in into hydrochloric acid, the
solution will fizz vigorously and the particles will
gradually disintegrate. A black residue will remain.
NOTE
Magnesium and aluminum react similarly in
hydrochloric acid. When in doubt, drop
particle in nitric acid. Aluminum does not
react noticeably in nitric acid while
magnesium does.
3. COPPER OR BRONZE. Particles of copper or
bronze will form a bright green cloud in nitric acid.
63-00-00
Rev. 5 Page 9
 NOTE:

The following information contained in this figure is provided for the evaluation of contamination
found on the drive system chip detectors.

It is impossible to depict the shapes of all possible particulates contamination, especially those
particles not generated within a gearbox, as a result of component wear or failure. However, the
following basic assumptions will permit a rather accurate assessment of any debris found, even
though the particles may be severely distorted as a result of passing through gear meshes.

DESCRIPTION:

Material, from the surfaces of gear teeth or rolling element bearings, is quite hard. Particles
broken from these surfaces may have razor-sharp edges but rarely have sharp pointed ends.
With few exceptions, surfaces of such particles will not appear smeared (as if cut by a shear)
under magnification; a grainy appearance on the fracture surfaces is more common.

When damaged by passing through gear meshes, these hard particles tend to break up with
relatively little deformation.

Foreign ferrous material introduced into gearboxes is often much softer than the surfaces of
gear teeth and bearings. The same is true of most nongear and nonbearing components
within gearboxes. The softer materials are usually quite ductile and malleable, i.e., particles
from such materials can be readily bent or rolled into a wide range of shapes without
fracturing.

Fragments of the softer material are capable of being torn or sheared from the parent
component without suffering brittle fracture (easily broken or snapped). Instead, during
separation the fragments are distorted and stretched such that they often exhibit surfaces that
appear stretched. Ends of soft material fragments are often sharp-pointed; the ductile nature
of the material permits such a condition.
Each type of debris has been identified as significant debris or insignificant debris at the
beginning of the explanation of significance to aid in troubleshooting.
CAUTION:
RECURRING ACCUMULATION OF INSIGNIFICANT DEBRIS WILL REQUIRE
OVERHAUL/REPAIR OF GEARBOX.

TYPICAL APPEARANCE DESCRIPTION SIGNIFICANCE

A few moderately-sized and/or (SIGNIFICANT DEBRIS)

numerous small nearly-flat flakes: This is a classic indication of
rolling element bearing failure.
flakes appears very smooth. alsoindicatespallingofgearteelh.
Flakes are silvery in color with an
occasional black side.
Common term for this condition Is OVERHAUL/REPAIR
flakes. GEARBOX

412-M63-1-1
Figure 63-1. Analysis of Drive System Chip Detector Debris (Sheet 1 of 3)

63-00-00
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 Bell Helicopter BHT-412-MM-6

TYPICAL APPEARANCE DESCRIPTION SIGNIFICANCE

Irregularly-shaped ferrous chunks (SIGNIFICANT DEBRIS)

of various sizes and shapes: Existence of this type of debris
most likely indicates gear and/or
Under magnification, one or more bearing damage within the drive
sides of particles appears rough system component.
and grainy. Color of particles is
silvery-gray often with one or more OVERHAUL/REPAIR
sides black. GEARBOX
This condition has no common
term.
Spiral curls or comma-shaped (INSIGNIFICANT DEBRIS)
particles:
Particles are fragments of chips or
When examined shavings produced during the
under
machining of ferrous components.
magnification, particles are often
Such contamination is often
smooth and shiny on their convex
introduced into the drive system
surfaces and quite rough on the
components on tools, during
other surfaces and edges. Colorof
dusting operations within the
particles is usually dull gray on
rough surfaces. component assembly area using
compressed air.
Common term for condition Is No corrective action is required
manufacturing debris, following discovery of such
material.

RECHECK DETECTOR DAILY

FOR NEXT 25 FLIGHT HOURS
Hair-like ferrous debris: (INSIGNIFICANT DEBRIS)
May have reclangularortriangular Debris commonly are scrapings,
cross sections. Generally 0.030 produced as components, and are
assembly of the drive system
thickness. Length may range from
0.100 inch (2.54 mm) to over components. Debris of this
general shape is also produced,
1.000 inch (25.4 mm). Color of
debris is usually light gray after long term operation, at the
corners of wear surfaces of such
although one or more sides may
have a black appearance. parts as Iransmission planetary
supports. This type debris can be
Common term for condition is Introduced Into the component
hairs. during periodic servicing.
Hairs can appear on chip
detectors at any point In the life of
the drive system component.
However, discovery of such
material does not necessitate any
corrective action.

RECHECK DETECTOR DAILY

FOR NEXT 25 FLIGHT HOURS
412-M63-1-2

Figure 63-1. Analysis of Drive System Chip Detector Debris (Sheet 2)

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BHT-412-MM-6 Bell Helicopter

TYPICAL APPEARANCE DESCRIPTION SIGNIFICANCE

Irregular-shaped ferrous particles: (INSIGNIFICANT DEBRIS)

Usually triangular In cross Particles of this type are

sections. Often spike-like Incommonly the result of tool
appearance. Under magnification.
slippage during assembly of the
drive system component. An
one side of triangular section will
usually appear sheared. Colorexample would be the sliver of
may be silvery-gray or black with
metal tor from the edge of a
one or more silver sides. screw slot as a screwdriver blade
Existence of two or more particles
slips out of place.
of this type on a chip detector at
This type of debris would most
any one time is rare. likely appear during the first 50
hours of operation following
Common term for condition is component assemblyorextensive
manufacturing debris. maintenance.
No corrective actions are required
following discovery of such
material.

RECHECK DETECTOR DAILY

Tiny whisker-like particles or
groups of dark microscopic
particles:
When removed with tape or
paper towel, apparently-large
chips disappear into a black
smudge.
FOR NEXT 25 FLIGHT HOURS
(INSIGNIFICANT DEBRIS)
Generally microscopic wear
particles produced by normal
wear within drive system
component. Particles are often
grouped by the field of the chip
detector magnet to assume the
shape of apparently large chips.

Common term for condition is Such material is common in

smudge or fuzz. gearboxes having several
hundred operating hours. In such
cases, this condition does not
necessitate corrective action.

Appearance of this type of debris

in relatively new or
recently-overhauled gearboxes
may indicate bearing or gear
micropitting. In such cases
detector should be inspected
more frequently for signs of
progressing damage.

RECHECK DETECTOR DAILY

FOR NEXT 25 FLIGHT HOURS

412-M-63-1-3

Figure 63-1. Analysis of Drive System Chip Detector Debris (Sheet 3)

63-00-00
Page 12 Rev. 5
 ENGINE-TO-TRANSMISSION (MAIN) DRIVESHAFT
63-5. ENGINE-TO-TRANSMISSION (MAIN)
DRIVESHAFT
The main driveshaft is installed between an adapter on
the engine combining (reduction) gearbox and input
drive quill on transmission. The driveshaft is a steel
tube with grease lubricated, spherical, splined
coupling assemblies on either end to provide flexibility.
63-6. TROUBLESHOOTING
Refer to table 63-1.
The following paragraphs provide maintenance
instructions for the main driveshaft. Vibration analysis
and balancing is contained in Chapter 62.
63-8. Removal
1. Remove left and right air inlet fairings.
2. Open left engine top cowling. Disconnect fire
detector leads at firewall. Disconnect left starter
generator air hose from vent in engine cowl.
3. Remove left engine top cowling.
4. Support driveshaft (4, figure 63-2) and remove
bolts (2 and 5).
NOTE
Index mark couplings (1 and 7) for
installation in same location.
Helicopters S/N 36020 and subsequent,
and helicopters modified by 412-570-001-
103 refer to figure 63-2, detail B.
5. Push driveshaft (4) forward until aft end is free.
Remove driveshaft.
63-9. Cleaning
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
C-304 Solvent
1. Prior to cleaning, inspect driveshaft for lubricant
leakage (figure 63-3).
DO NOT IMMERSE DRIVESHAFT IN
SOLVENT OR ANY CLEANING AGENTS.
2. Clean driveshaft parts, except boots (3 and 5),
304).
3. Dry driveshaft with filtered, compressed air.
4. Clean boots (3 and 5) with a clean, dry, lint-free
cloth.
63-10. Inspection
1. Inspect driveshaft in accordance with figure 63-3.
2. Perform serviceability check of over-temperature
indicator (TEMP-PLATE) as follows:
a. Over-temperature indicators (TEMP-PLATE)
must not show evidence of over-temperature,
deterioration, debonding, or discoloration of the epoxy
coating that prevents interpretation of the indicating
dots. If any of these conditions exist, proceed to step
b
b. If only one over-temperature indicator (TEMP-
PLATE) of a given color is missing, and no dot on any
other over-temperature indicator (TEMP-PLATE) (on
the same coupling) is discolored or shows mechanical
damage or degradation of the epoxy overcoating, the
helicopter may be returned to service. The discrepant
over-temperature indicator (TEMP-PLATE) should be
replaced as soon as practical.
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BHT-412-MM-6 Bell Helicopter

Table 63-1. Troubleshooting - Engine-to-Transmission (Main) Driveshaft

INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

High frequency vibration Improperly assembled driveshaft. Remove, disassemble, inspect,

Loss of grease from coupling.
Loose engine adapter or adapter
bolt.
Dirt or burr on mounting diameters
of driveshaft.
Loose coupling bolt(s).
and assembly driveshaft (BHT-
412-CR&O).
Remove, disassembly, inspect,
assembly, and install coupling
(BHT-412-CR&O).
Remove, inspect, and install
engine adapter.
Remove, inspect, clean, and install
driveshaft.
Loosen, then retighten coupling
bolts in sequence.

Driveshaft out of balance. Balance driveshaft (Chapter 18).

Improperly assembled driveshaft Remove, disassemble, inspect,
coupling, assembly, and install coupling
(BHT-412-CR&O).

Grease leakage Faulty packings or seals. Replace packings or seals (BHT-

412-CR&O).

Over-temperature indicator Refer to paragraph 63-10.

(TEMP-PLATE) shows discolora-
tion (from white to black)

c. If any indicator dot on either the red or yellow 1. Polish out acceptable defects on driveshaft (4,
bordered over-temperature indicator (TEMP-PLATE) figure 63-3). Use minimum radius of 0.500 in. (1.270
has changed color to black, see table 63-2 for mm) in polishing out surface damage. Ensure damage
probable cause and required corrective action. limits are not exceeded.

63-11. Repair 2. Refinish polished area with two coats of primer

(C-204).

MATERIALS REQUIRED 3. Replace over-temperature indicator (TEMP-

PLATE) (7) if mutilated or discolored (BHT-412-
Refer to BHT-ALL-SPM for specifications and source. CR&O).

NUMBER NOMENCLATURE

C-204 Primer

63-00-00
Page 14 Rev. 5
 Bell Helicopter BHT-412-MM-6

1. Flexible coupling (forward) 8. Nut

2. Bolt 9. Steel washer
3. Steel washers 10. Engine-to-drveeshaft curvic coupling adapter
4. Driveshaft 11. Main input quill curvic coupling adapter
5. Bolt 12. Steel washer
6. Steel washers 13. Nut
7. Flexible coupling (aft)
NOTES

Torque 1/4 inch bolts (2 and 5) 70 to 90 IN-LBS (7.91 to 10.27 Nm). Torque 5/16 inch bolts
(2 and 5) 100 to 140 IN-LBS (11.3 to 15.8 Nm). Torque bolts (2 and 5) in three steps,
one-third full torque, two thirds full torque and full torque respectively. Tighten bolts in
sequence as shown on detail A. Repeat sequence at each torque step.

Washer under bolt head only on 1/4 inch bolts (S/N 36020 and subsequent).

Washer under nut only on 5/16 inch bolts (S/N 33001 thru 33213 and 36001 thru 36019).
412-M-63-2

Figure 63-2. Engine-to-Transmission (Main) Driveshaft

63-00-00
Rev. 5 Page 15
63-12. Lubrication 7. After rotor is stopped, inspect couplings (1 and 7)
and surrounding structure for evidence of grease
Refer to BHT-412-CR&O for coupling lubrication leakage. If there is evidence of grease leakage,
instructions, remove driveshaft and inspect in accordance with
BHT-412-CR&O.
63-13. Installation
63-14. Balancing
NOTE Refer to Chapter 18 for balancing procedures.
Driveshaft (4 figure 63-2) may be installed
with either end forward. It is recommended 63-15. ENGINE-TO-DRIVESHAFT CURVIC
however, coupling with identification plate COUPLING ADAPTER
be installed in the forward position. 63-16. Removal
63-16. Removal
Helicopters S/N 36020 and subsequent, SPECIAL TOOLS REQUIRED
and helicopters modified by 412-570-001-
103 refer to figure 63-2, detail B.
NUMBER NOMENCLATURE
1. Position driveshaft in center firewall. T101588Wrench Set - Curvic
Coupling, or
NOTE T103063 Wrench Set (S/N 36020
and Subsequent and
It is necessary to push couplings (1 and 7) Helicopters Modid
412-570-001-103)
step. If possible, compress couplings
approximately an equal amount to avoid
displacing lubricant inside couplings. 1. Remove main driveshaft (paragraph 63-8).

2. Position coupling (1) on adapter (11). Position
coupling (7) on adapter (10). Install, but do not tighten,
bolts (2), washers (12), and nuts (13). Install, but do
not tighten, bolts (5), washers (9), and nuts (8).
3. Torque bolts (2 and 5) in accordance with
instructions on figure 63-2.
4. Connect starter generator air hose and connect
fire detector leads.
2. Straighten tang of washer (3, figure 63-4) to
permit removal of nut (4).
3. Position plate assembly (7, figure 63-5) on
adapter (1) and install retaining nut (4).
4. Install extension bar (6). Hold plate assembly (7)
and turn extension bar to loosen nut (5).
5. Remove extension bar (6), plate assembly (7),
and nut (5).

6. Remove adapter (2, figure 63-4).

NOTE 7. Discard washer (3).

Ground run and leak check must be
performed following installation of new,
repaired, or relubricated driveshaft
coupling.

6. Perform ground run of helicopter for

approximately five minutes at 100% rotor rpm (BHT-
412-FM).

63-00-00
Page 16 Rev. 5
 Bell Helicopter BHT-412-MM-6

Table 63-2. Main Driveshaft TEMP-PLATE Condition and Corrective Action

ONE YELLOW OTHERYELLOW ONE RED OTHER RED PROBABLE SEE

TEMP-PLATE TEMP-PLATE TEMP-PLATE TEMP-PLATE CAUSE NOTE

Good Black Good Good Defect/Instl. 1

Black Black Good Good Elevated Temp. 2
Good Good Black Good Defect/lnstl. 1
Good Good Black Black Defect/Instl. 4
Black Black Black Black Overtemp 3
Part Black Good Good Good Chem. Contamination 1
Part Black Part Black Good Good Chem. Contamination 1
Good Good Part Black Good Chem. Contamination 1
Good Good Part Black Part Black Chem. Contamination 4
Missing Good Good Good Defect/Instl. 1
Possible Elevated 2
Missing Missing Good Good Temperature
Temperature
Good Good Missing Good Defect/Instl. 1
Good Good Missing Missing Defect/lnstl. 4
Missing Missing Missing Missing Possible Overtemp 3
NOTES:
1. Resume operation. Defective TEMP-PLATE or improper installation, replace defective TEMP-PLATE as
soon as practical in accordance with BHT-412-CR&O Manual.
2. Elevated coupling temperature is indicated. Determine probable cause of elevated temperature indication
and take corrective action prior to continued operation. Accomplish checks in step "a" and "b". If probable
cause is not revealed from step "a" or "b", perform steps "c" and "d". It is recommended that the affected
TEMP-PLATE be replaced in accordance with BHT-412-CR&O Manual prior to resuming operation.
a. Check the driveshaft coupling for any sign of grease leakage. If leakage is detected, the coupling must be
serviced prior to returning the aircraft to service.
b. Review current aircraft operating conditions to determine the probable cause of elevated coupling tempera-
ture. For example, extended operation at CG limits, extended operation at high power, repeated heavy lift, or
high ambient temperature. Make appropriate adjustment to correct condition.
c. Inspect engine mounts and transmission pylon mounts for condition.
d. Verify engine to transmission alignment.
3. Coupling overtemperature condition is very likely. Remove driveshaft and perform overtemperature inspec-
tion in accordance with BHT-412-CR&O Manual.
4. Same as Note 1 except during operations before TEMP-PLATE replacement, a yellow-bordered TEMP-
PLATE indication shall be considered as an overtemperature indication and Notes 2 and 3 accomplished.

63-00-00
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BHT-412-MM-6 Bell Helicopter

63-17. Inspection 1. Position engine-to-driveshaft curvic coupling

adapter (2, figure 63-4) on engine. Lubricate threads
Inspect engine-to-driveshaft curvic coupling adapter and mating face of nut (4) lightly with gease (C-001) or
(2, figure 63-4) for mechanical and corrosion damage. bearing grease (C-007). Keep mating faces of washer
Superficial damage is acceptable without repair. Minor (3) and adapter (2) dry.
damage on coupling face which contacts driveshaft is
acceptable if polished out as described in the following 2. Install washer (3) and nut (4) on engine hand
paragraph. tight. Using suitable marker, mark an index line on
outer lock washer tang and adapter to enable
63-18. Repair verification lock washer does not rotate during
torquing.
Repair of adapter is restricted to polishing out minor
damage on face which contacts driveshaft. Polish out 3. Position plate assembly (7, figure 63-5) on
reparable damage with a fine India stone. adapter (1) and install nut (4). Position bar (6) in nut
(5).
63-19. Installation
4. Torque nut (5) 250 to 275 ft.-lbs. (339 to 373 N-m)
MATERIALS REQUIRED for initial torque. Loosen nut (5) then torque 125 to 200
ft.-lbs. (170 to 271 N-m).
Refer to BHT-ALL-SPM for specifications and source.
5. Remove bar (6) and plate assembly (7).
NUMBER NOMENCLATURE
6. Inspect washer (3, figure 63-4) to ensure tang
C-001 Grease indexed in step 2. has not rotated. If inspection reveals
washer (3) has rotated, replace washer and repeat
C-007 Bearing Grease steps 1. through 5. above.

SPECIAL TOOLS REQUIRED 7. Bend single tab of washer (3) into slot of nut (4).

NUMBER NOMENCLATURE

T101588 Wrench Set - Curvic

Coupling or
T103063 Wrench Set (S/N 36020
and Subsequent and
Helicopters Modified by
412-570-001-103)

63-00-00
Page 18 Rev. 5
 Bell Helicopter BHT-412-MM-6

NOTES

1. Evidence of lubricant leakage at couplings 12) or (6) is cause for overhaul evaluation of driveshaft. Refer to
BHT-412-CR&O manual.

2. Mechanical and corrosion damage limits on shaft (4) are defined on sheet 2.

412-M-63-3-1

Figure 63-3. Main Driveshaft - Damage Limits (Sheet 1 of 2)

63-00-00
Rev. 5 Page 19
BHT-412-MM-6 Bell Helicopter

Nicks and scratches running
parallel to, or within 15
degrees of parallel to shaft
axis.
Not exceeding 0.004 inch 10.10.1 millimeters) in depth
are acceptable without repair.
Not exceeding 0.008 inch (0.203 millimeters) in depth
or 1.5 inch (38 millimeters) in length are acceptable if
polished out. provided total polished area does not
exceed 10 percent of circumference at any point.

Nicks and scratches not Not exceeding 0.004 inch (0.101 millimeters) in depth
running within 15 degrees of are acceptable on up to 100 percent of the
shaft axis. circumference of shaft if polished out.

Not exceeding 0.008 inch (0.203 millimeters) in depth

or 1.5 inches (38 millimeters) in length are acceptable
provided the total polished area does not exceed 10
percent of the circumference at any point.

Corrosion pitting. Not exceeding 0.008 inch (0.203 millimeters) in depth

is acceptable provided it is polished out. Maximum
length of rework at any point must not exceed 1.5
inches (38 millimeters) nor cover more than 10 percent
of the circumference at any point. The maximum
acceptable total reworked area is 4.0 square inches
(2580 square millimeters).

3. Mechanical and/or corrosion damage on plate (1) or similar plate in couplings (6) that could
result in lubricant leakage.

4. Mechanical and/or corrosion damage on coots (3 and 5) that could result in lubricant leakage
is not acceptable.

5. Superficial mechanical damage on couplings (2 and 6) is acceptable without repair.

Mechanical damage in excess of superficial and/or corrosion damage is cause for overhaul
overhaul evaluation of driveshaft. Refer to BHT-412-CR&O.

6. Visual over-temperature indicator ("TEMP-PLATES") for discoloration and overheat

condition. A change in color of "TEMP-PLATES" dots from to black will indicate a possible
overheat condition and/or components, and cause of indicator ("TEMP-PLATES") dots
discoloration should be determined prior to condition operation. Refer to BHT-412-CR&O
manual for Inspection and Lubrication procedures.

412-M-63-3-2

Figure 63-3. Main Driveshaft - Damage Limits (Sheet 2)

63-00-00
Page 20 Rev. 5
 Bell Helicopter IS:lJA I BHT-412-MM-6

1. Engine
2. Engine-to-driveshaft curvic
coupling adapter
3. Washer

(170 TO 271 N.m)

Figure 63-4. Engine to Driveshaft Curvic Coupling Adapter

1. Adapter
2. Washer
3. Engine installation

7. Plate assembly

2. Insert extension bar (6) into plate (7). Ensure that extension bar (6) is seated
all the way Into nut (5) before attempting to loosen nut (5).

3. Install T103063 plate (7) on adapter I1) for model 412 S/N 36020 and sub.,
and helicopters modified by 412-570-001-103.
412-M63-5

Figure 63-5. Engine to Driveshaft Curvic Coupling Wrench Set - Tool Application

63-00-00
Rev. 5 Page 21/22
63-20. MAIN ROTOR MAST
The main rotor mast (2, figure 63-6) is a tubular steel
shaft which includes a bearing and plate for
attachment to top of transmission. A bearing race is
installed on lower end of mast which mates with a
roller bearing located in transmission.
412-240-028-101 MAST TORQUEMETER
ALIGNMENT TOOL. AFTER A MAST IS
INSTALLED INTO THE TRANSMISSION, A
ZERO TORQUE CALIBRATION IS
REQUIRED (CHAPTER 96).
2. Remove hub sleeve assembly (Chapter 62).

