bristol aerospace limited BELL 206 SERIES Wire Strike PROTECTION System £747, PRODUCT MANUAL PM-965-—002ALimited Product Liability Eristol Aerospace Limited hereby detines the remedy for non-pertormance or fallure of each new System and Its componente dollvered to the purchaser. Consequently, Bristol wil repalr or replace, at Its option, any defective ‘component free of charge, and delver the repaired oF replaced component to the Purchaser. f.0.b. Bristol plant ln Winnipeg, Canada, if: a component is found to be defective within twelve (12) months trom the date of Salvery: Bristolls given notice ofthe detect within thrty (20) days after its discovery: unless destroyed Becaus fof detect, the detective component Is promptly returned, transportation prepaid, to Bristol's plant in Winnipeg. Canada: and Bristol determines that the defect ie due to faulty workmanship or material deficiency onthe part of Bristol, oF ts subcontractors or suppl Bristot’s iabity ie expressly and exclusively Kmited to the above repair or replacement, and.no warranty is gvenin respect of defects caused by wear and tear, accident, misuse, neglect, alteration, improper maintenance, or intallation. With respect to a defective System or defective System components, Bristol expressly DISCLAIMS any other warranties, guarantees, obligations, and labiltes and the Purchaser expressly WAIVES any other rights, claims, and remedies, whether express or implied, which may arise by law or otherwise, This DISCLAIMER and WAIVER Include, but are not limited to: the implied warranty of MERCHANTABILITY: 1) any Implied warranty arising from course of performance, course of dealing. or usage of trade: 1H) any Implied warranty of FITNESS FOR A PARTICULAR PURPOSE: |W) any condition, express or Implied, statutory or otherwis Bristol shall not be subject to and the Purchaser walves: 1 any obligation or Habilty arising from tort, Including but not limited to: other than those contained within; 1) pre- and post- delivery negigence, whether actual or imputed: b)_ strict products labtty whether for damage to the product Itself or other property, or for personal injury to ‘employees or customers: Wi) any obigation or labuty for consequential and incidental damages, Including. without imitation, loss ofuse, revenue. or. profit, costs of inspection, shipping, andhandiing, andinjury to person or property proximately: and ‘vi) any obligation or lability for cefects, including those alleged to be latent, not discovered and Roticed to Bristol within the above-named limitations. ‘The validation of any litation on this repair or replacement agreement shall not be construed to lnabdate the whole, and all other provisions shall be construed as Ifthe Invalid term had been stricken, \with respect to any System purchased and alleged tobe the cause of any lots or damage to the Purchaser, Iitle lucclaly determined that Bristol's labiity or obligation for any such loss or damage isnot limited as otherwis ‘expressed provided, then the lnvolced selling price of such System shall be the celing lit of Bristol's labilty, if lany, whether founded In contract or tort (including negigence), arising out of or resulting trom: |) tho eriormance or breach of Bristol's obligations or warrant in, or 8) the design, manufacture, delivery, ‘Sale, repair, replacement, or use of any such System. ‘The scope of this Warranty and Remedy and Its Imitations regarding theory of recovery. remedy, time for recovery. and ctherwise, represents a conscious allocation of rik between equal parties. The Purchaser's recourse against Bristol is thus limited In consideration of the purchaser prices between Bristol and the Purchaser. and these limitations have a material influence on such purchase prices, Bristol's representatives may have in the past, or inthe future, make oral statements about the WSPS. Such statements do not constitute warranties, shall not be raled on by the Purchaser, and are not considered to be part of or have any effect on this Warranty and Remedy.BELL 206 SERIES Wire STRIKE PROTECTION System [2Z7=47,This Product Manual applies to Kit Numbers 965-36502-002 and 965-36504-005 WSPS? is a Registered Trade Mark of Bristol Aerospace Limited Canadian, U.S. and other patents apply. Copyright ® 1992 All rights reserved. No part of this manual may be reproduced in any form without written permission from Bristol Aerospace LimitedPreface This manual provides an overview of Bristol's WSPS product. It includes field information on installation and maintenance procedures, tabulated par lists with illustrations, as well as other pertinent information. Itis recommended that operators and maintenance personnel be familiar with this, booklet and that it be maintained in a safe location to ensure its availability when needed. Operators are requested to complete and return the enclosed “Owner Registra- tion” form, and should circumstances dictate, the “WSPS Equipped Helicopter Wire Strike Report” The kits described in this manual are approved for installation on Bell Helicopter manufactured airrames of the 