63-21. MAINTENANCE
3. Remove swashplate and support assembly
The following paragraphs provide maintenance (Chapter 62).
information for the main rotor mast.

63-22. Removal
WARNING
SPECIAL TOOLS REQUIRED

T101581 Hoist or Equivalent MAST NUT (1) (204-010-481-001).

T103211-101 Cover Lift Plate 4. Install mast nut (1). Attach clevis (204-011-178-
204-010-481-001 Mast Nut 001) to nut. Attach hoist to clevis.

X 20 UNC Threaded monopole sensor assembly (12) from bottom of

Shaft transmission and mast as follows:

1. Remove main rotor hub and blade assembly

Some oil will be trapped behind monopole

sensor assembly.

(14) and remove screws with washers (13).

HELICOPTERS S/N 36020 AND
SUBSEQUENT (AND HELICOPTERS b. Remove sealant from around base of
MODIFIED BY 412-570-001-103) HAVE A monopole sensor assembly (12) using a sharp plastic
TORQUEMETER ASSEMBLY (TORQUE scraper.
TUBE ASSEMBLY) INSTALLED INSIDE
THE MAST. REMOVAL OF PLUG AND
TUBE ASSEMBLY REQUIRES

412-375-004-105 MONOPOLE SENSOR

INSTALLED REQUIRE THE TORQUE
TUBE TO BE REALIGNED AT BHTI. DO NOT USE JACKSCREW(S) TO PULL
HELICOPTERS WITH A 412-375-004-109 SENSOR FROM CASE. DO NOT ALLOW
MONOPOLE SENSOR INSTALLED MAY PULLER TO BOTTOM OUT IN
HAVE TORQUE TUBE ALIGNED USING THREADED HOLE OF SENSOR.

63-00-00
Rev. 5 Page 23
BHT-412-MM-6 Bell Helicopter

c. Install slide hammer with 1/4 X 20 UNC
threaded shaft in outboard holes of sensor, pull sensor
from support case. Remove and discard packing (11).
6. Remove nuts (3), washers (4 and 6), temperature
bulb clamp bracket (5) and wire clamp bracket (6A)
from mast bearing retainer plate (7). Remove sealant
from around base of retainer plate with a sharp plastic
scraper.
1. Clean main rotor mast (2, figure 63-6) with a
clean, lint-free cloth damp with solvent (C-304).
2. Dry mast with filtered, compressed air.
63-24. Inspection and Repair
Inspect and repair mast in accordance with BHT-412-
CR&O.

7. Disconnect mast bearing oil hose (9) from 63-25. Installation

retainer plate (7). Cap or plug oil jet and hose.
MATERIALS REQUIRED

CAUTION Refer to BHT-ALL-SPM for specifications and source.

.................. . NUMBER NOMENCLATURE
DO NOT TOUCH THE SECTION OF MAST C-304 Solvent
INSTALLED IN TRANSMISSION WITH
BARE HANDS. C-308 Adhesive
C-328 Sealing Compound
NOTE C-405 Lockwire
Heating top case of transmission with a
heat lamp will aid in mast removal. SPECIAL TOOLS REQUIRED

8. Carefully lift mast (2) from transmission.

Immediately after removal, install cover lift plate NUMBER NOMENCLATURE

9. Position mast (2) on padded stand to prevent 204-010-481-001 Mast Nut

damage to mast. Place protective cover on lower
bearing race (8). Remove clevis (204-011-178-001). 204-011-178-001
Leave mast nut (1) installed to protect threads.
1. Remove cover plate from transmission.
63-23. Cleaning
2. Perform dimensional check of transmission to
MATERIALS REQUIRED prevent damage to upper planetary assembly as
follows:
Refer to BHT-ALL-SPM for specifications and source.
a. Place straight edge (1, figure 63-7) on
NUMBER NOMENCLATURE transmission top case (2). Measure from top of mast
driving adapter (3) to straight edge and record
C-304 Solvent dimension. If dimension is less than 2.226 in. (56.54
mm) comply with steps b. thorough d.

CAUTION

DO NOT ALLOW SOLVENT TO ENTER

MAST BEARINGS.

63-00-00
Page 24 Rev. 5
 Bell Helicopter BHT-412-MM-6

WARNING

DO NOT LIFT MAST (21 WITH MAST

CAP (412-010-160-103). USE MAST
NUT (1) (204-010-481-001).

SEE DETAIL A

DETAIL A

Figure 63-6. Main Rotor Mast

63-00-00
Rev. 5 Page 25
BHT-412-MM-6 Bell Helicopter
HANDLE MAST DRIVING ADAPTER (3)
CAREFULLY WHEN INDEXING BEARING
LINERS. INJURY TO FINGERS MAY
RESULT.
b. Inspect upper and lower bearing liners (5 and
6) to determine whether tangs are disengaged. If
tangs are disengaged, a gap of approximately 0.25 in.
(6.0 mm) will be evident.
c. Insert hands back-to-back through adapter
(3). Lift adapter slightly and rotate upper liner (5) until
tabs on upper liner (5) align with slots in lower liner (6)
and drop into position.
d. Repeat measurements described in substep
WARNING
DO NOT LIFT MAST WITH MAST CAP
(412-010-160-103). USE ONLY MAST NUT
(204-010-481-001) TO LIFT MAST.
3. Install mast nut (1, figure 63-6). Attach clevis
(204-011-178-001) to mast nut (1). Attach hoist to
clevis.
HELICOPTERS S/N 36020 AND
SUBSEQUENT (AND HELICOPTERS
MODIFIED BY 412-570-001-103) HAVE A
TORQUEMETER ASSEMBLY INSTALLED
IN MAST. FAILURE TO REMOVE
MONOPOLE SENSOR ASSEMBLY (12)
BEFORE INSTALLING MAST (2) CAN
CAUSE DAMAGE TO TORQUEMETER
ASSEMBLY.
63-00-00
Page 26 Rev. 5
NOTE
lamp will aid in installation.
4. Lower mast (2) carefully into transmission (10).
Guide lower bearing race (8) of mast into lower
bearing of transmission.
5. Align plate (7) with studs in top of transmission.
6. Apply a coat of sealing compound (C-328) to
mating surfaces of plate (7) and top of transmission
before allowing retainer plate to seat.
7. Lower mast until plate (7) is in contact with
transmission top case.
8. Install temperature bulb clamp bracket (5) next to
plate (7). Install steel washer (4) and nut (3). Install
under L bracket and one above bracket and one steel
washer (4) under nut (3). Torque nuts (3) 100 to 140
in.-lbs. (11.3 to 15.8 N-m).
10. Rotate transmission input quill by hand to ensure
there is no unusual noise or binding.
11. Remove clevis and mast nut (1). Use mast cap
assembly for final installation.
12. For helicopters S/N 36020 and subsequent (and
helicopters modified by 412-570-001-103), install
monopole sensor assembly (12) in bottom of
a. Lubricate new packing (11) with transmission
oil (Chapter 12) and install on monopole sensor
assembly.
b. Clean transmission support case free of oil
and adhesive residue using plastic scrapper and a
clean cloth damp with solvent (C-304).
c. Apply light coat of transmission oil (Chapter
12) to bore in support case.
 Bell Helicopter BHT-412-MM-6

1. Straight edge 5. Upper bearing liner

2. Transmission top case 6. Lower bearing liner
3. Mast driving adapter 7. Bearing
4. Mast driving adapter extension 8. Bearing

Figure 63-7. Mast Driving Adapter to Transmission Top Case Dimension Requirements

63-00-00
Rev. 5 Page 27
BHT-412-MM-6 Bell Helicopter

d. Align sensor assembly screw holes with holes
in support case of transmission (arrow pointing
forward).
e. Install four screws (14) with washers (13).
Secure screws with lockwire (C-405).
f. Apply a bead of adhesive (C-308) around
mating surface of sensor.
13. Install swashplate and support assembly
(Chapter 62).
14. Install hub and sleeve assembly (Chapter 62).
15. Install main rotor hub (Chapter 62).
16. For helicopters S/N 36020 and subsequent (and
helicopters modified by 412-570-001-103), calibrate
mast torque system (Chapter 96).
17. Install blade assembly (Chapter 62).
63-26. TORQUE TUBE ASSEMBLY ALIGNMENT
103) which have a 412-375-004-109
monopole sensor assembly and 412-040-
366-111 or -113 mast assembly. Torque
tube alignment for transmissions with 412-
375-004-105 monopole sensor assembly
and 412-040-366-109 mast assembly shall
be accomplished at Bell Helicopter only.
1. Remove monopole sensor (12) (paragraph 63-
22).
2. Remove torque tube (17, figure 63-6) from mast
as follows:
a. Remove mast nut (1).
b. Using a sharp plastic scraper, remove sealant
from torque tube and mast.
c. Cut and remove lockwire from bolts (15) and
remove bolts (15) from plug (16).
d. Remove plug (16) using jackscrews
(T103222).

MATERIALS REQUIRED e. Remove torque tube (17) from mast (2).

3. Clean surface of rotor in mast assembly which

transmission oil to surface. Verify surface is smooth

and clean.
C-339 Methyl Alcohol

DO NOT ROTATE ANY DRIVE SYSTEM

NUMBER NOMENCLATURE COMPONENTS WHILE TOOL IS
INSTALLED.
T103222 Jackscrews
4. Insert alignment tool (412-240-028-101) in bottom

Hold tool in place with four screws and washers, leave

NOTE
The following procedure is applicable to
helicopters S/N 36020 and subsequent
(and helicopters modified by 412-570-001-
screws loose enough to allow 1/4 inch movement of
tool.
5. Clean outer bearing surface of torque tube (17).
Verify surface is smooth. Using care to keep bearing

63-00-00
Page 28 Rev. 5
surface clean during installation, install tube into top of 9. Remove alignment tool by pulling tool past torque
mast. tube spline, rotating tool a few degrees, and pulling
tool out past mast spline.

Rotate torque tube (17) counterclockwise (looking 10. Install monopole sensor (12) (paragraph 63-25).
down from top of mast) as far as alignment tool will
11. Secure torque tube plug (16) with lockwire (C-
split flange with soft metal bar and mallet. Hold
torque tube.
alignment tool counterclockwise with upward pressure
while tube is lowered. If alignment tool is pushed down
while lowering torque tube this is an indication of 12. Install mast nut (1) (Chapter 62).
misalignment. Rotate torque tube gently until
alignment tool rises, this indicates the alignment tool 13. Perform mast torque system zero torque
has engaged both the signal and reference gears. calibration (Chapter 96).

14. Perform mast torque system flight check (Chapter

7. Install plug (16) into torque tube (17). Install bolts 96).
(15) and torque to 50 to 70 in.-lbs. (5.65 to 7.90 N-m)
in symmetrical manner.

8. Loosen bolts on alignment tool. Verify tool can be

rotated slightly and fits loosely in splines of mast and
torque tube. If tool cannot be rotated, repeat steps 6.
and 7.

Rev. 5 Page 29/30

 Bell Helicopter BHT-412-MM-6

TRANSMISSION

63-27. TRANSMISSION 63-29. MAINTENANCE

63-30. Removal
The transmission (figure 63-8) is a mechanical
reduction gearbox attached to fuselage structure by SPECIAL TOOLS REQUIRED
four isolation mounts at corners of transmission
support case and by lift link which is the main load
bearing component. The two aft isolation mounts NUMBER NO
attach to helicopter structure and also to friction AN100036 Cover
dampers. The lift link is attached to transmission
support case and helicopter lift beam. SWE13860 Adapter
SWE13875 Stand
63-28. TROUBLESHOOTING
T101581 Hoist
T102118-101 Dehydrator Assembly
NOTE
204-010-481-001 Mast Nut
In analysis of transmission oil system
troubles, consider the following 204-040-929-101 Cover and Lift Plate
characteristics of the system. 204-01 1
204-011-178-001 Clevis

1. Low oil level will not cause low oil pressure . .

transmission preservation by one of the following
cover pump inlet. Oil temperature however, may rise. methods:

2. Effects of an oil leak will depend on location of
leak within system and rate of fluid loss. Do not
exceed 10 drops per minute from any single source.
Do not exceed 15 drops per minute from all sources
on the transmission. An external leak can allow sump
to be pumped dry, causing internal failure of
transmission. While any oil remains in sump, the
pressure relief valve will tend to maintain normal
system pressure. This applies especially to leaks
between pump and relief valve. Leaks occurring
beyond the relief valve could cause indications of low
oil pressure. Leaks in the interior of transmission will
not affect oil level but may starve downstream
lubrication areas and also may affect indicated oil
pressure and temperature.
a. If helicopter and transmission are operational,
perform a ten minute ground run (BHT-412-FM) prior
to removal of transmission.
b. If transmission and engine cannot be ground
run, accomplish preservation after transmission is
removed as follows:
(1) Remove mast assembly (paragraph 63-
22).
(2) Spray inside of transmission through top
opening of transmission with four quarts of
transmission oil (Chapter 12). Rotate gears by hand
while spraying oil.

(3) Install cover and lift plate (204-040-929-

3. Cumulative clogging of oil filters will not show as
a gradual drop in oil pressure because the pressure
relief valve maintains normal system pressure. The
external filter has a visual indicator which will extend
when filter bypass conditions are impending. This
indicator should be checked during all normal
inspections.
101) or install mast assembly.
(4) Cut and remove lockwire from plug and
remove plug (AN814-6DL) from top case and install
dehydrator assembly (T102118-101).
2. Remove hub and blade assembly (Chapter 62).

63-00-00
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BHT-412-MM-6 Bell Helicopter

13. Main input quill

14. Oil temperature manifold
15. Oil pressure regulating valve
16. Oil jet No. 7
17. Oil jet No. 2
1. Oil pressure manifold 18. Oil jet No. 1
2. Filler neck, scupper, and mounting bracket 19. Cyclic controls spring bracket
3. Oil pressure transmitter 20. Planetary oil jets
4. Oil pressure switch 21. Oil jet No. 5
4A. Oil jet No. 6 22. Main input gear quill electric chip detector
5. No. 1 hydraulic pump drive quill 23. Quill port cover
6. Sight glasses 24. Oil jet No. 4
7. Oil pump inlet screen 25. Oil pump
8. Sump case electric chip detector 26. Lift link fitting
9. Sump internal filter 27. Rotor tachometer generator
10. Tail rotor drive quill 28. No. 2 hydraulic pump drive quill
11. Oil jet No. 3 29. Mast bearing electric chip detector

412-M-63-8

Figure 63-8. Transmission

63-00-00
Page 32 Rev. 5
 Bell Helicopter
NOTE
Hub and sleeve assembly may be removed
with swashplate and support assembly as a
unit. Care must be exercised to prevent
damage to mast and hub splines.
3. Remove hub and sleeve assembly (Chapter 62).
4.
4. Remove
Remove swashplate
swashplate and support assembly
and support assembly
(Chapter 62).
5. Remove main driveshaft (paragraph 63-8).
WHEN REMOVING THE TAIL ROTOR
DRIVESHAFT (10, FIGURE 63-9) ON
HELICOPTERS PRIOR TO S/N 36020
(NOT MODIFIED BY 412-570-001-103),
BOTH CLAMP ASSEMBLIES (9 AND 11)
MUST BE REMOVED PRIOR TO
REMOVING DRIVESHAFT (10). FAILURE
TO COMPLY MAY RESULT IN DAMAGE
TO FLEXIBLE COUPLINGS.
NOTE
Tail rotor driveshaft clamps (9 and 11) are a
matched set; keep in sets to maintain
balance. To replace one clamp half, or if
clamp halves are intermixed, each clamp
half shall be re-matched with one of equal
weight (within one gram).
6. Remove clamp assemblies (9 and 11)
remove tail rotor driveshaft (10).
7. For helicopters S/N 36020 and subsequent and
helicopters modified by 412-570-001-103, remove tail
rotor driveshaft connected to transmission (Chapter
65).
8. Drain oil from transmission sump (Chapter 12).
9. Disconnect oil inlet hose (7).
10. Disconnect oil outlet hose (23).
BHT-412-MM-6
11. Disconnect oil sump drain line (22).
12. If installed, disconnect rotor brake hydraulic
hoses and wiring.
13. Disconnect electrical connector (5).
14. Remove system 1 hydraulic pump (Chapter 29).
Install cover (6) on pump drive quill.
15. Remove fluid from hydraulic system 2 using a
suction gun. Disconnect all hoses from hydraulic
system 2 pump. Do not remove pump at this time. Cap
all open ports and hoses.
NOTE
If mast is not installed, cover and lift plate
(204-040-929-101) shall be installed on
transmissionforlifting.
CAUTION
BEFORE USING HOIST (T101581) TO
REMOVE OR INSTALL TRANSMISSION,
PLACE A SUPPORT UNDER TAILBOOM
TO STEADY FUSELAGE.
17. If a suitable stationary or portable hoist is not
available, install hoist assembly (T101581).
and
18. Attach hoist to clevis (1).
19. Remove bolts (19), washers (20), and shouldered
washers (21) from isolation mounts (24).
20. Tie forward isolation mounts (24) into position to
prevent mounts from disengaging from support case.
21. Remove bolt (26) from lift link (31).
22. Install adapter (SWE13860) on stand
(SWE13875) if not previously accomplished.
63-00-00
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BHT-412-MM-6 Bell Helicopter

7. Inspect transmission for loose, missing, or

VERIFY HYDRAULIC PUMP FOR NOTE

SYSTEM 1 AND ALL ELECTRICAL Pay special attention to attaching bolts (26
WIRING, HOSES, LINES, AND and 30, figure 63-9) for lift link (31) and four
ATTACHING HARDWARE IS REMOVED bolts (19) securing transmission support
BEFORE ATTEMPTING TO LIFT case to structure.
TRANSMISSION FROM HELICOPTER.
8. Inspect isolation mounts (24) and dampers (25)
23. Hoist transmission clear of airframe. Place for secure installation and distortion.
transmission in support stand and secure to stand with
bolts. 9. Inspect transmission and attached oil lines for
leaks. If main input quill is leaking, replace magnetic
24. If transmission is not to be reinstalled, remove seal (paragraph 63-174).
bolt assembly (30) and lift link (31).
10. Inspect transmission for mechanical and
63-31. Inspection corrosion damage (BHT-412-CR&O).

1. Inspect three electric chip detectors as follows: 11. Inspect transmission electrical wiring for secure
installation and damaged wires.
a. Remove, inspect, and install mast bearing
chip detector (3, figure 63-10) (paragraph 63-36). 12. Inspect main rotor mast (paragraph 63-24).

b. Remove, inspect, and install main input gear

quill chip detector (4) (paragraph 63-41). NOTE
Additional detailed inspections of the
c. Remove, inspect, and install sump chip transmission and component parts are
detector (8) (paragraph 63-46). found in BHT-412-CR&O.

2. Inspect main driveshaft couplings and tail rotor 63-32. BUILD-UP

drive quill couplings over-temperature indicator
(TEMP-PLATE) for discoloration. A change in color MATERIALS REQUIRED
indicates a possible overheat condition and/or
component degradation. Determine and correct cause Refer to BHT-ALL-SPM for specifications and source.
of discoloration prior to continued operation.
NUMBER NOMENCLATURE
3. Remove, inspect, and install external oil filter (9)
(paragraph 63-152). C-405 Lockwire

4. Remove, inspect, and install sump internal oil SPECIAL TOOLS REQUIRED
filter (10) (paragraph 63-136). Remove, inspect, and
install full flow debris monitor (10) (helicopters NUMBER NOMENCLATURE
modified by T.B. 412-91-94) (paragraph 63-140).
SWE13860 Adapter
5. Remove, inspect, and install oil pump inlet screen
(7) (paragraph 63-131).
T101581 Hoist
6. Inspect oil level sight glass (6) for crazing, cracks,
or
or staining
staining (paragraph
(paragraph 63-146).
63-146). 204-040-929-101 Cover and Lift Plate

63-00-00
Page 34 Rev. 5
1. Clevis (204-011-178-1)
2. Quick release pin
3. Mast nut (204-010-481-001)

9. Clamp assembly TORQUE) .

13. Engine to transmission driveshaft

14. Bolt
15. Main input quill
16. Thin steel washer
17. Nut
18. Pin

INSTALL BOLTS WITH

HEADS IN DIRECTION OF
ROTAT ION
TORQUE NUTS

ROTATION

412-M-63-9-1

Figure 63-9. Transmission Removal and Installation (Sheet 1 of 2)

63-00-00
Rev. 5 Page 35
 34 33 32 31
19 TORQUE

21. Washer (204-030-913-5) 30. Bolt assembly

22. Oil sump drain line 31. Lift link

24. Isolation mount 33. Steel washer

25. Damper 34. Nut
26. Bolt 35. Cotter pin
27. Thin steel washer 36. Transmission lift link fitting
412-M-63--2
Figure 63-9. Transmission Removal and Installation (Sheet 2)

63-00-00
Page 36 Rev. 5
 Bell Helicopter BHT-412-MM-6

6. Oil level sightglass

1.
2.
4.
Transmission
Transmission
Main input gearleftquillside)
(right
side electric chip detector
5. Rotor
6. Oil
7. Sump
brake
level
Oil pump sight glassquill port cover
drive
inlet screen
8. electric chip detector
9. External oil filter
10. Internal oil filter

412-M-63-10

Figure 63-10. Transmission Assembly

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BHT-412-MM-6 Bell Helicopter

1. Install adapter (SWE13860) on stand 7. Remove cover (10) and install rotor tachometer
(SWE13875). generator (19) (paragraph 63-203).

2. Install cover and lift plate (3, figure 63-11) on
transmission using steel washers (2) and nuts (1).
3. Remove transmission from shipping container
and position on stand (SWE13875). Secure
transmission to stand with bolts.
8. Remove plug (24) and packing (23). Install oil
pressure transmitter (40) and packing (39) (paragraph
63-212).
9. Remove cap (22). Install oil pressure switch (36)
and packing (38) (paragraph 63-116).

4. If transmission is to be installed in helicopter

immediately, open drain valve (8) and allow all NOTE
preservative oil to drain. Close valve (8). Refer to Chapter 98 for electrical wiring
diagrams to confirm wire numbers.

CAUTION
a. Connect electrical connector (42) to pressure
IF ANY OIL LINES FROM A switch(36).
TRANSMISSION WHICH WAS REMOVED
DUE TO INTERNAL FAILURE OR METAL b. Connect electrical connector (41) to pressure
CONTAMINATION ARE TO BE transmitter (40).
INSTALLED ON REPLACEMENT
TRANSMISSION, ENSURE ALL FOREIGN
PARTICLES ARE CLEANED FROM
HOSES. MAST ASSEMBLIES FROM
TRANSMISSIONS DESCRIBED ABOVE d. Install six clamps (30) (remaining four are
SHALL BE OVERHAULED PRIOR TO installed in step h. below).
FURTHER USE.
e. Remove cover (21). Install electrical terminal
and nipple (35) on thermoswitch (25).
NOTE
If components from transmission removed f. Connect terminal and nipple (37) to main input
from helicopter are to be used for buildup of gear quill chip detector (7) (paragraph 63-45).
replacement transmission, position
transmissions near each other to facilitate g. Connect terminal and nipple (34) to mast
transfer of components. bearing chip detector (4) (paragraph 63-40).

5. Install mast in transmission (paragraph 63-25). h. Install four clamps (30).

6. Remove cover (14, figure 63-11) and install i. Install terminal and nipple (29) on sump chip
system 2 hydraulic pump (Chapter 29). Cap or plug detector (27) or connect electrical harness to full flow
open ports on hydraulic line. debris monitor.

j. Install connector (28) on tachometer generator

NOTE
System 1 hydraulic pump will be installed
after transmission is installed in helicopter.
Leave hydraulic pump (system 1) drive quill
cover (26) installed at this time.
(19) and secure with lockwire (C-405).
k. If transmission is to be installed in a helicopter
equipped with a rotor brake, remove cover (6) and
install rotor brake quill (paragraph 63-215).

63-00-00
Page 38 Rev. 5
 1. Nut
2. Steel washer
3. Cover and lift plate
4. Mast bearing electric chip detector
5. Transmission
6. Rotor brake quill port cover
7. Main input quill electric chip detector
8. Drain valve
9. Gasket
10. Cover
11. Washer (AN960C416)
12. Nut
13. Gasket
14. Cover
15. Steel washer
16. Nut
17. Hydraulic pump (system II) drive quill

412-M-63-11-1

Figure 63-11. Transmission Build-up (Sheet 1 of 4)

63-00-00
Rev. 5 Page 39
BHT-412-MM-6 Bell Helicopter

18. Main rotor mast assembly

19. Rotor tachometer generator
20. Hydraulic pump (system II)
412-M-63-11-2

Figure 63-11. Transmission Build-up (Sheet 2)

63-00-00
Page 40 Rev. 5
 V

22. Cap
23. Packing
24. Plug

26. Hydraulic pump (system I) drive quill cover

412-M-63-11-3

Figure 63-11. Transmission Build-up (Sheet 3)

63-00-00
Rev. 5 Page 41
BHT-412-MM-6 Bell Helicopter

27. Sump electric chip detector 36. Oil pressure switch

28. Electrical connector 37. Electrical terminal and nipple
29. Electrical terminal and nipple 38. Packing
30. Clamps (ten) 39. Packing
31. Electrical connector 40. Oil pressure transmitter
32. Electrical harness 41. Electrical connector
33. Ground connection 42. Electrical connector
34. Electrical terminal and nipple 43. Electrical connector
35. Electrical terminal and nipple
412-M-63-11-4

Figure 63-11. Transmission Build-up (Sheet 4)

63-00-00
Page 42 Rev. 5
 Bell Helicopter BHT-412-MM-6

I. Install caps, covers, and plugs removed in
preceding steps on transmission removed from
helicopter.
63-33. Installation
(34) 60 to 80 ft.-lbs. (81 to 108 N-m). Install cotter pin
(35).
4. Erect hoist assembly (T101581 or equivalent).
Install clevis (1) on mast nut (3). Attach hoist to clevis.

MATERIALS REQUIRED
NOTE
Refer to BHT-ALL-SPM for specifications and source. If mast is not installed, cover and lift plate
(204-040-929-101) must be installed on
NUMBER NOMENCLATURE transmission for lifting.

C-405 Lockwire 5 Lift transmission from stand and lower into

U5.
position on isolation mounts (24) while guiding lift link
SPECIAL TOOLS REQUIRED (31) into position on lift beam.

NUMBER NOMENCLATURE 6. Align lift link (31) with lift beam and install bolt
(26), washer (27), and nut (29). Torque nut (29) 108 to
T101581 Hoist Assembly 125 ft.-lbs. (146.8 to 170 N-m). Install cotter pin (28).
204-010-481-001 Mast Nut
204-011-178-001 Clevis NOTE
Ensure countersunk side of washer (20) is
204-040-929-101
Cover, Lift Plate toward head of bolt (19). Washer (21) is
installed with beveled side down.

................ .7. Install bolts (19), washers (20), and washers (21)
CAUTION on isolation mounts (24). Torque bolts (19) 90 to 105

IF REPLACING TRANSMISSION FOR isolation mounts (24) in position.

INTERNAL FAILURE OR METAL
PARTICLES IN OIL, CLEAN ALL OIL
LINES AND REPLACE OIL COOLER,
EXTERNAL OIL FILTER, AND MAST
ASSEMBLY.
8. For helicopters prior to S/N 36020 (and not
helicopters modified by 412-570-001-103), install tail
rotor driveshaft (10) as follows:

1. Inspect condition of pylon structure and repair or NOTE

replace any unserviceable isolation mounts (24, figure
63-9) and/or dampers (25) (paragraph 63-219).
2. Install mast assembly (paragraph 63-25) and
replace dehydrator assembly (T102118-101) in top
case with plug (AN814-6DL). Helicopters modified by
T.B. 412-98-150 replace dehydrator assembly with
breather (A800V). Torque plug or breather 80 to 120
in.-Ibs. (9.04 to 11.52 N-m). Secure plug with lockwire
(C-405).
Clamp assemblies (9 and 11, figure 63-10)
are a matched set. To replace one clamp
half, or if clamp halves are inadvertently
mixed, each clamp half shall be rematched
with one of equal weight (within one gram)
to maintain balance.
a. Position tail rotor driveshaft (10) between tail
rotor drive quill (12) and tail rotor hanger coupling (8).

3. If not previously accomplished, position lift link NOTE

(31) and washer (32) between lugs of fitting (36). All nuts used on a clamp shall be the same
Install bolt (30), washer (33), and nut (34). Torque nut type and style. Nuts are self-locking and

63-00-00
Rev. 5 Page 43
BHT-412-MM-6 Bell Helicopter
shall not be used unless nut drag torque is
3.5 in.-lbs. (0.40 N-m) minimum and 30 in.-
lbs. (3.39 N-m) maximum.
b. Install clamp assembly (9) with bolt heads in
direction of rotation. Tighten clamp assembly bolts
evenly. Torque nuts 30 to 35 in.-lbs. (3.39 to 3.95 N-m)
above nut friction. Tap lightly around outer surface of
clamp assembly with plastic mallet to seat clamp,
Repeat torquing procedure.
c. Install clamp assembly (11) with bolt heads in
direction of rotation and with clamp joints 90 ° to clamp
assembly (9). Torque clamp assembly bolts in same
manner as described in step b. above.
9. For helicopters 36020 and subsequent (and
helicopters modified by 412-570-001-103), install
forward tail rotor driveshaft (Chapter 65).
10. Install main driveshaft (13) (paragraph 63-13).
11. Install hydraulic system 1 pump (Chapter 29).
12. Connect electrical connector (5) on right side of
transmission.
13. Connect transmission oil inlet hose (7) to oil filter.
14. Connect transmission oil outlet hose (23) to
manifold line.
15. Connect oil sump drain line (22).
16. If equipped, connect rotor brake hydraulic hose
and electrical wiring.
17. Connect hydraulic system 2 inlet and pressure
hoses, case drain hose, and seal drain hose to pump
fittings.
18. Service transmission (Chapter 12). Verify actual
presence of oil in sight gage.
19. If transmission has not been previously qualified
on run-in test stand, accomplish alternate run-in
procedures in the following paragraph.
63-00-00
Page 44 Rev. 5
1
63-34. ALTERNATE RUN-IN PROCEDURES
NOTE
After overhaul, it is desirable transmission
be test run and inspected in accordance
with publication furnished with run-in test
stand. In the event a test stand is not
available, the following functional test may
be accomplished as the minimum
acceptable alternate test.
Install sufficient ballast in cabin to obtain
maximum gross weight (BHT-412-FM).
2. Verify helicopter is properly serviced and
lubricated (Chapter 12). Visually inspect the following:
a. Oil system for security and leakage.
b. Fuel system for security and leakage.
c. Hydraulic system for security and leakage.
d. Flight controls for security.
3. Inspect engine accessories and controls for
NOTE
Throughout the entire procedure which
follows, carefully check for evidence of
leakage and abnormal noises.
4. Start engines (BHT-412-FM) and run at 60%
RPM for five minutes. Verify temperatures and
pressures are within limits.
5. Gradually increase RPM from 60 to 88% at the
rate of 7% each six minutes of operation.
6. Hold 88% for two minutes with collective applied
to the maximum which can be attained without
becoming airborne or exceeding 100% torque.
7. Shut down engines. Remove, inspect, clean, and
install the following components:
a. Three electric chip detectors (paragraph 63-
35).
 b. Oil pump inlet screen (paragraph 63-131).
d. External oil filter (paragraph 63-152).
e. Planetary oil jets (two) (paragraph 63-52).
f. Oil jet no. 1 (paragraph 63-58)
g. Oil jet no. 2 (paragraph 63-64).
h. Oil jet no. 3 (paragraph 63-70).
j. Oil jet no. 5 (paragraph 63-82).
k. Oil jet no. 6 (paragraph 63-88).
l. Oil jet no. 7 (paragraph 63-94).
8. Restart engines (BHT-412-FM) and gradually
increase RPM to 88% RPM. Operate at 88% for six
minutes. Move collective to the maximum position
RPM to 100% without exceeding 100% torque.
9.
9. At 100%
At 100% RPM,
RPM, check
check trandsmission
transmission oil
oil pressure.
pressure.
these limits, adjust pressure relief valve as follows:
a. Shut down helicopter.
b. Loosen jamnut on adjustment screw.
c. Turn adjustment screw clockwise to increase,
or counterclockwise to decrease, pressure as
required.
d. Tighten jamnut.
100% and recheck pressure.
f. Repeat steps a. through e. above, as required,
to obtain proper oil pressure.
10. Operate at 100% RPM for 30 minutes with
collective applied to maximum attainable without
becoming airborne or exceeding 100% torque.
11. Shut down helicopter and repeat inspections
listed in step 7. above.
12. Inspect main driveshaft couplings, tail rotor drive
quill couplings, and surrounding area for evidence of
grease leakage. If there is evidence of leakage,
replace or repair defective components. Repeat leak
test run in step 10. above.
13. Inspect main and tail rotor driveshaft couplings
over-temperature indicator (TEMP-PLATE) for
component degradation. If overheating is indicated,
cause shall be determined and corrected prior to
helicopter being released for flight. Refer to BHT-412-
couplings and for tail rotor driveshaft couplings.
14. Check transmission oil level. Service as required
(Chapter 12).
15. Install engine and transmission cowling.
16. Check for leaks at next helicopter ground run.
63-00-00
Rev. 5 Page 45/46
 TRANSMISSION OIL SYSTEM COMPONENTS

63-35. ELECTRIC CHIP DETECTORS 63-40. Installation

63-36. MAST BEARING ELECTRIC CHIP MATERIALS REQUIRED

DETECTOR
Refer to BHT-ALL-SPM for specifications and source.
the transmission top case (figure 63-12) to detect NUMBER NOMENCLATURE
foreign particles in the transmission oil originating from
the main rotor mast upper bearing. C-405 Lockwire

63-37. Removal 1. Lubricate new packing (7, figure 63-12) with

1. Remove nut (1, figure 63-12) and disconnect wire transmission oil (Chapter 12). Install packing (7) on
from stud (2). chip detector housing (6).

2. Push and twist chip detector (4) counterclockwise NOTE

to disengage locking lugs (3). Remove chip detector
(4) from chip detector housing (6). If a plug has been installed where the chip
detector housing (6) is normally installed,
3. Cut and remove lockwire from chip detector
housing (6), and remove chip detector housing from

4. Remove and discard packing (5) from chip
detector (4) and, if removed, discard packing (7) from
chip detector housing (6).
presence of metal particles. If any particles are found,
refer to paragraph 63-2 for required action.
with figure 63-13.
63-39. Cleaning
MATERIALS REQUIRED
3. Install chip detector housing (6) in top of
transmission (8).
4. Torque chip detector housing (6) 280 to 300 in.-
lbs. (31.7 to 33.9 N-m). Secure housing to
transmission with lockwire (C-405).
5. Lubricate new packing (5) with transmission oil
(Chapter 12) and install new packing (5) on chip
detector (4).
6. Insert chip detector (4) into housing (6). Push in
locking lugs (3).
7. Install electrical wire on stud (2).

Refer to BHT-ALL-SPM for specifications and source. 8. Install nut (1) on stud (2). Tighten nut (1) to a
maximum of 4.0 in.-lbs. (0.45 N-m) torque. Position
nipple over nut (1).
C-304 Solvent
63-41. MAIN INPUT GEAR QUILL ELECTRIC CHIP
DETECTOR
1. Clean electric chip detector with solvent (C-304).
The main input gear quill electric chip detector (figure
2. Dry with filtered, compressed air. 63-14) is installed to detect metal particles in the

63-00-00
Rev. 5 Page 47
BHT-412-MM-6 Bell Helicopter

transmission oil originating from the main input gear 63-45. Installation
quill.
MATERIALS REQUIRED
63-42. Removal

1. Remove nut (2, figure 63-14) and remove wire Refer to BHT-ALL-SPM for specifications and source.
from stud (3).
NUMBER NOMENCLATURE
2. Push in and twist electric chip detector (5) C-405 Lockwire
counterclockwise to disengage locking lugs (4).

3. Remove electric chip detector (5) from chip
detector housing (7).
4. Cut and remove lockwire from chip detector
housing (7), and remove chip detector housing from
transmission (1).
5. Remove and discard packing (6) from electric
chip detector (5) and, if removed, discard packing (8)
from chip detector housing (7).
63-43. Inspection
1. Inspect electric chip detector (5, figure 63-14) for
presence of metal particles. If any particles are found,
refer to paragraph 63-2 for required action.
1. Lubricate new packings (6 and 8, figure 63-14)
with transmission oil (Chapter 12). Install packing (8)
on chip detector housing (7) and packing (6) on
electric chip detector (5).
2. Install chip detector housing (7) on transmission
(1). Torque housing 280 to 300 in.-lbs. (31.7 to 33.9 N-
m). Secure housing to transmission (1) with lockwire
(C-405).
3. Insert electric chip detector (5) into housing (7).
Push in on electric chip detector (5) and twist
clockwise to engage locking lugs (4).
4. Install electrical wire on stud (3).

2. Inspect electric chip detector components in 5. Install nut (2) on stud (3). Tighten nut (3) to a
accordance with figure 63-13. maximum of 4.0 in.-lbs. (0.45 N-m) torque. Position
nipple over nut (1).
63-44. Cleaning
63-46. SUMP CASE ELECTRICAL CHIP
MATERIALS REQUIRED DETECTOR

Refer to BHT-ALL-SPM for specifications and source. The sump case electrical chip detector (4, figure 63-
15) is installed to detect metal particles which collect in
NUMBER NOMENCLATURE sump.

C-304 Solvent 63-47. Removal

1. Clean electric chip detector with solvent (C-304).

NOTE
2. Dry with filtered, compressed air. The sump case electric chip detector (4,
figure 63-15) may be removed for
inspection without draining sump. However,
if the electric chip detector self-closing
valve (2) is to be removed the sump must
be drained (Chapter 12).

1. Remove oil level access door on right side of

pylon.

63-00-00
Page 48 Rev. 5
 - 280 TO 300 IN-LBS

\< ~~~~~--
zn ~~ ~ LOCKWIRE

DETAIL A

3i l^Stud 2. 6. Chip detector housing

4. Chip detector 8. Transmission
412-M-63-12

Figure 63-12. Mast Bearing Electric Chip Detector

2. Move nipple (7) back on wire terminal (5) to
expose nut (6). Remove nut (6) and wire terminal (5)
from electric chip detector (4).
3. Push in and twist electric chip detector (4)
counterclockwise to disengage from locking detents.
4. Remove electric chip detector (4) from electric
chip detector self-closing valve (2).
5. Remove and discard packings (3) from electric
chip detector (4).
d. Remove gasket (1) from electric chip detector
self-closing valve (2).
63-48. Inspection
1. Inspect electric chip detector (4, figure 63-15) for
presence of metal particles. If any particles are found,
refer to paragraph 63-2 for required action.
2. Inspect electric chip detector components in
accordance with figure 63-16.

63-49. Cleaning
6. If the electric chip detector self-closing valve (2) is 63-49. Cleaning
MATERIALS REQUIRED
a. Drain transmission sump case (Chapter 12).
Refer to BHT-ALL-SPM for specifications and source.
b. Cut and remove lockwire from electric chip
detector self-closing valve (2), pump screen (8), and NUMBER NOMENCLATURE
plug (9). C-405 Lockwire
c. Remove electric chip detector self-closing
valve (2) from transmission sump case. 1. Clean electric chip detector with solvent (C-304).

63-00-00
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BHT-412-MM-6 Bell Helicopter

AREA

CHIP DETECTOR

AREA LIMITS

All No cracks allowed.

A Maximum depth of pitting is 0.030 inch (0.762 millimeter) with no more than 40
percent of any 1.0 inch square (645.16 sq. millimeters) or 20 percent of any total
area of any pitted surface.

B Maximum depth of pitting is 0.020 inch (0.508 millimeter) with no more than 40
percent of any 1.0 inch square (645.1 6 sq. millimeters) or 20 percent of total area
of any pitted surface. Thread damage is not permitted.

412-M-63-13

Figure 63-13. Electric Chip Detector (Typical) - Damage Limits

2. Dry with filtered, compressed air. c. Secure electric chip detector self-closing valve
(2) to pump screen (8) and plug (9) with lockwire (C-
63-50. Installation 405)
2. Lubricate new packings (3) with transmission oil
MATERIALS
REQUIRED (Chapter 12). Install packings (3) on electric chip
detector (4).
Refer to BHT-ALL-SPM for specifications and source.
3. Insert electric chip detector (4) into electric chip
NUMBER NOMENCLATURE detector self-closing valve (2). Push in on electric chip
detector (5) and turn clockwise to engage the locking
C-405 Lockwire detents.

1. If the electric chip detector self-closing valve (2, 4. Install wire terminal (5) on electric chip detector
figure 63-15) was removed perform the following (4)
steps:
5. Install nut (6) on electric chip detector (4). Tighten
nut (6) to a maximum of 4.0 in.-lbs. (0.45 N-m) torque.
a. Lubricate new gasket (1) with transmission oil P
(Chapter 12). Install gasket (1) on electric chip
detector self-closing valve (2).

b. Install electric chip detector self-closing valve

(2) on transmission sump case and torque 300 to 400
in.-lbs. (407 to 542 N-m).

63-00-00
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 Bell Helicopter BHT-412-MM-6

LOCKWIRE

SEE DETAIL

2. Nut 6. Packing
3. Stud 7. Chip detector housing
4. Locking lugs 8. Packing
412-M63-14

Figure 63-14. Main Input Gear Quill Electric Chip Detector

63-51. TRANSMISSION OIL SYSTEM 4. Disassemble planetary oil jet (8) as follows:
COMPONENTS
a. Loosen nut (5) and remove fitting (4) with
63-52. PLANETARY OIL JETS packings (6).

Two planetary oil jets (8, figure 63-17) are installed in b. Remove and discard packings (1 and 6).
the planetary gear case of the transmission to provide
positive lubrication to planetary gearing. 63-54. Inspection

63-53. Removal 1. Inspect oil jet for clogging. If passages are

NOTE
The planetary oil jet on the forward side of
transmission is shown in figure 63-17.
Maintenance procedures for the planetary
oil jet on left side of transmission are
similar.
1. Disconnect tube (2, figure ) from fitting (4).
clogged, determine source(s) of material (paragraph
63-3).
2. Inspect for corrosion. Superficial corrosion
damage on plate on exterior of transmission is
acceptable if removed.
3. Inspect for mechanical damage. Cracks and
distortion are not acceptable.

2. Cut and remove lockwire from screw (7) and

remove screw.

3. Remove planetary oil jet (8).

63-00-00
Rev. 5 Page 51
 \ij3j7
|: BC ^%/~~' ( / Xn- 6 (0.45 N.m)

DETAIL A

1. Gasket
2. Electric chip detector self-closing valve
3. Packings
4. Electric chip detector element
6. Wire terminal
6. Nut
7. Nipple
8. Pump screen
9. Plug

DRIP LOOP

DETAIL B

412M-63-15

Figure 63-15. Sump Case Electric Chip Detector

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 Bell Helicopter BHT-412-MM-6

AREA B A
A AREA
CHIP DETECTOR A
B7669B

AREA LIMITS

All No cracks allowed.

A Maximum depth of pitting is 0.030 inch (0.762 millimeter) with no more than
40 percent of any 1.0 inch (25.4 millimeters) square or 20 percent of total area
of any pitted surface.

B Maximum depth of pitting is 0.020 inch (0.508 millimeter) with no more than
40 percent of any 1.0 inch (25.4 millimeters) square or 20 percent of total area
of any pitted surface. Thread damage is not permitted.
412--63-16

Figure 63-16. Sump Case Electric Chip Detector- Damage Limits

63-55. Cleaning 63-57. Installation

MATERIALS REQUIRED MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications and source. Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

C-304 Solvent C-405 Lockwire

1. Clean oil jets using solvent (C-304). 1. Lubricate new packing (1, figure 63-17) with
transmission oil (Chapter 12). Install packing on
2. Dry with filtered, compressed air. planetary oil jet (8).

63-56. Repair 2. Lubricate new packing (6) with transmission oil

and install on fitting (4).
Repair of jets is limited to removal of corrosion
products from plate at base of jet on exterior of 3. Install nut (5) on fitting (4), and install fitting on
transmission. planetary oil jet (8).

4. Insert planetary oil jet (8) into transmission

housing and install screw (7). Secure screw (7) on
planetary oil jet (8) with lockwire (C-405).