206 commercial family. Installation on other airframes is carried out at the sole discretion of the installer, who assumes all responsibilty and liability for such installations. ‘The WSPS is also available for the OH-58 military variants, for which installation should be carried outin accordance with the following U.S. Amy Modification Work. Orders (MWO's) Model Kit No. mwo OH-584 965-36503-001 55-1820-228-90-34 OH-8c 965-36503-002 55-1520-228-50-23, Bell 2068-1 Models require Bristol's WSPS kit 965-36503-003 and the associated product manual and installation drawings.THIS PAGE LEFT BLANK INTENTIONALLY1. General Information (Specifications) 1.1 Design Objective The Wire Strike Protection System (‘WSPS” or “System’) is a proprietary product designed to provide a measure of protection for helicopters in the event of inadvertent fight into horizontally strung mechanical, electrical, and communica- tions wires and cables. 1.2 Product Description The basic System consists of a root mounted wedge-type cutter, a bottom fuselage cutter, and/or landing gear mounted cutters, and defiec- tors designed to help guide the wires over aircraft surfaces and windshields into the cutters. Addi- tional deflectors and cutters are added to some helicopter models to facilitate movement of wires over certain obstacles and to protect speciic equipment and/or areas of the helicopter. (See Figure 1-1) 1.3 Product Qualification/ System Capabilities 1.3.1. The capabilities of the WSPS to protect against wire strike damage have been demon- strated by Bristol Aerospace Limited, through extensive ground tests using a truck-mounted helicopter fuselage in runs against various wires and cables, including a single span 10M (10,000 bs. minimum breaking strength) cable and a combination of a 10M and a polyethylene shielded communications cable (100 pair, 24 gauge insu- lated copper wire). These tests were conducted at various velocities up to 60 miles per hour. 1.8.2 The effectiveness of the WSPS against wire sities involving wires and cables commonly used in the North American rural environment was ver fied by the U.S. Amy through pendulum swing tests conducted at the NASA Impact Dynamic Test Facilty at Langley, Virginia. Swing tests against ‘multiple spans of electrical and communications cables with combined strength in excess of 23,000 lbs. were conducted using the OH-S8A and against a single span of an 11,000 Ib. steet cable tests were conducted using the OH-58A, UH-1, OH-6A, AH-1S, UH-60, and AH-64 helicopters These tests were conducted with the helicopter in a substantially horizontal position at time of cable impact. The test results for the OH-58A are pres- ented in U.S. Army Applied Technology Laboratory report No, USAAVRADCOM-TM-80-D-7, “Investi- gation of Helicopter Wire Strike Protection Con- cepts", dated June, 1980. 1.3.3 The effectiveness of the WSPS against wire strikes involving wires commonly used in the Euro- ean rural environment was verified by Aerospa- tiale Division Helicoptéres through ground wire strike tests conducted at the French Army CEV/ Istres test facility. A truck-mounted, WSPS equipped Gazelle helicopter was driven into three spans of Aster 147 electrical cables (625° diame- ter, 19 strand aluminum electrical conductor) with a combined tensile strength of 32,100 Ibs. The test, results are documented in Aerospatiale report 341A.06.2479.JdG, dated 1 October, 1986. 1.3.4 Flight tests are conducted to determine the effect on aircraft handling characteristics and radio signal disturbance, etc., by various military and ci- vilian authorities on WSPS equipped helicopters, for the purpose of product certification. No in-flight wire strike tests to verify the System capability have been conducted. Wire strike protection systems for numerous civil and military helicopters were not tested, but were designed based on “Design Loads” established by a Bristol computer program which was formulated to project wire sliding and cutting loads to approximate test result. 1.4 Conditions and Limitations 1.4.1. The size of the safety envelope provided by the WSPS varies from one aircraft to another de- pending on aircraft limitations and customer speci- fied requirements provided at the time of original design adaptation of the WSPS to the helicopter. The degree of protection provided by the WSPS is, substantially reduced when the fight attitude devi- ates from straight and level. Other factors that can affectthe protection provided by the WSPS include forward speed, cable tension, cable angle, strike angle, and pilot reaction, etc. 1.4.2 Each WSPS is designed to suit a particular base-line helicopter configuration specified by the original customer. Civil helicopter installations are certified by the Federal Aviation Administration (FAA) onthe condition that “the compatibility of his modification with other previously approved modi-fications must be determined by the installer”. This determination should include the airworthiness as- pect as well as any obstacles that may prevent a wire from entering the WSPS cutters. FAA certifica- tion is also contingent on the system being in- stalled according to the approved installation in- struction document, and any deviation from the approved procedures is not permitted. Due to the variables occurring in actual fight conditions, Bris- tol can not warrant the performance of the System. 