5. Connect tube (2) and tighten nut (3).

63-00-00
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BHT-412-MM-6 Bell Helicopter

SEE DETAIL LOCKWIRE

(MS20995C32)
DETAIL A

1. Packing
2. Tube
3. Nut
4. Fitting
5. Nut
6. Packing
7. Screw
8. Planetary oil jet

412-M-63-17

Figure 63-17. Planetary Oil Jet

6. Check for oil leaks at next helicopter ground run. 63-62. Repair

63-58. OIL JET NO. 1 Refer to paragraph 63-56.

63-59. Removal 63-63. Installation

1. Cut and remove lockwire from screw (9, figure 63- MATERIALS REQUIRED
18) and screw (3), and remove screw (9).
Refer to BHT-ALL-SPM for specifications and source.
2. Remove oil jet (6) from housing (2) on
transmission (1). NUMBER NOMENCLATURE

3. Remove screw (3) and washers (4 and 5). C-405 Lockwire

4. Remove and discard packings (7 and 8). 1. Install screw (3, figure 63-18) with washers (4 and
5) on oil jet (6).
63-60. Inspection
2. Lubricate new packings (7 and 8) with
Refer to paragraph 63-54. transmission oil (Chapter 12) and install in grooves of
oil jet (6).
63-61. Cleaning
3. Carefully insert oil jet (6) into housing in top case
Refer to paragraph 63-55. (2).

63-00-00
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 Bell Helicopter BHT-412-MM-6

4. Install screw (9). Secure screw (9) to screw (3) 4. Install screw (1). Secure screw (1) to screw (7)
using lockwire (C-405). using lockwire (C-405).

5. Check for oil leaks at next helicopter ground run. 5. Check for oil leaks at next helicopter ground run.

63-64. OIL JET NO. 2 63-70. OIL JET NO. 3

63-65. Removal 63-71. Removal

1. Cut and remove lockwire from screw (1, figure 63- 1. Cut and remove lockwire from bolt (1, figure 63-
19), and remove screw (1) from oil jet (4). 20) and screw (10).

2. Remove 2. oil Remove

oil jet
jet (4)
(4) from
from housing
housing (8) on
(8) on 2. Remove bolt (1), washer (2), and bracket (3) from
transmission. oil jet (7).

3. (7) and
3. Remove
Remove screw (7) and washers (5
screw
washers and 6).
(5 and 6). 3. Remove oil jet (7) with packing (4, 5, and 6).

4. Remove and discard packings (2 and 3).

5. Remove and discard packings (4, 5, and 6).

63-66. Inspection

Refer to paragraph 63-54. 63-72. Inspection

.
63-67. Cleaning

Refer to paragraph 63-55. 63-73. Cleaning

Refer to paragraph 63-55.

63-68. Repair
63-74. Repair
Refer to paragraph 63-56.
Refer to paragraph 63-56.
63-69. Installation
63-75. Installation
MATERIALS REQUIRED
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.
Refer to BHT-ALL-SPM for specifications and source.
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
C-405 Lockwire
C-405 Lockwire
1. Install screw (7, figure 63-19) with washers (5 and
6) on oil jet (4). 1. Carefully install screw (10, figure 63-20) with
washers (8 and 9) on oil jet (7).
2. Lubricate new packings (2 and 3) with
transmission oil (Chapter 12) and install in grooves of 2. Lubricate new packings (4, 5, and 6) with
jet. transmission oil (Chapter 12) and install in grooves of
oil jet (7).
3. Carefully insert oil jet (4) into housing (8) on
transmission. 3. Carefully insert oil jet (7) into manifold (11).

63-00-00
Rev. 5 Page 55
 SEE DETAIL B

LOCKWIRE
SEE DETAIL A (MS20995C32)

2. Top case
3. Screw
4. Thin steel washer
5. Washer (NAS1598-3Y)
6. Oil jet No. 1
7. Packing (MS29561-011)
8. Packing (MS29561-010)
9. Screw

412-M-63-18

Figure 63-18. Oil Jet No. 1

63-00-00
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 Bell Helicopter BHT-412-MM-6

SEE DETAIL A DETAIL A

DETAIL B

1. Screw
2. Packing (MS29561-010)
3 Packing (MS29561-011)
4. Oil jet No. 2
5. Washer (NAS1598-3Y)
6. Thin steel washer
7. Screw
8. Housing

412M-63-19

Figure 63-19. Oil Jet No. 2

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BHT-412-MM-6 Bell Helicopter

4. Install bolt (1), washer (2), and bracket (3). 63-81. Installation
Torque bolt (1) 50 to 70 in.-lbs. (5.7 to 7.9 N-m).
MATERIALS REQUIRED
5. Secure bolt (1) to screw (10) using lockwire (C-
405). Refer to BHT-ALL-SPM for specifications and source.

6. Check for oil leaks at next helicopter ground run. NUMBER NOMENCLATURE

63-76. OIL JET NO. 4 C-405 Lockwire

63-77. Removal 1. Install screw (7, figure 63-21) with washers (5 and
1. Remove access door on right side of pylon ) on oi je (4).
support in cabin.
2. Lubricate new packings (2 and 3) with
2. Cut and remove lockwire from screw (8, figure 63- transmission oil (Chapter 12) and install in grooves of
21) and screw (7). Remove screw (8). oil jet (4).

3. Carefully insert oil jet (4) into sump case (1).

NOTE
When removing oil jet No. 4 (4) from sump 4. Install screw (8) to secure oil jet (4) into sump
case, make sure packings (2 and 3) are case (1). Secure screw (8) to screw (7) using lockwire
extracted with the oil jet. (C-405).

3. Remove oil jet (4) with packings (2 and 3) from 5. Check for oil leaks at next helicopter ground run.
sump case (1).
63-82. OIL JET NO. 5
4. Remove screw (7) and washers (5 and 6) from oil
jet (4). 63-83. Removal

5. Remove and discard packings (2 and 3). 1. Cut and remove lockwire from screw (4, figure 63-
22) and screw (5). Remove screw (4).
63-78. Inspection
Refer63-54..
Refer to paragraph to paragraph
63-54. ~2. Carefully remove oil jet (3) with packing (1 and 2).

63-79. Cleaning 3. Remove screw (5) and washers (6 and 7) from oil
jet (3).
Refer to paragraph 63-55.
4. Remove and discard packings (1 and 2).
63-80. Repair

Refer to paragraph 63-56. 63-84. Inspection

Refer to paragraph 63-54.

63-85. Cleaning

Refer to paragraph 63-55.

63-86. Repair

Refer to paragraph 63-56.

63-00-00
Page 58 Rev. 5
 DETAIL B

SEE DETAIL
B

1. Bolt
2. Thin steel washer
3. Bracket
4. Packing (MS29561-011)
5. Packing (MS29561-010)
6. Packing (MS29561-008)
7. No. 3 oil jet
8. Washer (NAS1598-3Y)
9. Thin steel washer
10. Screw
11. Manifold

412-M-63-20

Figure 63-20. Oil Jet No.

3

63-00-00
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BHT-412-MM-6 Bell Helicopter

DETAIL A

DETAIL A

412-M-63-21

Figure 63-21. Oil Jet No. 4

63-00-00
Page 60 Rev. 5
 Bell Helicopter BHT-412-MM-6

63-87. Installation 63-93. Installation

MATERIALS REQUIRED MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications and source. Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

C-405 Lockwire C-405 Lockwire

1. Install screw (6, figure 63-23) with washers (4 and

1. Install screw (5, figure 63-22) with washers (6 and 5) on oil jet (8).
5) on oil jet (8).
7) on oil jet (3).
2. Lubricate new packings (1, 2, and 3) with
2. Lubricate new packings (1 and 2) with transmission oil (Chapter 12) and install in grooves of
transmission oil (Chapter 12) and install in grooves of oil jet (8).
oil jet (3).
3. Carefully insert oil jet (8) into transmission case.
3. Carefully insert oil jet (3) into transmission case.
4. Install screw (7). Secure screw (7) to screw (6)
4. Install screw (4), and secure screw (5) to screw with lockwire (C-405).
(4) using lockwire (C-405).
5. Check for oil leaks at next helicopter ground run.
5. Check for oil leaks at next helicopter ground run.
63-94. OIL JET NO. 7

63-88. OIL JET NO. 6 63-95. Removal

63-89. Removal 1. Cut and remove lockwire from oil pressure

1. Cut and remove lockwire from screw (7, figure 63-
23) and screw (6), and remove screw (7).
2. Remove oil jet (8) with packings (1, 2, and 3)
3. Remove screw (6) and washers (4 and 5).
regulating valve (1, figure 63-24) and thermoswitch
(11) and thermobulb (12).
2. Remove oil pressure regulating valve (1, figure
63-24) with packing (2). Discard packing (2).
6
3. Cut and remove lockwire from screw (8) and
screw (9), and remove screw (8) and washer (7).

4. Remove and discard packings (1, 2, and 3). 4. Remove oil jet (6) with packings (3, 4, and 5).

63-90. Inspection 5. Remove screw (9) and seal (10). Discard seal
(10).
Refer to paragraph 63-54.
6. Discard packings (3, 4, and 5).
63-91. Cleaning
63-96. Inspection
Refer to paragraph 63-55.Refer
. to paragraph 6 Refer to paragraph 63-54.

63-92. Repair 63-97. Cleaning

Refer to paragraph 63-56. Refer to paragraph 63-55.

63-00-00
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BHT-412-MM-6 Bell Helicopter

LOCKWIRE

1. Packing (MS29561-010) 5. Screw

EIALS
R UI 3. Oil jet No. 5 7. Washer (NAS 1598-3Y)
4. Screw

412-M-63-22

Figure 63-22. Oil Jet No. 5

63-98. Repair 5. Lubricate new packing (2) with transmission oil

(Chapter 12) and install on oil pressure regulating
Refer to paragraph 63-56. valve (1).

Refer to BHT-ALL-SPM for specifications and source. 7. Secure oipresse regulating valve (1) to
thermoswitch (11) and thermobulb (12) with lockwire
NUMBER NOMENCLATURE (C-405).

C-405 Lockwire 8. Check for oil leaks at next helicopter ground run.

2. Lubricate new packings (3, 4, and 5) with 63-101. Removal

transmission oil (Chapter 12) and install in grooves of
oil jet (6). 1. Cut and remove lockwire from oil pressure
regulating valve (1, figure 63-25) and thermoswitch (3)
3. Carefully insert oil jet (6) into transmission case. and thermobulb (4).

4. Install screw (8) and washer (7). Secure screw (8) 2. Remove oil pressure regulating valve (1) and
to screw (9) with lockwire (C-405). packing (2). Discard packing (2).

63-00-00
Page 62 Rev. 5
 Bell Helicopter BHT-412-MM-6

1. Packing (MS29561-010)
2. Packing (MS29561 -01 1)

LOCKWI RE
(MS20995C32)

Figure 63-23. Oil Jet No. 6 63-00-00

Rev. 5 Page 63
63-102. Cleaning 2. Install oil pressure regulating valve (1) in manifold
(Detail A).
MATERIALS REQUIRED
3. Secure oil pressure regulating valve (1) to
Refer to BHT-ALL-SPM for specifications and source. thermoswitch (3) and thermobulb (4) with lockwire (C-
405).
NUMBER NOMENCLATURE

C-304 Solvent 63-106. OIL TEMPERATURE MANIFOLD

63-107. Removal

DO NOT IMMERSE VALVE IN SOLVENT

1. Wipe oil pressure regulating valve (1, figure 63-
25) with clean cloth damp with solvent (C-304).
2. Dry using filtered, compressed air.
2. Remove bolt (16), thin steel washer (17), and
bracket (18).
3. Remove oil jet (14) and packings (11, 12, and 13).
Discard packings (11, 12, and 13).

63-103. Inspection 4. Cut and remove lockwire from electrical

Inspect oil pressure regulating valve (1, figure 63-25)
for damaged threads and for mechanical or corrosion
damage. Damage in excess of superficial is
unacceptable. Corrosion damage shall be removed.
connector and disconnect electrical connector from
thermobulb (6).
5 Disconnect hose (9) from elbow (8).

63-104. Repair 6. Identify and tag electrical wire installed on

Repair of oil pressure regulating valve (1, figure 63-25)
is limited to removal of superficial corrosion from areas
exposed on exterior of transmission.
63-105. Installation
thermoswitch (23), and disconnect electrical wire from
thermoswitch (23).
7. Identify and tag electrical wires installed on
bracket (21). Remove electrical wires from bracket
(21).

MATERIALS REQUIRED
8. Remove bolt (19), thin steel washer (20), and
bracket (21).
Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE 9. Cut sealant from around tube (2) using a sharp
plastic scraper.
C-405 Lockwire
10. Carefully work manifold (24) loose and remove
1. Lubricate new packing (2, figure 63-25) with manifold with tube (2), packings (1, 3, 4, and 5), and
transmission oil (Chapter 12), and install packing on oil gasket (25). Discard packings (1, 3, 4, and 5) and
pressure regulating valve (1). gasket (25).

63-00-00
Page 64 Rev. 5
Bell Helicopter BHT-412-MM-6

LOCKWIRE

SEE DETAIL B

DETAIL A
LOCKWIRE

1. Oil pressure regulating valve

2. Packing
3. Packing (MS29561-010)
4. Packing (MS29561-011)
5. Packing (MS29561-008)

7. Thin steel washer

8. Screw
9. Screw
10. Seal (PRP110-3/16)
11. Thermoswitch
12. Thermobulb
412-M-63-24

Figure 63-24. Oil Jet No. 7

63-00-00
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BHT-412-MM.6 Bell Helicopter

LOCKWIRE
(MS20995C32)

2. Packing
3. Thermoswitch
4. Thermobulb

412-M-63-25

Figure 63-25. Oil Pressure Regulator Valve

63-00-00
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 Bell Helicopter BHT-412-MM-6

63-108. Installation 11. Connect electrical plug to thermobulb (6) and

secure with lockwire (C-508).
MATERIALS REQUIRED
12. Connect electrical wire to thermoswitch (23).
Refer to BHT-ALL-SPM for specifications and source.
13. Install electrical wires on bracket (21). Remove
NUMBER NOMENCLATURE identification tag.
C-308 Adhesive
14. Apply a bead of adhesive (C-308) around each
C-405 Lockwire end of tube (2) at mating joint.
C-508 Lockwire

1. If removed, coat new packing (10, figure 63-26) 63-109. OIL PRESSURE TRANSMITTER
with transmission oil (Chapter 12) and install in
manifold (24). Install elbow (8) and nut (7) on manifold. 63-110. Removal
Do not tighten nut (7) at this time.
1. Cut and remove lockwire from electrical
2. Lubricate new packings (1 and 3) with connector (5, figure 63-27), and disconnect electrical
transmission oil and install on tube (2). Install tube (2) connector.
in oil manifold assembly (24).
2. Cut and remove lockwire securing oil pressure |
3. Lubricate new packings (4 and 5) with transmitter (4).
transmission oil and install in oil manifold assembly
(24). Lubricate new gasket (25) with transmission oil 3. Remove oil pressure transmitter (4) with packing
and install on oil manifold assembly (24). (3). Discard packing (3).

4. Carefully work oil manifold assembly (24) into
position on transmission case. Ensure tube (2) is
seated on oil jet No. 3 housing and bushings on
bottom of oil manifold assembly are seated on
transmission case.
5. Install bolt (19) with washer (20) and bracket (21).
Do not torque bolt (19) at this time.
6. Lubricated new packings (11, 12, and 13) and
install packings on oil jet (14).
4. Cap or plug exposed cavity in oil pressure
manifold (2).
63-111 Inspection
Inspect oil pressure transmitter (4, figure 63-27) and
electrical connector for bent pins, damaged threads,
dents, or other mechanical damage rendering
transmitter unserviceable.
63-112. Installation

7. Carefully install oil jet (14) in oil manifold (24) and MATERIALS REQUIRED
install bolt (16) with washer (17) and bracket (18).
Refer to BHT-ALL-SPM for specifications and source.
8. Torque bolt (16) 50 to 70 in.-lbs. (5.6 to 7.9 N-m).
Secure bolt (16) to screw (15) with lockwire (C-405). NUMBER NOMENCLATURE
C-405 Lockwire
9. Torque bolt (19) 50 to 70 in.-lbs. (5.6 to 7.9 N-m).
Secure bolt (19) to thermoswitch (23) and thermobulb C-508 Lockwire
(6) with lockwire (C-405).
1. Lubricate packing (3, figure 63-27) with
10. Install hose (9) on elbow (8). Tighten nut (7). transmission oil (Chapter 12).

63-00-00
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BHT-412-MM-6 Bell Helicopter

2. Install packing (3) on oil pressure transmitter (4). 3. Install electrical connector (5). Secure connector
with lockwire (C-508).
3. Install oil pressure transmitter (4) in oil pressure
manifold (2). Secure oil pressure transmitter with 4. Perform functional check of pressure switch
lockwire (C-405). (Chapter 96) and check for oil leaks at next helicopter
ground run.
4. Install electrical connector (5) and secure
electrical connector with lockwire (C-508). 63-117. OIL PRESSURE MANIFOLD

5. Perform functional check of pressure transmitter 63-118. Removal

(Chapter 96) and check for oil leaks at next helicopter
ground run. 1. Remove oil pressure switch (paragraph 63-114).

PRESSURE SWITCH
63-113. OIL PRESSURE SWITCH 2. Remove oil pressure transmitter (paragraph 63-
63-114. Removal 110).

1. Cut and remove lockwire from electrical 3. Remove tube assembly (2, figure 63-29).
connector (5, figure 63-28), and disconnect electrical
connector (5).
4. Remove nuts (7) and washers (5 and 6) securing
oil manifold (4). Remove manifold (4) and spacer (3)
2. Cut and remove lockwire from pressure switch from transmission
(4), and remove pressure switch (4) with packing (3).
Discard packing (3).
63-119. Cleaning
3. Cap or plug cavity in oil pressure manifold (2). MATERIALS REQUIRED

63-115. Inspection
Refer to BHT-ALL-SPM for specifications and source.
Inspect pressure switch (4, figure 63-28) and electrical
connector for bent pins, damaged threads, dents, or NUMBER NOMENCLATURE
other mechanical damage which would render switch
unserviceable. C-304 Solvent

63-116. Installation 1. Wipe oil manifold (4, figure 63-29) with clean cloth
damp with solvent (C-304).
MATERIALS REQUIRED

2. Dry using filtered, compressed air.

Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE 63-120. Inspection

C-405 Lockwire Inspect oil manifold (4, figure 63-29) for damaged
threads and for mechanical or corrosion damage.

Corrosion damage shall be removed.

1. Lubricate packing (3, figure 63-28) with
transmission oil (Chapter 12), and install packing (3)
on pressure switch (4).
2. Install pressure switch (4) in manifold (2), and
secure pressure switch (4) with lockwire (C-405).
63-121. Repair
Repair of oil manifold (4, figure 63-29) is limited to
removal of superficial corrosion from areas exposed
on exterior of transmission.

63-00-00
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 Bell Helicopter BHT-412-MM-6

TORQUE

TORQUE

1. Packing 13. Packing (MS29561-011 )

2. Tube 14. Oil jet No. 3
3. Packing 16. Screw
4. Packing 16. Bolt
5. Packing 17. Thin steel washer
6. Thermobutb 18. Bracket
7. Nut 19. Bolt
8. Elbow 20. Thin steel washer
9. Hose 21. Bracket
10. Packing 22. Oil pressure regulating valve
11. Packing (MS29561-008) 23. Thermoswitch
12. Packing (MS29561-010) 24. Oil manifold
25. Gasket

412-M-63-26

Figure 63-26. Oil Temperature Manifold

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BHT-412-MM-6 Bell Helicopter

63-122. Installation 63-125. Cleaning

1. Position spacer (3, figure 63-29) and manifold (4) MATERIALS REQUIRED
on transmission (1).
Refer to BHT-ALL-SPM for specifications and source.

then steel washers (6) and install nuts (7).

C-304 Solvent
3. Install tube assembly (2).
1. Wipe all parts with clean cloth damp with solvent

and pressure switch (63-116).

5. Perform functional check of pressure switch and
transmitter (Chapter 96) and check for oil leaks at next
helicopter ground run.
63-123. FILLER NECK, SCUPPER, AND MOUNTING
BRACKET
63-124. Removal
1. Disconnect hose assembly (16, figure 63-30)
from elbow (18).
2. Dry using filtered, compressed air.
63-126. Inspection
1. Inspect scupper (1, figure 63-30) and oil filler cap
for cracks and distortion or other damage rendering
either component unserviceable. A loose fitting cap
and/or cracked or distorted scupper is not acceptable.
Unserviceable components shall be replaced.
Superficial damage such as dents, nicks, or scratches
not affecting serviceability are acceptable without
repair. Light surface corrosion is acceptable provided it
is removed and original surface finish restored.

2. Inspect bracket (5) and tube (13) for damage

2. Remove nut (24), washer (25), and screw (17).
3. Disconnect tube assembly (19).
4. Loosen and remove nut (14) from extension cap
(15), and loosen nut (12) from elbow (11). Remove
tube (13).
5. Loosen nut (10) and remove elbow (11) with
packing (9). Discard packing (9).
such as distortion and cracks. Loose fitting, cracked,
and/or severely distorted parts are unacceptable and
shall be replaced. Superficial dents, nicks, and
scratches not affecting serviceability are acceptable
without repair.
63-127. Installation
1. Install aluminum washers (22, figure 63-30) on
scupper assembly (1). Position scupper assembly (1)
on bracket (5).

2. Install aluminum washers (21) and nuts (20).

6. Remove nuts (20) and washers (21). Remove Torque nuts (20) 50 to 70 in.-lbs. (5.6 to 7.9 N-m).
scupper assembly (1) from bracket (5) and remove
washers (22) from
washers (22) from bracket (5). 3. Install nut (10) on elbow (11).

7. Remove nuts (8) and washers (6 and 7) from 4. Lubricate packing (9) with transmission oil
bolts (2), and remove bracket (5). (Chapter 12). Install packing (9) on elbow (11).

8. Remove bolts (2) and washers (3 and 4) from 5. Install elbow (11) on scupper assembly (1). Do
bracket (5). not tighten nut (10) at this time.

63-00-00
Page 70 Rev. 5
 LOCKWIRE
(MS20995C32)

DETAIL A

SEE DETAIL A

pressure transmitter manifold

3. Packing
4. Pressure switch
5. Electrical connector

412-M-63-27

Figure 63-27. Oil Pressure Transmitter

63-00-00
Rev. 5 Page 71
BHT-412-MM-6 Bell Helicopter

LOCKWIRE

DETAIL A

1. Transmission

pressure transmitter manifold

3. Packing

412-M-63-28

Figure 63-28. Oil Pressure Switch

63-00-00
Page 72 Rev. 5
 Bell Helicopter BHT-412-MM-6

6. Position bracket assembly (5) on transmission 5. Remove nut (9) and washer (8). Remove bracket
and install bolts (2) with steel washers (3) under bolt (10), tee connection (14), nut (12), and washer (13)
heads and aluminum washers (4) next to bracket (15). together as an assembly.

6. Clean sealant from puller hole in bottom center of

230 to 250 in.-lbs. (25.9 to 28.2 N-m).

DO NOT USE JACKSCREWS TO

PULLER BOLT TO BOTTOM OUT IN

10. Install screw (17), washer (25), and nut (24). THREADED HOLE OF PUMP.

7. Install slide hammer type puller equipped with 1/4

8. Loosen jamnut on drain valve (13A) and rotate

counterclockwise.
Extension cap (15) may be installed by
inserting cap on transmission, pressing 9. Remove remaining nuts (7) with washers (5 and
down on cap and twisting clockwise to 6) and remove pump (4) with packings (2 and 3).
engage lock.
10. Remove and discard packings (2 and 3).
12. Check for leaks at next helicopter ground run.
63-130. Installation
63-128. OIL PUMP
MATERIALS REQUIRED
63-129. Removal
Refer to BHT-ALL-SPM for specifications and source.
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE

C-405 Lockwire
---- Slide Hammer with 1/4
X 28 UNF Threaded 1. Lubricate packings (2 and 3, figure 63-31) and
Shaft mating surfaces of pump (4) and transmission sump
assembly (1) with transmission oil (Chapter 12). Install
packings (2 and 3) on pump (4).
1. Remove access door in front of pylon support in
cabin area.
NOTE
2. Drain transmission oil (Chapter 12) from The main rotor can be manually rotated, as
transmission sump assembly (1, figure 63-31). necessary, to obtain alignment of oil pump
shaft.
3. Cut and remove lockwire securing oil pump
screen (17) and remove oil pump screen with packing 2. Warm sump case port with a heat lamp and insert
(16). Discard packing (16). pump into mounting port. Align pump shaft with
internal splines of transmission shaft (18). Use a
flashlight to verify engagement of pump and shaft (18)
4. Remove tubes (11 and 15). through open port of oil pump screen (17).

63-00-00
Rev. 5 Page 73
BHT-412-MM-6 Bell Helicopter

SEE DETAIL A 2 0 S

DETAIL A

1. Transmission
2. Tube assembly
3. Spacer
4. Oil manifold
5. Aluminum washer
6. Steel washer
7. Nut

412-M-63-29

Figure 63-29. Oil Pressure Manifold

63-00-00
Page 74 Rev. 5
3. Install bracket (10), tee connection (14), washer 63-134. Cleaning
(13), and nut (12) on pump mounting stud.
MATERIALS REQUIRED
4. Install steel washer (8) and nut (9). Position drain
valve (13A), as required, and tighten jamnut. Refer to BHT-ALL-SPM for specifications and source.

5. Install washers (5), steel washers (6), and nuts NUMBER NOMENCLATURE
(7). Torque nuts (7) and nut (9) 50 to 70 in.-lbs. (5.6 to C-304 Solvent
7.0 N-m).

6. Connect drain tubes (11 and 15). 1. Rinse inlet oil pump screen (1, figure 63-32) with
solvent (C-304).
7. Lubricate packing (16) with transmission oil
(Chapter 12). Install packing (16) on oil pump screen
(17).
63-135. Installation
8. Install oil pump screen (17) and torque oil pump MATERIALS REQUIRED
screen 300 to 400 in.-lbs. (33.9 to 45.1 N-m).

9. Secure oil pump screen (17) to electric chip

detector base with lockwire (C-405). NUMBERNOMENCLATURE

10. Service transmission (Chapter 12). C-405 Lockwire

11. Install access door. 1. Lubricate new packing (2, figure 63-32) with
transmission oil (Chapter 12). Install packing (2) on
12. Check for oil leaks at next helicopter ground run. inlet oil pump screen (1).

63-131. OIL PUMP INLET SCREEN 2. Install inlet oil pump screen (1) on transmission
sump assembly (3).
63-132. Removal
3. Torque inlet oil pump screen (1) 300 to 400 in.-
1. Drain transmission oil sump (Chapter 12). bs. (33.9 to 45.1 N-m).

2. Cut and remove lockwire from oil pump inlet 4. Secure inlet oil pump screen (1) to transmission
screen (1, figure 63-32). sump assembly (3) with lockwire (C-405).

3. Remove oil pump inlet screen (1) from 5. Check for oil leaks at next helicopter ground run.
transmission sump assembly (3).
63-136. SUMP INTERNAL FILTER
4. Remove and discard packing (2).
The following procedures apply to helicopters S/N
33001 to 33214 not modified by T.B.412-91-94. For
63-133. Inspection maintenance procedures applicable to helicopters
modified by subject T.B. (installation of full flow debris
1. Inspect oil pump inlet screen (figure 63-33) for paragraph 63-140.
metal particles. If metal particles are present, refer to
paragraph 63-3. 63-137. Removal

2. Inspect inlet oil pump screen (1) for damage in 1. Remove access door on right side of pylon
accordance with figure 63-33. support in cabin area.

63-00-00
Rev. 5 Page 75
 FWD ~\

1. Scupper assembly 13. Tube

2. Bolt 14. Nut
3. Thin steel washer 15. Extension cap
4. Thin aluminum washer 16. Hose assembly
5. Bracket 17. Screw
6. Thin aluminum washer 18. Elbow
7. Thin steel washer 19. Tube assembly
8. Nut 20. Nut
9. Packing 21. Aluminum washer
10. Nut 22. Aluminum washer
11. Elbow 23. Fitting

25. Washer
412-M-6330

Figure 63-30. Filler Neck, Scupper, and Mounting Bracket

63-00-00
Page 76 Rev. 5
 Bell Helicopter BHT-412-MM-6

2. Remove nuts (1, 11, and 13, figure 63-34) with

washers (2, 10, and 12). Remove bracket (3). NOTE
Perform step 1, if it is not possible to
3. Remove nut (9) with washers (7 and 8). sufficiently clean the filters while
assembled.
4. Remove filter assembly (4).
Perform steps 2 and 3, if it is possible to
sufficiently clean the filters while
5. Remove and discard packing (5) from filter assembled.
assembly (4).
1. To disassemble filter, proceed as follows:
6. Cap or cover filter mounting port in sump case
(6). a. Straighten tangs on washer (2, figure 63-35)
and remove nut (1).
63-138. Inspection
b. Remove washer (2), spacer (3), and wafer
screens (4).
NOTE
If the sump internal filter must be c. Wash wafer screens (4) with solvent (C-304).
disassembled for inspection, refer to Dry wafer screens (4) with filtered, compressed air.
paragraph 63-139 and perform steps 1.a.
and d. Assemble filter, with spacer (3) first, with
eleven spacers (3), ten screens (4), washer (2) and
1. Inspect filter for metal particles and/or other nut(1).
material. If metal particles are found, refer to
paragraph 63-3.
when turned by hand.
2. Inspect wafer screens (4, figure 63-35) for
distortion or tears. Damage that can be detected f. Bend one tang of washer (2) over a flat side of
visually is not acceptable. nut(1).

3. Inspect spacers (3) for corrosion and 2. Wash filter assembly (4, figure 63-34) with
deformation. Damage in excess of superficial is not solvent (C-304).
acceptable.
3. Dry with filtered, compressed air.
4. Inspect nut (1) for corrosion and thread damage.
Damage in excess of superficial is not acceptable. 63-140. Installation

5. Inspect filter body (5) for
corrosion damage (figure 63-36).
63-139. Cleaning
MATERIALS REQUIRED
mechanical and 1. Lubricate new packing (5, figure 63-34) with
transmission oil (Chapter 12). Install packing (5) on
filter (4).
2. Insert filter assembly (4) in mounting port of sump
(6).

Refer to BHT-ALL-SPM for specifications and source. 3. Position bracket (3) over filter (4) and studs on
sump case (6).
NUMBER NOMENCLATURE
4. Install washers (2, 10, and 12) and nuts (1, 11,
C-304 Solvent and
and 13).
13).

63-00-00
Rev. 5 Page 77
BHT-412-MM-6 Bell Helicopter

SEE DETAIL A

1. Transmission sump assembly 10. Bracket

2. Packing 11. Tube
3. Packing 12. Nut
4. Pump 13. Washer

6. Steel washer 14. Tee connection (

7. Nut 15. Tube
8. Steel washer 16. Packing
9. Nut 17. Pump screen
18. Shaft DETAIL A
412-M-63-31

Figure 63-31. Transmission Oil Pump

63-00-00
Page 78 Rev. 5
 Bell Helicopter BHT-412-MM-6

IN-LBS (33.9 T 045.1 N.m)

Is /

i,.
v
.1< ^~ 3 DETAIL A

1. Screen

SEE A
DETAIL 3. Transmission sump assembly

412-M63-32

Figure 63-32. Oil Pump Screen

5. Install aluminum washer (7) next to filter housing 5. Remove cup (8), scupper (7), and screen tube
and steel washer (8) adjacent to nut (9). (10).

6. Install nut (9). Torque nuts (1, 9, 11, and 13) 50 to
70 in.-lbs. (5.6 to 7.0 N-m).
7. Check for oil leaks at next helicopter ground run.
63-141. FULL FLOW DEBRIS MONITOR
The following procedures are applicable to helicopters
S/N 36020 and subsequent and earlier numbered
helicopters modified by T.B.412-91-94.
63-142. Removal
63-143. Inspection
1. Inspect chip detectors and screen tube (9 and 10,
figure 63-37) for metal particles and/or other material.
If metal particles are found, refer to paragraph 63-2.
2. Inspect chip detectors and screen tube for
distortion or tears. Damage which can be detected
visually is not acceptable.
3. Inspect nuts (5) for corrosion and thread damage.
In excess of superficial is not acceptable.

1. Remove access door on right side of pylon 63-144. Cleaning

support in cabin area.
MATERIALS REQUIRED
2. Disconnect electrical harness (2, figure 63-37).
Refer to BHT-ALL-SPM for specifications and source.
3. Remove nuts (5), washers (4), and brackets (1
and 3). NUMBER NOMENCLATURE

4. Remove debris monitor from sump case. C-304 Solvent

63-00-00
Rev. 5 Page 79
BHT-412-MM-6 Bell Helicopter

AREA
A

SCREEN
204-040-237-001

AREA LIMITS

All No cracks allowed.

A Maximum depth of pitting is 0.030 inch (0.762 millimeter) with no more than
40 percent of any 1.0 inch (25.4 millimeters) square or 20 percent of any pitted
surface.

B Maximum depth of pitting is 0.020 inch (0.508 millimeter) with no more than
40 percent of any 1.0 inch (25.4 millimeters) square or 20 percent of total area
of any pitted surface. Corrosion is not permitted on screen. Thread damage
is not permitted.
412-M63-33

Figure 63-33. Oil Pump Inlet Screen - Damage Limits

1. Wash chip detectors (9, figure 63-37) and screen 8. Torque nuts (5) 50 to 70 in.-lbs. (5.6 to 7.0 N-m).
tube (10) with solvent (C-304).
9. Install electrical harness (2).
2. Dry with filtered, compressed air.
10. Install access door on right side of pylon support
63-145. Installation in cabin area.

1. Lubricate new packings (6 and 11, figure 63-37) 11. Check for oil leaks at next helicopter ground run.
with transmission oil (Chapter 12).
63-146. SIGHT GLASSES
2. Install packings on debris monitor.

3. Install screen tube (10), scupper (7), and cap (8) NOTE
on debris monitor. The following maintenance procedures are
detailed for indicator (4, figure 63-38).
4. Torque cap (8) 22 to 30 in.-lbs. (2.5 to 3.4 N-m). Maintenance procedures for indicator (6)
are similar.
5. Perform operational check (Chapter 96) 63-147. Removal

6. Install debris monitor in transmission sump case. 1. Drain transmission oil as necessary (Chapter 12)
to a level below sight gage.
7. Install brackets (1 and 3) using washers (4) and
nuts (5). 2. Remove retainer ring (1, figure 63-38).

63-00-00
Page 80 Rev. 5
 SEE DETAIL A

DETAIL A

1. Nut 8. Thin steel washer

2. Thin steel washer 9. Nut
3. Bracket 10. Thin steel washer
4. Filter assembly 11. Nut
5. Packing 12. Thin steel washer
6. Sump case 13. Nut
7. Thin aluminum washer
412-M63-34

Figure 63-34. Sump Internal Filter (pre T.B. 412-91-94)

63-00-00
Rev. 5 Page 81
 1. Nut
2. Washer
3. Spacer
4. Wafer screens
5. Filter body
6. Name plate

412-M63-35

Figure 63-35. Sump Internal Filter

3. Carefully remove glass (3) with packing (2) and determination of oil level. If any of these conditions are
discard packing. present, replace glass.

4. Remove indicator (4). 2. Inspect indicator (4) for stains that might present
a false oil level reading. If such condition exists,
5. Cover opening in transmission sump case (5). replace indicator.

63-148. Cleaning 3. Inspect retainer ring (1) for distortion, cracks, tool
marks, and insufficient tension. If any of these
MATERIALS REQUIRED conditions exist, replace retainer.

Refer to BHT-ALL-SPM for specifications and source. 63-150. Installation

NUMBER NOMENCLATURE 1. Lubricate new packing (2, figure 63-38) with

transmission oil (Chapter 12). Install indicator (4) in
C-304 Solvent sump.

1. Wipe components with a clean cloth damp with 2. Install new packing (2) on sight glass (3) and
solvent (C-304). insert glass in sump over indicator.

2. Dry with filtered, compressed air. 3. Install retainer ring (1).

63-149. Inspection 4. Service transmission (Chapter 12).

1. Inspect glass (3, figure 63-38) for cracks, crazing,
and stains which would prevent an accurate 5. Check for oil leaks at next helicopter ground run.

63-00-00
Page 82 Rev. 5
 Bell Helicopter BHT-412-MM-6

FILTER BODY
(Q2W10116)

AREA LIMITS

All No cracks allowed.

A Maximum depth of pitting is 0.030 inch (0.762 millimeter) with no more than
80% of any 1.0 inch square (645.16 square millimeter) or 30% of any pitted
surface.

B Maximum depth of pitting (including inside of bolt holes) is 0.020 inch (0.508
millimeter) with no more than 20% of area or wall of any hole to be pitted.

C Maximum depth of pitting is 0.020 inch (0.508 millimeter) with no more than
30% of any 1.0 inch square (645.16 square millimeters) or 30% of total area of
any pitted surface. Thread damage is not permitted.

412-M-63-36

Figure 63-36. Sump Internal Filter - Damage Limits

63-00-00
Rev. 5 Page 83
 LOOKING INBOARD RH SIDE

1. Bracket 5. Nut 9. Chip detector

2. Electrical harness 6. Packing 10. Screen Tube
3. Bracket 7. Scupper 11. Packing
4. Washer 8. Cap 412-M-63-37

Figure 63-37. Full Flow Debris Monitor

63-00-00
Page 84 Rev. 5
 Bell Helicopter BHT-412-MM-6

1. Retainer ring 4. Indicator (204-040-508-5) 7. Glass

2. Packing 5. Transmission sump case 8. Packing
3. Glass 6. Indicator (204-040-508-7) 9. Retainer ring

412-M-63-38

Figure 63-38. Sight Glass

63-00-00
Rev. 5 Page 85/86
 TRANSMISSION OIL COOLING SYSTEM

63-151.TRANSMISSION OIL COOLING 63-154. Inspection

SYSTEM

The transmission oil cooling system detailed in this NOTE

Chapter consists of an external oil filter, thermal oil
bypass valve, two drain valves, and connecting tubes
and hoses. Maintenance procedures applicable to the
oil cooler and blower is described in Chapter 79.
63-152. EXTERNAL OIL FILTER
Inspect oil filter components both before
and after cleaning.
1. Inspect oil filter element (17, figure 63-39) for
contamination. If metal particles are present, refer to
paragraph 63-3. Do not reuse element.

The external oil filter (figure 63-39) is located inside
the right pylon support below the sump case and is
connected to an oil cooler outlet line. The filter element
is replaceable and is made of pleated paper. The filter
head includes a bypass valve to assure oil flow in the
event of filter clogging. If a bypass condition is
impending, a red indicator button extends to provide a
positive visual indication,
2. Inspect flange areas of filter body (19) and filter
3. Inspect area contacted by packing (15) for
damage such as distortion and sharp edges. Minor
surface irregularities may be removed. Distortion or
sharp edges necessitates replacement.

63-153. Removal 63-155. Cleaning

1. Remove access door on front of pylon support in MATERIALS REQUIRED

cabin area. Place container under external oil filter
body (19, figure 63-39) to catch oil spillage.
body
63-39) to figure
(19, Refer to BHT-ALL-SPM for specifications and source.
2. Cut and remove lockwire from v-band clamp (14) NUMBER NOMENCLATURE
and open v-band clamp (14). Remove external oil filter
body (19). C-304 Solvent

3. Remove filter element (17) and make a visual

check for evidence of contamination of metal particles. NOTE
Inspect oil filter components both before
4. Remove packing (16) from center boss under
filter head (13). Remove packing (18) from boss inside and after cleaning.
bottom of external oil filter body (19). Discard packings . ip i i

5. If it is necessary to remove the filter head (13), .

perform the following-:~
perform the following: 2. Dry with filtered, compressed air.

a. Disconnect inlet tube (20) and outlet hose (5). 63-156. Installation

b. Cut and remove lockwire from bolts (3). MATERIALS REQUIRED

MATERIALS REQUIRED

c. Remove bolts (3), washers (4), and spacers Refer to BHT-ALL-SPM for specifications and source.
(24) from bracket (25). Remove filter head (13).
NUMBER NOMENCLATURE

63-00-00
Rev. 5 Page 87
BHT-412-MM-6 Bell Helicopter

1. If removed, install filter head (13, figure 63-39) 63-158. Removal

with outlet port aft. Install spacers (24) between filter
bracket (25) and filter head (13). Install bolts (3),
washers (4), and secure with lockwire (C-405). NOTE
Thermostat (1, figure 63-40) may be
2. Remove plugs or caps and install inlet tube (20) removed without removing valve body (3).
from thermal bypass valve to reducer (21) in filter inlet.
1. Disconnect tubes (7, 10, 11, and 16) from valve
body (3).
3. Install hose (5) to fitting (6) in filter outlet.

2. Remove screws and washers (4) and remove

4. Lubricate packings (15, 16, and 18) with valve body (3) from bulkhead.
transmission oil (Chapter 12).
3. Remove unions (6, 9, 12, and 15) with packings
5. Place packing (18) on boss inside bottom of (5, 8, 13, and 14) and discard packings.
external oil filter body (19). Insert new filter element
(17) and seat firmly on boss. Place large packing (15) 4. Cut and remove lockwire from thermostat (1).
around upper lip of external oil filter body (19) next to Remove thermostat (1) and gasket (2) from valve body
flange. (3) and discard gasket.

6. Install packing (16) around center boss under 63-159. Cleaning

filter head (13). Insert external oil filter body (19) into
filter head (13) while pressing upward until seated. MATERIALS REQUIRED

7. Install v-band clamp (14) around mating flanges Refer to BHT-ALL-SPM for specifications and source.
of head and body. While tapping clamp (14) lightly to
aid in seating, torque nut on clamp to 50 in.-lbs. (5.7 N- NUMBER NOMENCLATURE
m). Secure v-band clamp (14) with lockwire (C-405).
C-304 Solvent

8. Service transmission (Chapter 12).

1. Wipe components with a clean cloth damp with
solvent (C-304).
9. Check for oil leaks at next helicopter ground run.
2. Dry with filtered, compressed air.
63-157. THERMAL BYPASS VALVE
63-160. Installation
The thermal oil bypass valve (figure 63-40) is installed
on the rear bulkhead of cargo hook compartment. The MATERIALS REQUIRED
valve is located in oil lines between transmission and
oil cooler. The assembly consists of a valve body and
a thermostat. The thermostat will be completely open Refer to BHT-ALL-SPM for specifications and source.
when transmission oil temperature is 130°F (55°C) or
below causing oil to bypass cooler and flow directly to NUMBER NOMENCLATURE
transmission. The thermostat partially closes at C-405 Lockwire
temperatures between 130 ° and 175°F (55 ° and
79°C) passing some oil through oil cooler while
allowing remainder to bypass directly to transmission. 1. Lubricate new gasket (2, figure 63-40) and new
At higher temperatures, all oil flow is directed through packings (5, 8, 13, 14) with transmission oil (Chapter
oil cooler before being routed to transmission. 12).

63-00-00
Page 88 Rev. 5
 Bell Helicopter BHT-412-MM-6

2. Install thermostat (1) with gasket (2) in valve body 63-163. Cleaning
(3). Tighten thermostat (1) sufficiently to prevent
leakage. Secure thermostat (1) with lockwire (C-405). MATERIALS REQUIRED

3. Install unions (6, 9, 12, and 15) with new packings Refer to BHT-ALL-SPM for specifications and source.
(5, 8, 13, and 14).
NUMBER NOMENCLATURE
4. Install valve body (4) on bulkhead bracket with C-304 Solvent
screws and washers (4).
1. Wipe components with a clean cloth damp with
5. Service transmission (Chapter 12). solvent (C-304).