1.5 Ordering Replacement Parts To ensure getting approved replacement parts, of- der from your locally authorized distributor or agent, or contact Bristol Aerospace Limited direct- ly. All hardware used on the WSPS is of approved aircraft grade. 1.6 Supplemental Type Certificates 1.6.1 Installation of the WSPS has been approved by the Federal Aviation Administration, through issuance of Supplemental Type Certificates, a copy of which is provided in the Addendum, NOTE: — Approval from Canadian and other aviation regulatory bodies may also be in effect. Information is available upon request. 1.6.2 Except where indicated, the (WSPS) Gener- al, Installation, and Maintenance and Repair Instructions. sections apply only to those aircraft model numbers listed on the FAA Supplemental ‘Type Certificates included in the addendum 1.7 Additional Information For additional information concerning the WSPS, please contact your locally authorized distributor or sales agent, or contact: Mail: Bristol Aerospace Limited P.O. Box 874 Winnipeg, Manitoba, Canada RSC 284 ‘Attn: WSPS Contracts Dep't. Courier: 660 Berry St. Winnipeg, Manitoba Canada RSH OSS Telephone: 204-775-8331 Telex: 07-5774 Fax: 204-885-3195 CABLE DEFLECTOR/CUTTER CUTTER BLADES WINDSHIELD DEFLECTOR/CUTTER, SUPPORT STRUT CABLE DEFLECTOR/CUTTER CUTTER BLADES ‘SUPPORT STRUT Nownenea Figure 1~1 Bell 206 Series Helicopter ~ WSPS General Configuration2. Flight Instructions NOTES: The following definitions are used in this manual and originate in the aircraft operators handbook: 1, Land as soon as possible - Land without delay at nearest suitable area (le. open field) at which a safe approach and landing is reasonably assured. 2, Land as soon as practical - The landing site and duration of the flight are at the discretion of the pilot. Extended flight beyond the nearest approved landing area is not recom- mended, 2.1 General Information 2.1.1 The Wire Strike Protection System (WSPS) is @ proprietary product designed to provide a measure of protection for helicopters in the event of inadvertent flight into horizontally strung me- chanical, electrical, and communications wires and cables. 2.1.2 With a lower cutter installed, running take-off involving abnormally negative pitch atti tudes (nose low) should be exercised with caution, particularly on rough and/or obstructed terrain as lower cutter ground contact may occur. CAUTION During maximum performance take- offs (with helicopter landing gear close to the ground), negative pitch attitudes may result in ground contact ofthe WSPS lower cutter tip. Note that conditions of forward C.G., high gross weight, high density altitude, transi- tional lft settling, or tail wind may in- crease the probability of ground con- tact. 2.1.3 If ground contact is experienced, land helicopter as soon as possible and inspect lower WSPS for damage and security. 2.2 In-Flight Wire Strikes 2.2.1 The most effective defense against wire stiikes is avoidance. However, because of the many different encounters that can occur, it is not Possible to provide a procedure to cover every situation. Success in coping with an emergency depends on quick analysis of the situation and reacting with a proper evasive manoeuvre. Never- theless, if avoidance is not possible or not effective, a wire strike will occur 2.2.2 Immediately prior to and during cable impact, deflection, and cutting: 2. Maintain straight and level fight. Itin other than level tight (climb, descent, or turn) and unable to correct to level flight, maintain steady maneuver. b. Maintain airspeed. ¢. Do not initiate any violent maneuvers. d. Once clear of the wire strike area, land the helicopter as soon as possible and inspect it for damage, particularly in the main rotor control tube area, 2.3 Weight and Balance Data The effect on weight and balance is as follows: 2.3.1 WSPS Kit No. 965-36502.002, Standard Breakaway Tip installed. AVERAGE WEIGHT (Ibs) ARM" (in) MOMENT (InJtbs) 16.4 33.4 547.4 2.3.2. WSPS Kit No. 965-36502-002 with Kit No. 965-36504-005 Extension Breakaway Tip Installed AVERAGE WEIGHT (is) ARM (In). MOMENT (Indibs) 16.9 32.53 549.9 *Average arm calculated from Aircraft Station 0.0.THIS PAGE LEFT BLANK INTENTIONALLY3. Installation 3.1 Parts Requirements 3.1.1 Allparts required for installation are supplied in the Bristol Aerospace Limited WSPS Bell 206 Model Kit No. 965-96502-002. 3.1.2. The kits broken down into two sections: Up- er Cutter Installation and Lower Cutter installa- tion. See Section 5, Parts Listing, for complete breakdown, 3.1.3. KitNo. 