6. Check for oil leaks and proper operation at next
helicopter ground run.
63-161. OIL DRAIN VALVES
Two ball type drain valves (one for inlet and one for
outlet oil) are installed in lowest part of oil system
(figure 63-41) between thermal oil bypass valve and
transmission oil cooler. The valves are provided to
drain oil trapped in lines of oil cooler to transmission
system.
NOTE
Maintenance procedures for drain valves
are identical. The procedures for inlet drain
valve are provided.
63-162. Removal
1. Place a container beneath drain valves to catch
oil spillage.
2. Open drain valve (3, figure 63-41) and drain oil.
3. Disconnect tubes (2, 9, and 15). Cap or plug
tubes to prevent contamination.
4. Remove tee (12) with drain valve (3) as an
assembly.
5. Complete disassembly by loosening nut (4) and
removing valve (3) and packing (5). If required,
remove bushing (6) with packing (7), union (10) with
packing (11), and union (14) with packing (13).
6. Discard packings (5, 7, 11, and 13).
2. Dry with filtered, compressed air.
63-164. Inspection
1. Inspect components for cracks and thread
damage. No cracks or thread damage is permissible.
2. Inspect valve for proper operation.
3. Discard components that are not serviceable.
63-165. Installation
1. Lubricate new packings (5, 7, 11, and 13, figure
63-41) with transmission oil (Chapter 12).
2. Install unions (10 and 14) with new packings (11
and 13) into side ports of tee (12).
3. Install packing (7) on bushing (6) and install
bushing in lower port of tee (12).
4. Install valve (3) with packing (5) and nut (4) in
bushing (6). Tighten nut (4) sufficiently to prevent
leakage.
.
helicopter after removing protective cover/caps from
lines, hoses, and ports.
6. Install tubes (9 and 15) and install tube (2) with
new grommet (1) (if required) on lower portion of
valve.
7. Service transmission (Chapter 12).
8. Check for oil leaks and proper operation at next
helicopter ground run.

63-00-00
Rev. 5 Page 89
BHT-412-MM-6 Bell Helicopter

1. Thin aluminum washers (4 places)

2. Bolt (4 places)
3. Bolt (4 places)
4. Thin aluminum washers (4 places)
5. Outlet hose

11. Union
12. Packing
13. Filter head

18. Packing
19. External oil filter body
20. Inlet tube
21. Reducer
22. Packing
23. Bypass indicator
24. Spacer (4 places)
25. Filter bracket

412-M-63-39

Figure 63-39. Transmission External Oil Filter

63-00-00
Page 90 Rev. 5
 Bell Helicopter BHT-412-MM-6

3. Valve body
4. Screw and washer (2 places)
5. Packing
6. Union
7. Oil inlet tube

11. Oil drain tube

12. Union
13. Packing
14. Packing
15. Union
16. Oil outlet tube
THERMO OIL BY-PASS VALVE
412-M-63-40

Figure 63-40. Thermal Oil Bypass Valve

63-166. TRANSMISSION OIL COOLER AND

BLOWER

Refer to Chapter 79 for maintenance procedures

applicable to the combination reduction gearbox oil
and transmission oil cooler and combination engine oil
and transmission oil cooler blower assemblies.

63-00-00
Rev. 5 Page 91
BHT-412-MM-6 Bell Helicopter

5. Packing (2 places)
6. Bushing (2 places)
7. Packing (2 places)
8. Tee to by-pass valve tube
9 Tee to by-pass valve tube
10. Union (2 places)

16. Tee to cooler inlet tube

DRAIN VALVES

412-M-63-41

Figure 63-41. Oil Drain Valve

63-00-00
Page 92 Rev. 5
 TRANSMISSION QUILLS

63-167.TRANSMISSION QUILLS
The transmission quills consists of main input quill,
hydraulic system 2 drive quill, hydraulic system 1 and
tachometer drive quill, rotor brake quill, and tail rotor
drive quill.
10. Position quill (6) at right angle, for clearance, and
remove from transmission pylon cavity.
11. Remove oil transfer tube (19) with packings (18
and 20). Discard packings (18 and 20).
12. Install cover (paragraph 63-218) over main input

The main input quill provides the means for engine to

provide power to transmission through the main 63-170. Cleaning
driveshaft.
MATERIALS REQUIRED
63-169. Removal
Refer to BHT-ALL-SPM for specifications and source.
SPECIAL TOOLS REQUIRED
NUMBER NOMENCLATURE
NUMBER NOMENCLATURE C-304 Solvent

T101308 Jackscrew Set

NOTE
1. Open engine and transmission cowling.
Inspect quill for evidence of leakage prior to
2. Remove main driveshaft (paragraph 63-8). cleaning. The cause of any leakage shall be
corrected prior to further use. For a
definition of acceptable leakage, refer to
3. Disconnect drain tube (26, figure 63-42). paragraph 63-171 below.

4. Remove nut (11) with clip (10) from lower right 1. Wipe external surfaces of quill with a clean cloth
stud on transmission. damp with solvent (C-304).

5. Remove nuts (12). 2. Dry with filtered, compressed air.

6. Using a sharp plastic scraper, cut sealant around 63-171. Inspection

edge of quill.
1. Inspect quill for evidence of leakage. External
7. Cut and remove lockwire from screw (8) and leakage around seals is not acceptable. A small
remove screws. amount of seepage, however, is acceptable. A
continuous flow of droplets is considered leakage.
8. Using a heat lamp or a 250 watt light bulb, heat
case (1) in area of quill. Heat case until area near quill
is hot to the touch with bare hands. Install three
jackscrews (T101308) in holes where screws (8) were CAUTON

separate quill (6) from transmission (1). THIS COMPONENT IS DYNAMICALLY

BALANCED. SIGNIFICANTLY
9. After quill (6) has completely separated from REWORKED DAMAGED AREAS MAY
case, remove jackscrews and install three screws (8) CAUSE HIGH FREQUENCY VIBRATIONS
with washers (7) to secure cap to quill sleeve. AFTER INSTALLATION.

63-00-00
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BHT-412-MM-6 Bell Helicopter

2. Inspect visible portion of main driveshaft curvic 63-173. Installation

coupling adapter (4, figure 63-43). Superficial damage
is permissible without rework. MATERIALS REQUIRED

3. Inspect visible portions of input quill cap Refer to BHT-ALL-SPM for specifications and source.
assembly (3). Maximum depth of pitting is 0.030 in.
(0.76 mm), provided no more than 40% of any 1.0 NUMBER NOMENCLATURE
square in. (645.15 square mm) or 20% of total area of
any surface is affected. Repair acceptable damage in C-308 Adhesive
accordance with paragraph 63-172.
C-405 Lockwire
4. Inspect visible portion of input sleeve (2). Light C-452 Antiseize Compound
oxidation is permitted provided no more than 40% of
any 1.0 square in. (645.15 square mm) or 20% of total
area of any surface is affected. Remove acceptable SPECIAL TOOLS REQUIRED
oxidation as described in paragraph 63-172.
NUMBER NOMENCLATURE
5. Inspect teeth on quill pinion (1) for abnormal gear
wear pattern (BHT-412-CR&O). Abnormal gear wear T101586-5 Pusher Set
pattern is not acceptable and is cause to inspect
mating gear in transmission.
1. Remove setscrews (17, figure 63-42) from studs
in
6. Inspect bearings inside quill by rotating main in transmission
transmission (1).
(1).
driveshaft curvic coupling adapter (4) while holding
input sleeve (2). Bearing roughness which can be
detected by feel is not acceptable. If bearings exhibit NOTE
roughness, refer to BHT-412-CR&O for overhaul If rotor brake quill is installed, remove cover
procedures. from port on opposite side of transmission
(paragraph 63-217). If this port is removed,
63-172. Repair it will be necessary to remove oil jet no. 6
(paragraph 63-89) to allow clearance for
MATERIALS REQUIRED work and plug.

Refer to BHT-ALL-SPM for specifications and source. 2 Remove cover (22) (paragraph 63-217).

NUMBER NOMENCLATURE 3. Reach through port where cover was removed

and position work aid (3, figure 63-42 and 2, figure 63-
C-204 Primer 44) to hold rollers of bearing (2, figure 63-42) against
outer race of bearing.
C-423 Abrasive Cloth or Paper
C-464 India Stone 4. Using a heat lamp or a 250 watt light bulb, heat
case (1) in area of quill port. Heat case until area near
1. Repair quills that have leakage by installing a new quill port is hot to the touch with bare hands.
seal (paragraphs 63-178 or 63-184, as applicable).
5. Lubricate new packings (18 and 20) with
2. Polish out acceptable corrosion and mechanical transmission oil (Chapter 12) and install on tube (19).
damage (as defined in paragraph 63-171) using a fine Position tube in transmission case.
India stone (C-464) and 600 grit abrasive cloth or
paper (C-423). 6. Lubricate new packings (4 and 5) with
transmission oil (Chapter 12). Install packing (5) in
3. Touch-up repaired areas that were previously groove of quill (6) nearest flange and packing (4) in
painted using primer (C-204). groove nearest pinion. Leave center groove open.

63-00-00
Page 94 Rev. 5
 TORQUE NUTS (11 AND 12)
160 TO 190 IN-LBS
(IB.I TO 21.4 N.m)
(18.1 TO 21.4 N.m)

2. Bearing 16. Deleted

3. Workaid (rubber plug) 17. Setscrew
4. Packing 18. Packing
5. Packing 19. Oil transfer tube
6. Main Input quill 20. Packing
7. Aluminum washer 21. Packing
8. Screw 22. Cover
9. Aluminum washer (AN960JD616) 23. Aluminum washer (AN960JD616)
10. Clip 24. Steel washer
11. Nut 25. Bolt
12. Nut 26. Tube (seal drain)
13. Thin steel washer 27. Union
14. Aluminum washer (AN960JD616) 28. Packing

412-M-63-42

Figure 63-42. Main Input Quill

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BHT-412-MM-6 Bell Helicopter
7. Position quill (6, figure 63-42) into port with drain
tube union (15, figure 63-44) for drain tube at bottom.
8. Install the three pusher set studs (13) in holes
where setscrews were removed in step 1. above.
9. Carefully slide quill (6) into transmission case.
Align input quill pinion (6) teeth with input gear quill (5)
teeth. Align front of pinion (6, figure 63-44) with
bearing rollers (3).
10. Slide spacers (11) over studs and install nuts (12)
on studs.
11. Tighten nuts (12) evenly to keep quill aligned.
When quill is started into bearing, remove work aid
plug (2) to prevent pushing work aid into oil jet no. 6 (if
installed).
12. Continue tightening nuts (12) to fully seat quill.
When quill is fully seated, loosen nuts (12) and remove
studs (13) and spacers (11).
NOTE
14, figure 63-42) use only AN960JD616
(aluminum) washer next to transmission
case. Do not substitute any other type
(including NAS1197).
13. Install washer (9), clip (10), and nut (11) on lower
right stud. Install six washers (14) (next to
transmission case), six washers (13) (under nut), and
six nuts (12) on remaining studs. Torque nuts (11 and
12) 160 to 190 in.-lbs. (18.1 to 21.4 N-m).
14. Rotate main driveshaft curvic coupling adapter (4,
figure 63-43) on outboard end of main input quill (6,
figure 63-42) by hand. Check for binding and verify
presence of backlash. Any binding or roughness is not
acceptable.
15. Place a small amount of antiseize compound (C-
452) on threads of union (27).
16. If removed, lubricate a new packing (28) with
transmission oil (Chapter 12), and install on union
63-00-00
Page 96 Rev. 5
(27). Install union (27) in main input quill (6) and install
tube (26) in union.
Install three washers (7) (AN960JD616 only) on
screws (8) and install screws. Secure screws (8) to
main input quill (6) with lockwire (C-405).
18. Install three setscrews (17) into studs on
transmission case.
NOTE
If port cover opposite cover (22) was
removed, install oil jet no .6 (paragraph 63-
93) and cover (paragraph 63-218).
19. Lubricate new packing (21) with transmission oil
(Chapter 12), and install packing (21) on cover (22).
NOTE
Aluminum washers (23) are installed next to
transmission case and steel washers (24)
are installed directly under heads of bolt
(25).
20. Install steel washers (24) and then aluminum
washers (23) under heads of bolt (25).
21. Install bolts (25) on cover (22). Torque bolts 160
to 190 in.-lbs. (18.1 to 21.4 N-m).
22. Apply a bead of adhesive (C-308) around flange
of quill and cover which was removed where there is
contact with case
23. Install main driveshaft (paragraph 63-13).
.
24. Close engine and transmission cowling.
25. Perform engine ground run (BHT-412-FM) and
check for proper operation and leakage.
 1. Pinion
2. Input sleeve
3. Input quill cap assembly
412-M-63-43

Figure 63-43. Main Input Quill Assembly

63-174.MAIN INPUT QUILL MAGNETIC SEAL a. Remove lock spring (4).

(412-040-111)
b. Insert T101306 splined wrench (9, figure 63-
63-175. Removal 46) in nut (5). Install T101588 wrench (3) on main
driveshaft curvic coupling adapter (1) so splines on
SPECIAL TOOLS REQUIRED wrench (3) engage splines of wrench (9). Tighten wing
nuts (2) to lock wrench (3) to adapter (1).
NUMBER NOMENCLATURE

T101306 Wrench and engage wrench (9).

T101588 Wrench Set d. Hold wrench (3) and loosen nut (5) so it can
be removed by hand. Leave nut (5) installed. Remove
412-240-001-101 Wrench

1. Open engine and transmission cowling. e. Remove retainer ring (7, figure 63-45).

2. Remove main driveshaft (paragraph 63-8). f. Remove nut (5, figure 63-46).

5. For helicopter S/N 36020 and sub. (and

3. Remove retainer ring (1, figure 63-45), plate (2), helicopters modified 412-570-001-103) proceed as
and packing (3). Discard packing (3). follows:

4. For helicopters prior to S/N 36020 not modified by a. Remove lock washer (14, figure 63-45) and
412-570-001-103 proceed as follows: retaining ring (13).

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BHT-412-MM-6 Bell Helicopter

b. Install wrench (412-240-001-101) on input 8. Remove carbon seal (2) from seal retainer (6).
quill.
9. Remove packing (1) from seal (2). Discard
c. Loosen nut (15) so it can be removed by hand. packing.
Leave nut (15) installed. Remove wrench.

ring (7)10.
d. Remove
d. Remove retainer ring retainer
(7). Remove magnetic ring (3) from seal retainer (6)
(Detail C).
e. Remove nut (15).
11. Remove packings (4 and 5) from seal retainer (6).
Discard packings.
NOTE
Adapter and magnetic seal assembly (12) 63-176. Cleaning
consists of all the parts shown on figure 63-
45. These parts may be removed as an MATERIALS REQUIRED
assembly.
Refer to BHT-ALL-SPM for specifications and source.
6. Use two screwdrivers to remove adapter and
magnetic seal (12) as an assembly. Position two NUMBER NOMENCLATURE
screwdrivers 180 ° apart and engage groove in seal
retainer (8). Pry against input quill cap assembly (9) to C-304 Solvent
remove adapter and magnetic seal assembly (12).
Carefully place assembly on bench with main
1. Clean seal retainer (6, figure 63-47) and main
facing down. driveshaft curvic coupling adapter (8) with solvent (C-
304).

2. Dry with filtered, compressed air.

CAUTION

MAGNETIC RING (3) AND CARBON SEAL

MAGNETIC RING (3) AND CARBON SEAL 1. Inspect main driveshaft curvic coupling adapter
(2) MUST BE KEPT CLEAN IF THEY ARE
TO BE REINSTALLED. STORE THESE (8, figure 63-47) (paragraph 63-17).
PARTS IN A CLEAN PLASTIC BAG
IMMEDIATELY AFTER REMOVAL TO 2. Inspect seal retainer (6) (BHT-412-CR&O).
PREVENT METAL PARTICLES OR
OTHER MATERIAL FROM COLLECTING. 63-178. Repair

7. Remove carbon seal (2) and seal retainer (6) and Polish out nicks and burrs on seal retainer (6, figure
magnetic ring (3) from main driveshaft curvic coupling 63-47) which could damage packings.
adapter (8) as an assembly (Detail B).
63-179. Installation

Refer to BHT-ALL-SPM for specifications and source.

MAGNETIC RING (3) AND CARBON SEAL
(2) SHALL BE SEPARATED BY PULLING NUMBER NOMENCLATURE
HALVES STRAIGHT AWAY FROM EACH
OTHER. ALLOWING HALVES TO SLIDE C-001 Grease
AGAINST EACH OTHER MAY DAMAGE
MATING SURFACES. C-024 Assembly Fluid

63-00-00
Page 98 Rev. 5
 SEE
DETAIL
A

HARD RUBBER DISC, APPROX.

2 1/8 INCHES (53.9 mm) IN
DIAMETER AND AT LEAST 1/4
INCH (6.35 mm) THICK.

- LIGHT CHAIN, APPROX. 2. Work aid plug

6 INCHES (152 mm) LONG. 3. Bearing (roller)
4. Bearing outer race
5. Input gear quill (driven gear)

DETAILA 12. Nut

12. Nut
APPROX. 2 FEET (609 mm) OF 13. Pusher set stud
SEMIRIGID WIRE - 0.041 INCH (T101586-5)
(1.04 mm) DIAMETER OR HEAVIER.1. Curvic coupling adapter

RED WARNING FLAG. STENCILED. 15. Drain tube union

REMOVE BEFORE CLOSING
TRANSMISSION.
412-M-63-44

63-00-00
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BHT-412-MM-6 Bell Helicopter

SPECIAL TOOLS REQUIRED e. Very carefully place carbon seal (2) on

magnetic ring (3). Align so magnetic seal assembly
NUMBER NOMENCLATURE may be installed on adapter (8) (detail A).

T101306 Wrench 2. Position retaining ring (7) on adapter (8) (detail

A).
T101588 Wrench Set
412-240-001-101 Wrench 3. Position seal retainer (6), and parts assembled in
step 1. above, on adapter (8) (detail A).
1. Assemble magnetic seal and adapter assembly
(12, figure 63-45) as follows: 4. Coat outer diameter of packing (4) and contact
area of seal retainer (6) with assembly fluid (C-024).

CAUTION

LEAVE SEAL IN PACKAGING UNTIL

READY FOR INSTALLATION. SEAL
CAVITY SHALL BE CLEAN AND FREE OF
BURRS ON PACKING CONTACT
DIAMETERS. WHEN SEAL PACKAGE IS
OPENED, SEAL SHALL BE SEPARATED
BY PULLING HALVES DIRECTLY AWAY
FROM EACH OTHER TO PREVENT
DAMAGE TO MATING SURFACES.
INSTALL SEAL BY HAND PRESSURE
ONLY. PRIOR TO INSTALLATION OF
SEAL, LUBRICATE PACKINGS AND
MATING DIAMETERS WITH ASSEMBLY
FLUID (C-024).
a. Coat packings (4 and 5, figure 63-47) and seal
retainer (6) contact diameters with assembly fluid (C-
024).
DO NOT PUSH ON SEAL RETAINER (6)
WHILE INSTALLING MAGNETIC SEAL
AND ADAPTER ASSEMBLY. CARBON
SEAL (2) MAY BE PUSHED OFF EDGE
OF ADAPTER.
5. Align splines of coupling (6, figure 63-45) with
splines of pinion (11). Using hand pressure only, push
coupling (6) inward to obtain contact with splines of
pinion.
6. Locate groove in edge of seal retainer (8). Rotate
retainer (8) to align groove with pin at upper side of
cap (9), then push coupling (6) in against triplex
bearings. Refer to figure 63-46 for a sectional view of
installed adapter and magnetic seal assembly.

b. Install packing (5) in inner groove of seal -.....

retainer. Install magnetic ring (3) in seal retainer (6). CAUTION

c. Install packing (4) on outer groove of seal
retainer (6).
d. Coat packing (1) sparingly with assembly fluid
(C-024) and install in inner groove of carbon seal (2)
as shown in detail B.
DO NOT SEAT SEAL RETAINER (6,
FIGURE 63-46) INTO INPUT QUILL CAP
ASSEMBLY (7) AT THIS TIME.
7. For helicopters prior to S/N 36020 not modified by
412-570-001-103 proceed as follows:

a. Install nut (5, figure 63-45) finger tight to hold

b. Install wrench set (T101306) and (T101588)

DO NOT SLIDE SEAL HALVES ON EACH as described in paragraph 63-175. Torque nut (5) 350
OTHER DURING ASSEMBLY. to 400 ft.-lbs. (475 to 542 N-m).

63-00-00
Page 100 Rev. 5
 Bell Helicopter BHT-412-MM-6

1. Retainer ring
2. Plate
3. Packing
4. Lock-spring
5. Nut
6. Main driveshaft
curvic coupling
7. Retainer ring
8. Seal retainer
9. Input quill cap assembly
10. Transmission
11. Input quill pinion
12. Adapter and magnetic
seal assembly
13. Retaining ring
14. Lockwasher
15. Nut

TORQUE
350 TO 400 FT-LBS 1

subsequent and helicopters

modified by 412-570-001-103.

412-M-63-45

Figure 63-45. Main Input Quill Magnetic Seal

63-00-00
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BHT-412-MM-6 Bell Helicopter

2. Wing nut (MS35426-14) 6. Seal retainer

3. Plate (T101588) 7. Input quill cap assembly
4. Extension bar (L-122) 8. Input quill pinion
9. Tool (T101306)
412-M-63-46

Figure 63-46. Tool Application - Spline Wrench (T101306), Wrench Set (T101588), and Extension Bar
(L-122)

63-00-00
Page 102 Rev. 5
SEE DETAILS A. B, AND C FOR SECTIONAL
VIEWS OF ASSEMBL1ED PARTS A

1. Packing 5. Packing
2. Carbon seal 6. Seal retainer
3. Magnetic ring 7. Retaining ring
4. Packing 8. Main driveshaft curvic coupling adapter

Figure 63-47. Main Input Quill Curvic Coupling Adapter and Magnetic Seal Assembly

63-00-00
Rev. 5 Page 103
BHT-412-MM-6 Bell Helicopter

c. Install lockspring (4). Ensure tang on 63-180. MAIN INPUT QUILL SEAL (28203-3655)
lockspring fully engages nut (5) and pinion (11).
63-181. Removal

8. For helicopters S/N 36020 and subsequent and SPECIAL TOOLS REQUIRED
those modified by 412-570-001-103 proceed as
follows:
NUMBER NOMENCLATURE

a. Lightly coat nut (15) threads with gease (C- T101306 Wrench
001) and coat nut flange face with transmission oil T101588 Wrench Set
(Chapter 12).
--- Grinder, Handheld
b. Install nut (15) and tighten nut to 450 to 500
ft.-lbs. (610 to 678 N-m) using wrench (412-240-001- 1. Remove retaining ring (12, figure 63-48) and
101). plate (11) with packing (10). Discard packing.

2. Remove lockspring (9). Remove nut (8) using

c. Remove nut (15) and wipe clean. wrench (T101306) and wrench set (T101588)
(paragraph 63-175).
d. Repeat steps a. and b.

e. Wipe clean all excess grease from threads CAUTION

and around nut flange interface.

WHEN CUTTING THROUGH OLD WEAR

f. Install lockwasher (14) and retaining ring (13).
9. Using hand pressure only, seat seal retainer (6,
figure 63-46) in groove on input quill cap assembly (7).
Ensure seal retainer is fully seated.
10. Install retaining ring (7, figure 63-45) in groove on
input quill cap assembly (9). Ensure seal retainer (6,
figure 63-46) is fully seated.
11. Install packing (3, figure 63-45) on plate (2).
Install plate (2) on main driveshaft curvic coupling (6).
12. Install retainer ring (1). Ensure retainer ring is fully
seated.
SLEEVE IN THE FOLLOWING STEP, USE
EXTREME CARE TO AVOID DAMAGING
ADAPTER (7).
3. Remove adapter (7). Using a handheld grinder,
cut a groove almost through wear sleeve (6). Strike
wear sleeve (6) with a rubber mallet to break uncut
portion of wear sleeve. Remove and discard wear
sleeve (6).
4. Remove retaining ring (5) and sleeve (4) from cap
(3). Remove and discard packing (1).
5. Remove seal (2) from sleeve (4) by pressing
inboard.

13. Install main driveshaft (paragraph 63-13).

14. Close and secure engine and transmission

cowling.

15. Perform engine ground run (BHT-412-FM) to

check for operation and leaks.

63-00-00
Page 104 Rev. 5
 Bell Helicopter BHT-412-MM-6

63-182. Cleaning Remove light surface corrosion from adapter (7, figure
63-48) and sleeve (4) with a plastic scraper and
MATERIALS REQUIRED abrasive pad (C-407).

63-185. Installation
Refer to BHT-ALL-SPM for specifications and source.
MATERIALS REQUIRED
NUMBER NOMENCLATURE

C-304 Solvent Refer to BHT-ALL-SPM for specifications and source.

C-407 Abrasive Pad NUMBER NOMENCLATURE

C-028 Dry Lubricant

1. Clean disassembled components with an
abrasive pad (C-407). C-317 Adhesive
C-327 Promoter
2. Clean adapter (7, figure 63-48) and sleeve (4)
with a plastic scraper and an abrasive pad (C-407) to C-328 Sealing Compound
remove foreign matter.
C-345 Primer

3. Rinse adapter (7) and sleeve (4) with solvent (C- C-407 Abrasive Pad
304). C-427 Barrier Material

4. Dry parts using filtered, compressed air. SPECIAL TOOLS REQUIRED

63-183. Inspection NUMBER NOMENCLATURE

1. Inspect parts for excessive wear and corrosion. T101306 Wrench

T101588 Wrench Set
2. Inspect parts for cracks. No cracks are allowed.
--- Brush, Hog Bristle,
Unpainted Handle
3. Inspect packing grooves in cap (3, figure 63-48)
and plate (11) for sharp nicks and distortion.

4. Inspect threaded components for thread damage. CAUTION

No thread damage is allowed.
BONDING SHALL BE ACCOMPLISHED
5. Inspect retaining rings (5 and 12) for distortion. WITHOUT DELAY BETWEEN STEPS.
No distortion is allowed. FOUR HOURS IS THE MAXIMUM TIME
INTERVAL BETWEEN SANDBLASTING
63-184. Repair AND THE NEXT STEP.

MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE

C-407 Adhesive Pad

63-00-00
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BHT-412-MM-6 Bell Helicopter

Cap
3.. Packing 9
7. Lockspring
Adapter
4. Sleeve 10. Packing
5. Retaining ring 11. Plate
6. Wear sleeve 12. Retaining ring

412-M-6348

Figure 63-48. Main Input Quill Seal (28203-3655)

63-00-00
Page 106 Rev. 5

NOTE
Precautions shall be taken when
accomplishing the following steps to keep
wear sleeve and adapter clean. Wear clean
white gloves when handling parts and
change gloves when soiled. Cover work
bench with clean white paper. Avoid any
contact with mold release agents such as
silicone, oil, waxes, grease, etc. Area where
work is performed shall be maintained at
64 to 82F (18 to 28C) with relative
humidity below 75%. Area shall be dust-
free to the extent that bonding operations
are not affected.
1. Mask outer diameter of new wear sleeve (6,
figure 63-48).
2. Mask all surfaces of adapter (7) except those
surfaces which mate with wear sleeve (6).
3. Sandblast unmasked surfaces of wear sleeve (6)
and adapter with 60 grit garnet at 5 to 10 psi and
remove residue. If there is to be any delay before
accomplishing the next step, wrap parts in clean
barrier material (C-427) after sandblasting.
4. Stir primer (C-345) thoroughly in its container and
apply to unmasked portion of adapter (7) only. Scrub
primer into surface of adapter with abrasive pad (C-
407). Repeat scrubbing as required to ensure adapter
is clean.
5. Allow degreaser residue to dry to a white powder.
Remove residue from adapter with a clean, dry
cheesecloth.
. ......... ..
KEEP PROMOTOR (C-327) IN A
COVERED, NON-ABSORPTIVE
CONTAINER AND KEEP LID TIGHTLY
CLOSED WHEN NOT IN USE.
EXPOSURE TO ATMOSPHERE WILL
CAUSE DECOMPOSITION. SEDIMENT
OR BROWN RESIDUE IN BOTTOM OF
CONTAINER INDICATES
DECOMPOSITION OF PROMOTER TO
THE EXTENT IT SHALL BE DISCARDED.
PROMOTER PH RANGE SHALL BE
MAINTAINED BETWEEN 7.0 AND 8.0.
NOTE
If the next step is not to be accomplished
immediately, wrap adapter (7) with clean
barrier material (C-427).
6. Apply promotor (C-327) to unmasked portion of
wear sleeve (6) and adapter (7) with a pure hog bristle
brush with an unpainted handle. Apply only enough
promoter to wet the surfaces.
7. Allow promoter to dry for a minimum of 30
minutes at 65° to 85°F (18° to 29°C) or for 15 minutes
at 150 ° to 160°F (66 ° to 71°C).
NO
If the next step is not to be accomplished
immediately, wrap parts with clean barrier
material (C-427).
8. Mix adhesive (C-317) 33 parts B to 100 parts A.
The pot life of mixed adhesive is 30 to 50 minutes.
9 Coat inside diameter of wear sleeve (6) and
mating surface on adapter (7) with mixed adhesive (C-
317)
10. Press wear sleeve (6) on adapter (7) until inner
shoulder of wear sleeve (6) contacts adapter.
11. Clean excess adhesive from wear sleeve (6)
thoroughly and remove all protective masking
material. Allow adhesive to cure at 65 ° to 85°F (18° to
29°C)
.... for 24 hours.
CAUTION
ENSURE NO EXCESSIVE BONDING
MATERIAL REMAINS BETWEEN WEAR
SLEEVE (6) AND COUPLING RACE.
BONDING MATERIAL WILL BECOME
HARD AND FLAKE OFF. THIS FLAKING
BETWEEN SEAL LIP AND WEAR RING
WILL CAUSE LEAKAGE.
63-00-00
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BHT-412-MM-6 Bell Helicopter

12. Apply a film of sealing compound (C-328) to
outside diameter of new seal (2). Press seal into
sleeve (4) until bottomed out. Remove excess sealant.
13. Lubricate packing (1) with transmission oil
(Chapter 12). Install packing (1) on sleeve (4). Align
cutout in sleeve (4) with pin in cap (3) and install
sleeve (4) in cap (3) by pressing with hand pressure.
Install retaining ring (5).
2. Using a sharp plastic scraper, cut sealant at
mating flanges of tachometer generator (13, figure 63-
49), hydraulic pump (3), and quill (8). Remove sealant
from jackscrew holes.
3. Remove tachometer generator (13) (paragraph
63-199).
4. Remove hydraulic pump (3) (Chapter 29).

14. Spray wear sleeve (6) with dry lubricant (C-028). 5 Install jackscrews (T101308) on quill (8).
Position adapter (7) on quill pinion.

15. Install wrench (T101306) and wrench set

(T101588) as described in paragraph 63-175. Torque CAUT
nut (8) 350 to 400 ft.-lbs. (475 to 542 N-m). -

TIGHTEN JACKSCREWS CAREFULLY

16. Install lockspring (9) in hole of nut that is in line AND EVENLY TO KEEP QUILL ALIGNED
with slot in pinion. DURING REMOVAL.

17. Lubricate new packing (10) with transmission oil
(Chapter 12). Install packing on plate (11). Install plate
in adapter (7).
18. Install retaining ring (12) in adapter (7).
19. Install main driveshaft (paragraph 63-13).
20. Close engine and transmission cowling.
21. Perform engine ground run (BHT-412-FM) and
check for proper operation and leakage.
6. Using a heat lamp or a 250 watt light bulb to heat
sump (10) in area of quill (8). Heat area until hot to the
touch with bare hands. Remove quill (8) by tightening
jackscrews evenly. Cover open mounting port.
7. Remove and discard packing (9) from quill (8).
63-188. Cleaning
MATERIALS REQUIRED
Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE
63-186. NO. 1HYDRAULIC PUMP DRIVE QUILL NUMBER NOMENCLATURE
C-304 Solvent
The No. 1 hydraulic system pump and tachometer
drive quill is located on the forward right side of the
transmission sump assembly. 1. Clean sealant residue from both quill (8) and
transmission mounting port using a sharp plastic
63-187. Removal scraper.

SPECIAL TOOLS REQUIRED 2. Clean external surfaces of parts using solvent (C-
304).
NUMBER NOMENCLATURE
3. Dry with filtered, compressed air.
T101308 Jackscrew Set
63-189. Inspection
1. Remove access door on right side of pylon
support in cabin area. 1. Visually inspect all accessible parts for damage.

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 Bell Helicopter BHT-412-MM-6

2. Rotate quill gear and check bearings for smooth
operation. Roughness that can be detected by feel is
unacceptable.
3. Inspect gear teeth for nicks, dents, cracks and
abnormal wear pattern. Any such damage that can be
detected visually is unacceptable.
c. Remove and discard gasket (3) from sleeve
assembly (4) studs.
d. Press seals (2 and 9) from cover (1).
e. Clean seal housing in cover (1) with solvent
(C-304) and dry using filtered, compressed air.

4. Inspect seals for evidence of leakage, damage, f. Install seals (2 and 9) on sleeve assembly (4).
and abnormal wear. Leaking, damaged, or worn seals
are unacceptable. g. Position new gasket (3) on sleeve assembly
(4) studs.
5. For additional, detailed inspection criteria, refer to
BHT-412-CR&O. h. Install cover assembly (1) on sleeve assembly
(4).
63-190. Repair

MATERIALS REQUIRED NOTE

Bracket (7) replaces washer (6) at 12
o'clock position only.
Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE i. Install bolt (5) with aluminum washers (8) next
to quill housing and steel washers (6), or bracket (7),
C-304 Solvent next to bolt head.

SPECIAL
REQUIRED
TOOLS j. Install nuts (12) with aluminum washers (10)
SPECIAL
REQUIRED
TOOLS next to cover (1) and steel washers (11) next to nut.

NUMBER NOMENCLATURE 63-191. Installation

T101308 Jackscrew Set MATERIALS REQUIRED

1. Quill (8) shall be replaced as an assembly when Refer to BHT-ALL-SPM for specifications and source.
inspection requirements are not met, however, seals
may be replaced as required. NUMBER NOMENCLATURE

2. Replace seals (2 and 9, figure 63-50) as follows: C-308 Adhesive

a. Remove nuts (12), washers (11 and 10), and 1. Lubricate new packing (9, figure 63-49) with
bolt (5) with washers (6 and 8) and bracket (7). transmission oil (Chapter 12). Install packing (9) in
groove around quill sleeve (8).

NOTE 2. Using a standard heating lamp (or 250 watt light

As sleeve (4) and cover (1) separate, tap
splined end of gear shafts (not shown)
where they protrude through seals (2 and 9)
to prevent binding of shaft bearing in sleeve
assembly.
bulb), heat sump mounting port until unit is hot to the
touch.
3. Coat mating surfaces of quill (8) and sump (10)
with transmission oil (Chapter 12).

b. Using jackscrew (T101308) carefully and 4. Position quill (8) on mounting port with
evenly remove cover (1) from sleeve assembly (4). tachometer generator pad forward.

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BHT-412-MM-6 Bell Helicopter

5. Insert quill (8) into sump. Mesh gears carefully 5. Install jackscrews (T101338) in holes on quill (1).
and guide sleeve flange over mounting studs. Tighten jackscrews carefully and evenly to remove
quill (1) from transmission (4) case.
6. Install aluminum washers (7), steel washers (6),
and nuts (5) on two studs (11). Torque nuts 100 to 140
in.-bs. (11.3 to 11.7 N-m).

7. Check quill (8) to verify presence of backlash. 7. Cover open mounting port to prevent foreign
objects from entering transmission case.
8. Install hydraulic system 1 pump (Chapter 29).

63-194. Cleaning
9. Install rotor tachometer generator (paragraph 63- 63-194. Cleaning
203).
MATERIALS REQUIRED
10. Apply a bead of adhesive (C-308) around mating
surfaces of quill (8), pump (3), and tachometer Refer to BHT-ALL-SPM for specifications and source.
generator (13).
NUMBER NOMENCLATURE
11. Install access door on right side of pylon support
in cabin area. C-304 Solvent

12. Perform engine ground run (BHT-412-FM) and 1. Clean sealant residue from both quill and
transmission mounting port using a sharp plastic
leakage.
scraper.
63-192. NO. 2 HYDRAULIC PUMP DRIVE QUILL
2. Clean external surfaces of parts using solvent (C-
The No. 2 hydraulic system pump is driven by a quill 304)
located on forward side of transmission.

63-193. Removal 3. Dry with filtered, compressed air.

SPECIAL TOOLS REQUIRED

63-195. Inspection
NUMBER NOMENCLATURE

T101338 Jackscrew Set obvious mechanical and corrosion damage (BHT-412-

CR&O).
1. Open transmission forward cowling.
2. Rotate pinion in sleeve and check for rough
2. Remove hydraulic system No. 2 pump (Chapter bearings. Bearing roughness that can be detected by
29). feel is not acceptable.

3. Using a sharp plastic scraper, cut sealant from

around flange of quill assembly (1, figure 63-51). 63-196. Repair
Clean sealant from jackscrew holes (5).
For repair and overhaul instructions, refer to BHT-412-
4. Remove bolts (8) and washers (6 and 7). CR&O.

0
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 Bell Helicopter BHT-412-MM-6

* 0

1. Nut 9. Packing
2. Steel washer 10. Sump
3. Hydraulic pump 11. Drive quill mounting studs
4. Gasket 12. Gasket
5. Nut 13. Tachometer generator
6. Steel washer 14. Steel washer
7. Aluminum washer 15. Nut
8. Quill

412-M-63-49

Figure 63-49. No. 1 Hydraulic Pump Drive Quill

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BHT-412-MM-6 Bell Helicopter

63-197. Installation (2) which also drives the system 1 hydraulic pump (1).
The hydraulic pump (1) and tachometer generator
MATERIALS REQUIRED drive quill (2) is located on the transmission sump case
(3).
Refer to BHT-ALL-SPM for specifications and source.
63-199. Removal
NUMBER NOMENCLATURE

C-308 Adhesive 1. Disconnect electrical connector from rotor

tachometer generator (5, figure 63-52).
1. Lubricate packing (3, figure 63-51) with
transmission oil (Chapter 29) and install on quill (1). 2. Remove nuts (7) and steel washers (6).

2. Lubricate mating surfaces of quill (1) and

3. Using a heat lamp (or 250 watt light bulb), heat
sump mounting port until unit is hot to the touch.
4. Position quill (1) with oil hole (2) straight up. Insert
quill (1) into transmission while rotating pinion
simultaneously to permit gear meshing.
3. Using a sharp plastic scraper, cut sealant from
flange of rotor tachometer generator (5).
4. Remove rotor tachometer generator (5) and
gasket (4). Discard gasket (4).
63-200. Cleaning

MATERIALS REQUIRED
NOTE
Install AN960JD616 aluminum washers (6) Refer to BHT-ALL-SPM for specifications and source.
next to quill sleeve. Do not substitute any
other type washer (including NAS1197). NUMBER NOMENCLATURE

5. Install bolts (8) with steel washers (7) under bolt C-304 Solvent
heads and aluminum washers adjacent to quill flange.
Torque bolts 160 to 190 in.-lbs. (11.9 to 12.3 N-m).
1. Clean sealant residue from both quill and mating
6. Check. quill pinfsurface of offset drive using a sharp plastic scraper.
6. Check quill pinion for freedom of rotation and
existence of backlash.
2. Clean external surfaces of parts using solvent (C-
7. Fill gap between flange on quill (1) and flange on 304).
transmission with adhesive (C-308). Also fill jackscrew
holes with same sealant. Allow to cure.
3. Dry with filtered, compressed air.
8. Install hydraulic system no. 2 pump (Chapter 29).
63-201. Inspection
9. Perform engine ground run (BHT-412-FM) and
check for proper operation of hydraulic system 2 and 1. Inspect rotor tachometer generator (5, figure 63-
leakage. 52) for mechanical and corrosion damage. Superficial
damage is acceptable providing all corrosion is
63-198. ROTOR TACHOMETER GENERATOR removed.

The rotor tachometer generator (5, figure 63-52) is

driven by a chain-and-sprocket offset drive from the 2. Inspect electrical connector for damaged threads
hydraulic pump and tachometer generator drive quill and distorted or missing pins.

63-00-00
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 Bell Helicopter BHT-412-MM-6

1. Cover 7. Bracket
2. Seal 8. Aluminum washer
3. Gasket 9. Seal
4. Sleeve assembly 10. Aluminum washer
5. Bolt 11. Steel washer
6. Steel washer 12. Nut
412-M-63-50

Figure 63-50. No. 1 Hydraulic Pump Drive Quill Assembly

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BHT-412-MM-6 Bell Helicopter

1. Quill assembly
2. Oil hole
3. Packing
. 4. Transmission
5. Jackscrew hole
6. Aluminum washer (AN960PD616)
7. Steel washer
8. Bolt
TORQUE 160 TO 190 IN-LBS
(18.0 TO 21.4 N.m)

412-M63-51

Figure 63-51. No. 2 Hydraulic Pump Drive Quill

63-202. Repair 63-203. Installation

MATERIALS REQUIRED MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specifications and source. Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

C-304 Solvent C-007 Bearing Grease

C-407 Abrasive Pad C-304 Solvent

1. Remove any surface corrosion using abrasive C-308 Adhesive

pad (C-407).
1. Clean mating surfaces of rotor tachometer
2. Remove residue by wiping area with a clean cloth generator (5, figure 63-52) and drive quill (2) with
damp with solvent (C-304). solvent (C-304).

3. Dry with filtered, compressed air. 2. Lubricate rotor tachometer generator (5) shaft
splines with bearing grease (C-007).

3. Position gasket (4) on hydraulic pump and

tachometer generator drive quill (2).

63-00-00
Page 114 Rev. 5
4. Position rotor tachometer generator (5) on quill 6. Install jackscrews (T101338) in holes on quill.
(2) with electrical connector positioned for attachment Tighten jackscrews carefully and evenly to remove tail
of wiring. Install steel washers (6) and nuts (7). rotor quill (7) from transmission sump assembly (11).

5. Apply a bead of adhesive (C-308) around mating

flange of rotor tachometer generator (5) and quill (2).
Allow sealant to cure.
8. Cover open mounting port to prevent foreign
6. Perform helicopter ground run (BHT-412-FM). objects from entering transmission case.
Check for oil leaks and perform operational check of
triple tachometer indicating system (Chapter 95).
63-206. Inspection
63-204. TAIL ROTOR DRIVE QUILL
MATERIALS REQUIRED
Helicopters prior to S/N 36020 have a tail rotor drive
quill equipped with a flexible coupling and located on Refer to BHT-ALL-SPM for specifications and source.
aft side of transmission sump case. The tail rotor
driveshaft is connected to the drive quill by a V-band NUMBER NOMENCLATURE
clamp set.
C-304 Solvent
Helicopters S/N 36020 and sub. (and helicopters
modified by 412-570-103-103) have a tail rotor drive
quill equipped with a rigid adapter rather than the
flexible coupling noted previously and is also located NOTE
on aft side of transmission sump case. The tail rotor The following inspection procedures shall
driveshaft is bolted to an independent flex coupling be accomplished when tail rotor drive quill
which is attached to the rigid adapter. is removed for normal maintenance.

63-205. Removal
1. Inspect coupling (10, figure 63-53) for grease
SPECIAL TOOLS REQUIRED leakage. Wetting of adjacent areas by grease is cause
for replacement of defective parts with the following
NUMBER NOMENCLATURE exception: A small amount of grease expelled from
around lip of seal (9) and/or other quill parts provided
T101338 Jackscrew Set the following evaluation of grease leakage is
accomplished.
1. Remove access doors from left and right side of
pylon support in cabin area.

2. Disconnect and remove forward section of tail CAUTION

rotor driveshaft (Chapter 65). . . .
DO NOT CLEAN OR SPRAY BEARING OR

OF SOLVENT DURING INSPECTION.

USE ONLY CLEAN CLOTH DAMP WITH
4. Remove nuts (1, figure 63-53), steel washers (2),
OF QUILL.
5. Using a sharp plastic scraper, cut sealant
between quill mounting flange and transmission case. a. Wipe grease from coupling (10) and adjacent
Remove sealant from jackscrew holes (6). parts with clean cloths.

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BHT-412-MM-6 Bell Helicopter

1. Hydraulic pump (System 1)

2. Hydraulic pump and tachometer generator drive quill
3. Transmission sump case
4. Gasket
5. Rotor tachometer generator
6. Steel washer
7. Nut
412-M-63-52

Figure 63-52. Rotor Tachometer Generator

b. Inspect coupling (10) over-temperature 63-207. Cleaning

indicator (TEMP-PLATE) for discoloration and
overheat condition. A change in color of over- MATERIALS REQUIRED
temperature indicator (TEMP-PLATE) (from white to
black) indicates a possible overheat condition and/or Refer to BHT-ALL-SPM for specifications and source.
component degradation. Cause of discoloration shall
be determined and corrected prior to continued NUMBER NOMENCLATURE

procedures.

c. Inspect coupling (10) for grease leakage and

for discoloration due to overheating at frequent CAUTION
intervals during the next ten flight hours. If grease .
leakage and/or overheating occurs, replace quill. DO NOT IMMERSE TAIL ROTOR DRIVE
QUILL IN SOLVENT OR SPRAY SOLVENT
2. Inspect seal (9) for protrusion and other evidence ON QUILL. USE ONLY CLEAN CLOTHS
of damage. Protruding and/or damaged seals are not DAMP WITH SOLVENT (C-304) TO
acceptable.
acceptable. EXTERIOR OF QUILL.

1. Clean sealant residue from both quill and

3. Inspect tail rotor drive quill in accordance with transmission mounting port using a sharp plastic
BHT-412-CR&O. scraper.

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 Bell Helicopter BHT-412-MM-6

2. Clean external surfaces of parts using solvent (C-

304). NOTE
Install AN960JD616 aluminum washers (5)
3. next to quill sleeve. Do not substitute any
lint-free cloths. other type washer (including NAS1197).

6. Install aluminum washers (5), thin steel washers

3-208. Repair (4), spacers (3), thin steel washers (2), and nuts (1).
Torque nuts 50 to 70 in.-lbs. (5.45 to 7.91 N-m).
1. Repair mechanical and corrosion damage in
accordance with BHT-412-CR&O.
7. Check quill pinion for freedom of rotation and
existence of backlash.
2. Replace seal (9, figure 63-53) in accordance with
BHT-412-CR&O.
8. Fill gap between flange on quill (7) and flange on
transmission sump assembly (11) with adhesive (C-
3. Lubricate coupling (10) (paragraph 63-208). 308). Also fill jackscrew holes with same sealant.
Allow to cure.
4. Replace over-temperature indicator (TEMP-
PLATE) if required (BHT-412-CR&O). 9. Install forward section of tail rotor driveshaft
(Chapter 65).
63-209. Installation
10. Ground run helicopter (BHT-412-FM) and check
MATERIALS REQUIRED for leaks at quill flange and loss of lubricant at
coupling. If lubricant loss is evident, refer to Chapter
65.
Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE 11. Install access doors on both sides of pylon

support in cabin area.
C-308 Adhesive
63-210. ROTOR BRAKE QUILL
1. Lubricate new packing (8, figure 63-53) with
transmission oil (Chapter 12). Install packing in groove For helicopters so equipped, the rotor brake quill is
around tail rotor drive quill (7) sleeve. installed on left side of transmission main case (figure
63-54).
2. Verify mating surfaces of quill (7) sleeve and
transmission case are free of all foreign material. 63-211. Removal

3. Lubricate mating surfaces of quill (7) and SPECIAL TOOLS REQUIRED

transmission mounting port with transmission oil
(Chapter 12). NUMBER NOMENCLATURE

T100929 Jackscrew Set

4. Using a heating lamp (or 250 watt light bulb), heat
sump mounting port until unit it is hot to the touch.
1. Open left side engine and transmission cowling to
gain access to transmission.
5. Insert quill (7) into transmission while rotating
pinion simultaneously to permit gear meshing. Position
mounting holes in sleeve over transmission studs. 2. Remove brake assembly (Chapter 29).

63-00-00
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 63-213. Inspection

ROTOR BRAKE DISC AND FLANGE 2. Inspect quill and pinion gear for obvious
ASSEMBLY SHALL BE REMOVED AS AN mechanical and corrosion damage (BHT-412-CR&O).
ASSEMBLY. DO NOT ATTEMPT TO
REMOVE DISC FROM FLANGE WHILE 3. Rotate pinion and check for rough bearings.
ASSEMBLY IS INSTALLED ON QUILL. DO Bearing roughness which can be detected by feel is
NOT SEPARATE DISC FROM FLANGE IF not acceptable.
DISC IS NOT BEING REPLACED.
63-214. Repair
3. Cut lockwire and remove nut (7, figure 63-54) with
packing (8). Remove disc and flange assembly from For complete repair procedures, refer to BHT-412-
CR&O.
quill (2).
63-215. Installation
4. Using a sharp plastic scraper, cut sealant from
between quill mounting flange and transmission case. MATERIALS REQUIRED
Clean sealant from jackscrew holes.
Refer to BHT-ALL-SPM for specifications and source.
5. Remove bolts (5), steel washers (4), and
aluminum washers (3). NUMBER NOMENCLATURE
C-308 Adhesive
6. Install jackscrews, T100929, and tighten carefully
and evenly to remove rotor brake drive quill (2) with C-405 Lockwire
packing (1) from transmission. Discard packing.
1. Remove cover from mounting port in
7. Cover mounting port in transmission to prevent ransmission.
entry of foreign material.
2. Ensure mating surfaces of quill and transmission
are free of all sealant and other foreign matter. Clean
63-212. Cleaning as required.

MATERIALS REQUIRED 3. Lubricate new packing (1, figure 63-54) with

transmission oil (Chapter 12). Install packing in groove
Refer to BHT-ALL-SPM for specifications and source. on quill (2).

NUMBER NOMENCLATURE 4. Apply a light coat of transmission oil to bore of

transmission quill port and to mating diameter of quill
C-304 Solvent assembly.

1. Clean sealant residue from both quill and mating 5. Using a heating lamp (or 250 watt light bulb), heat
surface of transmission using a sharp plastic scraper sump mounting port until unit is hot to the touch.
and solvent (C-304).

NOTE
2. Clean external surfaces of parts using solvent (C-
304) During installation of quill assembly, lightly
tap quill inward uniformly around face of
quill flange near outer edge with a plastic
3. Dry with filtered, compressed air. mallet. Do not strike end of quill shaft.

63-00-00
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 Bell Helicopter BHT-412-MM-6

DETAIL A X

1. Nut 7. Tail rotor drive quill

2. Steel washer 8. Packing
3. Spacer 9. Seal
4. Steel washer 10. Coupling
5. Washer 11. Sump assembly
6. Jackscrew holes

NOTE: Location of over-temperature indicators (TEMP-PLATE).

412-M-63-53

Figure 63-53. Tail Rotor Drive Quill

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BHT-412-MM-6 Bell Helicopter

6. Insert quill into transmission while rotating pinion 10. Fill gap between flange on quill (2) and flange on
simultaneously to permit gear meshing. transmission sump with adhesive (C-308). Also fill
jackscrew holes with same sealant. Allow to cure.

NOTE 11. Install brake assembly (Chapter 29).

Deleted.
12. Apply a light coat of transmission oil to splines in
quill (2) and mating splines on brake disc (6) and
7. Install NAS1197 washers (3) against flange of flange assembly.
quill, AN960JD616 washers (4) under head of bolts (5)
and install bolts (5). Torque bolts 160 to 190 in.-lbs.
(18.1 to 21.47 N-m). 13. Install disc and flange assembly (6) on quill (2).

14. Lubricate new packing (8) and install on nut (7).

8. Check quill pinion for freedom of rotation and
existence of backlash.
9. Secure bolts (5) with lockwire (C-405).
15. Install nut (7) in center of disc and flange
assembly. Tighten nut 125 to 150 ft.-lbs. (169.8 to 204
N-m). Secure nut with lockwire (C-405).

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Bell Helicopter BHT-412-MM-6

1. Packing
2. Rotor brake drive quill
3. Aluminum washer
4. Steel washer
5. Bolt
6. Brake disk
7. Nut
8. Packing

412-M63-54

Figure 63-54. Rotor Brake Quill

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 TRANSMISSION QUILL PORT COVERS

63-216.TRANSMISSION QUILL PORT COVERS 5. Carefully and evenly, tighten all three jackscrews
and remove cover (5).

NOTE
6. Remove and discard packing (1).
Removal and installation procedures for
both left and right quill port covers are
identical. The following procedures detail 63-218. INSTALLATION
removal and installation of rotor brake quill
port cover which is used when there is no MATERIALS REQUIRED
rotor brake quill installed.
Refer to BHT-ALL-SPM for specifications and source.
63-217. REMOVAL
NUMBER NOMENCLATURE
SPECIAL TOOLS REQUIRED
C-308 Adhesive
NUMBER NOMENCLATURE
T101308 Screw Set 1. Lubricate new packing (1, figure 63-55) with
transmission oil (Chapter 12).

1. Remove bolts (4, figure 63-55), steel washers (3),

and aluminum washers (2). 2. Install packing (1) on cover (5).

2. Cut sealant from around edge of cover (5) using a
sharp plastic scraper. Clean sealant from jackscrew
holes.
3. Clean sealant from tapped holes (6).
4. Install jackscrew set (T101308) in three tapped
holes (6).
3. Place cover (5) over transmission quill port and
install bolts (4) with steel washers (3) under bolt heads
and aluminum washers (2) next to cover (5). Torque
bolts (4) 160 to 190 in.-lbs. (18.1 to 21.4 N-m).
4. Apply a bead of adhesive (C-308) around
perimeter of cover where it meets transmission case
(7).

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BHT-412-MM-6 Bell Helicopter

TORQUE

(18.0 To 21.4 N.m)

1. Packing 5. Cover
2. Aluminum washer 6. Tapped hole
3. Steel washer 7. Transmission case
4. Bolt

412-M-63-55

Figure 63-55. Quill Port Covers

63-00-00
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 Bell Helicopter
TRANSMISSION MOUNTS
63-219.TRANSMISSION MOUNTS
The transmission mounts consists of forward and aft
isolation mounts, aft friction dampers, and a lift link.
63-220. AFT ISOLATION MOUNT AND FRICTION
DAMPERS
NOTE
Maintenance procedures for left and right
mounts are identical.
63-221. Removal
1. Remove transmission and mast assembly
(paragraph 63-31).
2. Remove bolts (15, figure 63-56) and thin steel
washers (14).
3. Disengage boot (5) from isolation mount support
(1). Remove mount and filler plate (2).
4. Remove nut (10) and bolt (8). Remove friction
damper (9), bolt (13), bushing (6), and boot (5) as a
unit.
63-222. Inspection (Transmission Mounts)
1. Perform spring rate check as follows:
a. Fabricate a steel support sleeve and pressing
be square in relation to sides so mount will be
deflected in vertical plane only.
b. Place mount, long end down, in support
b. Place mount, long end down, in support
c. Place support and mount in a suitable press.
Press indicator should be marked in 5 lb. increments
and should have a range of 0 to 5000 Ibs. (or
equivalent).
d. Center steel pressing button over inner sleeve
of mount.
e. Apply pressure to button and mount with press
ram so as to deflect mount in a vertical plane to 0.4 in.
BHT-412-MM-6
(10.16 mm) at approximately one cycle per minute.
Repeat cycle three times.
f. Mount a dial indicator to press with the finger
of indicator touching pressing button.
g. Apply slight pressure to button with ram to
ensure button is seated.
h. Apply enough pressure to button to deflect
mount 0.1 in. (2.54 mm) and record load. Apply
enough pressure to pressing button to deflect mount
0.3 in. (7.62 mm) and record load. Subtract load noted
at 0.1 in. (2.54 mm) from the load at 0.3 in. (7.62 mm).
If the value is less than 1320 Ibs. (5872 N) for -105
mount or 1610 (7162 N) for -107 mount, replace
mount.
2. Inspect elastomer for cracks, tears, or debonded
areas. Replace if a 0.005 in. (0.127 mm) feeler gage
can be inserted more than 0.25 in. (6.35 mm). Normal
elastomer fretting (eraser type dust) is not cause for
replacement.
3. Inspect bolts and bushings for cracks, corrosion,
scoring, wear, and scratches. Replace damaged parts.
Replace damaged boots.
4. Replace isolation mounts when excessive
vibration is believed to be caused by defective mounts
or when there is other evidence of malfunction.
63-223. Inspection (Aft Mount Friction Dampers)
1. Inspect friction damper (9, figure 63-56) for oil
and grease contamination. If oil and grease
contamination is present, disassemble and inspect
2. Inspect bearing and damper fittings on dampers
for maximum radial play of 0.004 in. (0.101 mm) and
no axial movement.
3. Inspect dampers for binding, rough movement, or
actual lack of movement by stationing personnel
around pylon mounting point. Move pylon fore and aft
using the mast as a lever to rock pylon. If any of the
above conditions are noted replace damper(s).
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BHT-412-MM-6 Bell Helicopter

SEE
SEE DETAIL A -

1. Isolation mount support

2. Filler plate
3. Pylon support
4. Damper fitting
5. Boot
6. Bushing
7. Bolt
8. Bolt
9. Friction damper
10. Nut
11. Thin steel washer
12. Nut A
13. Bolt DETAIL A
14. Thin steel washer
15. Bolt (SEE NOTE)

NOTE: INSTALL LONGER BOLTS IN FORWARD OUTBOARD AND AFT

INBOARD MOUNTING HOLES. INSTALL SHORTER BOLTS IN
REMAINING HOLES
412-M63-56

Figure 63-56. Transmission Aft Isolation Mounts and Friction Dampers

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 Bell Helicopter BHT-412-MM-6

63-224. Installation 63-226. Inspection

1. Place bolt (13, figure 63-56) on friction damper Refer to paragraph 63-223 for inspection procedures.
(9), and install bolt (7), thin steel washer (11), and nut
(12). 63-227. Installation

2. Place bushing (6) and boot (5) on bolt (13).
3. Place friction damper (9) and bolt (13) in pylon
support (3) from inside pylon. Fit bottom of friction
damper (9) on damper fitting (4). Install bolt (8) and nut
(10).
4. Place filler plate (2) on isolation mount support
(1). Place isolation mount support (1) on bolt (13) and
ensure bushing (6), and boot (5) are installed on bolt
(13).
1. Place isolation mount assembly (3, figure 63-58)
and filler plate (4) on pylon support (5).
2. Place bushing (7) and boot (6) on bolt (8). Install
bolt assembly in isolation mount assembly (3) from the
bottom. Fit boot (6) to bushing (7) and isolation mount
assembly (3).
3. Tie bolt (8) in position until transmission
installation is completed.

CAUTION
BOLTS (1) ARE DIFFERENT LENGTHS.
BOLTS (15) ARE DIFFERENT LENGTHS. LONGER BOLTS SHALL BE INSTALLED
THE TWO LONGER BOLTS SHALL BE IN FORWARD MOUNTING HOLES AND
INSTALLED IN FORWARD OUTBOARD SHORTER BOLTS SHALL BE INSTALLED
AND AFT INBOARD HOLES. THE TWO IN AFT MOUNTING HOLES.
SHORTER BOLTS SHALL BE INSTALLED
IN REMAINING HOLES. 4. Install bolts (1) and washers (2). Ensure bolts are
correct grip length.
5. Install bolts (15) and washers (14). Ensure bolts
(15) are correct grip length. 5. Install transmission and mast assembly
(paragraph 63-33).
6. Install boot (5) on isolation mount support (1).
63-228. LIFT LINK
7. Install transmission and mast assembly
(paragraph 63-33). 63-229. Removal

SPECIAL TOOLS REQUIRED

63-225. Forward Isolation Mounts

1. Remove transmission and mast assembly NUMBER NOMENCLATURE

T101581 Hoist

2. Remove bolt (8, figure 63-58). 204-011-128-001 Clevis

3. Disengage boot (6) from isolation mount 1. Open transmission cowling. Remove right or left
assembly (3). Remove boot (6) and bushing (7). access doors on pylon support in cabin.

4. Remove bolts (1). Remove isolation mount 2. Erect hoist (T101581 or equivalent), to steady
assembly (3) and filler plate (4). transmission while link is removed.

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BHT-412-MM-6 Bell Helicopter

PRESS RAM

FABRICATE LOCALLY
STEEL

(6.35 mm THICK X 44.45 mm DIA.)

ISOLATION MOUNT

(76.20 mm) (4.750 mm)

Figure 63-57. Isolation Mount Inspection Work Aid - Tool Application

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 Bell Helicopter BHT-412-MM-6

NOTE

SEE DETAIL A

1. Bolt (See Note)

2. Thin steel washer
3. Isolation mount assembly
4. Filler plate
5. Pylon support
6. Boot
7. Bushing
8. Bolt

DETAIL A
NOTE: INSTALL LONGER BOLTS IN FORWARD MOUNTING HOLES AND
SHORTER BOLTS IN AFT MOUNTING HOLES

412-M-63-58

Figure 63-58. Forward Isolation Mounts

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BHT-412-MM-6 Bell Helicopter

63-232. Installation

WARNING 1. Install hoist and clevis (paragraph 63-229).

MAST NUT (CAP ASSEMBLY 2. Position washer (5, figure 63-59) and link
RETENTION NUT) (412-010-160-103) assembly (7) on transmission lift link fitting (1).
SHALL NOT BE USED TO LIFT
HELICOPTER OR HELICOPTER 3. Install bolt (special) (6), washers (4), and nut (3).
COMPONENTS EXCEPT WHEN MAIN
ROTOR HUB IS INSTALLED. IF MAIN 4. Torque nut (3) 60 to 80 ft.-lbs. (81 to 108 N-m).
ROTOR HUB IS NOT INSTALLED, USE Install cotter pin (2).
MAST NUT (204-010-481-001) ON MAST.
5. Raise transmission sufficiently to allow insertion
3. Install clevis (204-011-128-001) on mast nut. of bolt (12) by hand pressure only.
Attach hoist to clevis. Raise transmission sufficiently to
remove bolt (12, figure 63-59) by hand.
NOTE

bolt (12) shall be forward.

5. Remove cotter pin (2), nut (3), steel washer (4),
bolt (special) (6), washer (special) (5), and remove link
assembly (7).
63-230. Cleaning
6. Position link (7) on beam fitting (11).
7. Install bolt (12), washer (10), and nut (9). Torque
nut (9) 108 to 125 ft.-lbs. (146.8 to 170 N-m).

MATERIALS REQUIRED 8. Install cotter pin (8).

9. Remove hoist and clevis.

Refer to BHT-ALL-SPM for specifications and source.

required.
C-304 Solvent
63-233. LIFT LINK FITTING

60) between lift link fitting (6) and existing

DO NOT IMMERSE BEARING END OF washer (3). It is recommended this washer
LINK IN SOLVENT. (2) be added any time fitting is removed for
any reason.
1. Wipe link clean with a clean cloth damp with
solvent (C-304). 63-234. Removal

2. Dry with a clean, dry cloth or filtered, compressed 1. Remove lift link (paragraph 63-229).
air.
2. Remove cotter pins (5, figure 63-60), nuts (4),
63-231. Inspection and Repair washers (3), and washers (2) if installed.

Refer to BHT-412-CR&O for inspection criteria and 3. Remove lift link fitting (6) from mounting studs of
repair limits and procedures. main support case (1).

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 412-M63-59

Figure 63-59. Transmission Lift Link

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BHT-412-MM-6 Bell Helicopter

63-235. Cleaning 63-237. Installation

MATERIALS REQUIRED 1. Position fitting (5, figure 63-60) on mounting studs

of main support case (1).
Refer to BHT-ALL-SPM for specifications and source.

NUMBER NOMENCLATURE Install nuts (4). For helicopter not modified by T.B. 412-
89-82, torque nuts (5) 37 to 42 ft.-lbs. (50 to 56 N-m).
C-304 Solvent For helicopters modified by T.B. 412-89-82, torque
nuts (4) 40 to 58 ft.-lbs. (54 to 79 N-m). Install cotter
1. Wipe fitting clean with a clean cloth damp with pins.
solvent (C-304).
3. If desired, install lift link (paragraph 63-232).
2. Dry with a clean, dry cloth or filtered, compressed
air.

63-236. Inspection and Repair

Refer to BHT-412-CR&O for inspection criteria and

repair limits and procedures.

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 Bell Helicopter BHT-412-MM-6

SEE NOTE

1. Main support case

2. Washer
3. Steel washer
4. Nut
5. Cotter pin
6. Lift link fitting

NOTE: HELICOPTERS MODIFIED BY T.B. 412-89-82

412-M-63-60

Figure 63-60. Lift Link Fitting

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 Bell Helicopter
SERVICEABILITY CHECKS
63-238.SERVICEABILITY CHECKS - minute particles are found, continue transmission in
TRANSMISSION, TAIL ROTOR GEARBOX
AND INTERMEDIATE GEARBOX
Perform the following procedures when any doubt
exists as to the serviceability of a transmission, tail
rotor gearbox, or intermediate gearbox after finding
63-239. TRANSMISSION
1. Drain transmission, oil cooler, and connecting
lines.
2. Insert a magnet into pump screen boss of plug to
check for additional contamination.
3. Flush oil cooler and connecting lines with clean
approved oil (Chapter 12).
4. Clean and install chip detector plug, pump inlet
screen, and sump oil filter. Replace external oil filter
element.
CAUTION
NOTE CONDITION OF PACKINGS,
SEALS, AND GASKETS BEFORE
INSTALLATION. REPLACE IF DAMAGED.
5. Service transmission with oil (Chapter 12).
6. Ground run helicopter (BHT-412-FM) for one hour
at 100% Nr with maximum pitch which can be applied
without becoming airborne and tail rotor pedal
equivalent to flight position.
7. Drain transmission oil into a clean container and
inspect for chips.
8. Inspect sump internal filter and all chip detectors.
9. If number of particles has increased, or if there
are particles which can be visually identified as chip or
flakes from a gear or bearing, replace transmission,
mast assembly, and transmission oil cooler. Flush oil
lines. If number of particles has decreased and only
BHT-412-MM-6
service.
10. After five hours of service, inspect sump internal
filter and three chip detectors for particles.
.
there are particles which can visually be identified as
chips or flakes from a gear or bearing, replace
transmission, mast assembly, and transmission oil
cooler. Flush oil lines. If the number of particles has
decreased and only minute particles are found,
continue transmission in service.
63-240.INTERMEDIATE OR TAIL ROTOR
GEARBOX
1. Remove, inspect, and clean appropriate chip
detector.
2. Drain gearbox oil into a clean container. Inspect
oil for chips.
3. Flush gearbox with clean, approved oil (Chapter
12). Inspect for chips.
4. Service gearbox with clean, approved oil.
5. Accomplish ground run in accordance with
paragraph 63-239, step 6.
6. Repeat steps 1., 2., and 4. above.
7. If number of particles has increased, or if particles
can be visually identified as chip or flakes from a gear
or bearing, replace gearbox. If number of particles has
decreased and only minute particles are found,
continue gearbox in service.
8. After five hours of service, repeat steps 1., 2., and
4. above.
9. If the number of particles has increased, or
particles can be visually identified as chips or flakes
from a gear or bearing, replace gearbox. If the number
of particles has decreased and only minute particles
are found, continue gearbox in service.
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