965-36504-005 is provided for use on high skid gear mounted aircraft, if required, 3.2 Tool/Material Requirements 3.2.1 The following tools (or equivalents) are re- quired for the installation of the Bristol WSPS but are not supplied with the kit: * Cherry Riveter Kit G-784 HSR or 1/8" nominal riv- et diameter Cherry Hand Riveter G-55. * 1/8" nominal rivet diameter hand riveter, angle head 90 degrees, c/w hose pieces, HP-2. * Desouter 90 degree Angle Drill ype MB2-S-2500. * Special extension piece for riveter G-55. See Fig- ure 3-1 for manufacturing details. * Hole finder for matching sheet stock covering ex: isting holes. See Figure 3-1 for manufacturing de- tails. 3.2.2. The following materials are required for the installation of the Bristol WSPS but are not supplied with the kit: * Sealant, 6 oz cartridge, Proseal 890 or equiva- lent. * Epoxy Polyamide Primer, Aerosol, 16 oz 3.2.3 Material Rendered Surplus. Part No.: 206-031-210-389 Description: Door Assembly Qyy: 1 Disposition: Scrap STAKE RIVET FIRMLY, TEMPORARY HOLE FINDER NOTES, 1. Hole locating tool is used to align new holes in repair members which must be in alignment with the existing holes. 2. temporary hole locating tool may be made from any heat-treated aluminum alloy, using only the strap material for a drill guide. Drill hole for rivet undersize; press rivet into place and stake as shown. Do not chamfer |.D. EXTENSION PIECE FOR CHERRY LOCK TOOL MODEL Gs. MAKE FROM % INCH MILD STEEL ROD, 7/16 INCH LONG DRILL 0.090 HOLE CONC. WITH O.D. Figure 3-1 Locally Manutactured Work Aids3.3 Installation Procedure: Aircraft Preparation 3.3.1 Aircraft Preparation Procedure (refer to the Aircraft Manufacturer's Maintenance Manual) NOTE: Follow all standard safety procedures. a. Ensure that the battery is disconnected and that external power is not applied, b. Remove the forward transmission fairing. Cov- er the exposed area with plastic sheeting or ‘other suitable material to prevent entry of metal shavings. . Cover the windshield and overhead window with suitable protective material to prevent damage. 4. Open the circuit breaker panels. Remove rotor ‘brake pump handle if installed. Cover the back Of the circuit breaker panel and the glare shield with a suitable material to protect from metal particles, e. Remove the interior overhead trim panel Disconnect overhead speakers. Remove the LH and RH upper sound proofing blankets, 1. Remove the Outside Air Temperature gauge and store in a sate area. 9. Remove the center windshield post cover. Remove the cable clamps from the wire bundles running from the circuit breaker panels down between the windshields and lower the bundles as far as possible without disconnect. ing. h. Mask off the air intake grils to prevent metal Particles from entering the intake. j. Install pitot tube covers. 3.4 Installation Procedure: Upper Cutter Kit 3.4.1 Installation procedure: Refer to Bristol Dug No. 365-8305 and Figure 3-2. 10 WARNING When using any chemical or com- Pound, observe all manufacturer's safety notes, cautions and warnings. Wear appropriate protective clothing and use appropriate safety equipment and practises at all times. CAUTIONS 1. When drilling out rivets take care not to drill through any electrical cables or hydraulic hoses. 2. Filings or cuttings created during installation of the Bristol Wire Strike Protection System may contaminate the aircratt electrical systems. Ensure that all control panels, electrical com- ponents, electronic panels and elec- trical panels are protected during in- stallation. 3. The following instructions are based on the helicopter manufactur- er's location of rivets and fasteners. It is recommended to use the exi fastener locations where possible. However, these locations may vary from aircraft to aircraft, and it may be necessary to flush existing rivets and add new rivets in some locations. The recommended minimum number of fasteners must be maintained to en- sure the structural integrity of the air- craft and the system. 3.4.2 Aircraft preparation procedure: a Drill out the rivets running between the wind- shields, using a #30 drill Drill out the three center rivets on the upper windshield retaining strip using a #27 drill Countersink and replace with rivets (NAS1739B4-2) Drill out the remainder ofthe blind rivets on the upper windshield retaining strips using a #30 iil (except for the flush rivets on the aircraft Centerline). Drill out the designated rivets aft of the windshield retaining strips using a #30 drid. Drill out rivets as necessary on the upper window retaining strips using a #30 dil e. Drill out the seven centrally located lower windshield retaining strip rivets using a #30 drill. Enlarge holes using a #16 drill. Counter- sink and install a flush rivet (NAS173985-2) in the center hole position, 3.4.3 Using template (365-89041-1) and a hole finder, locate and dill the lower twelve rivet holes in the windshield centerpost through the template using a #30 dril a. Position template on channel (865-83008-13) and transfer the holes in the template to the channel section using a #30 dil . Position the channel using cleco fasteners. Ensure that channel is centrally located and that lower end is flush on aircraft. Backdrill the remaining holes in the channel using a #30 aril ©. Enlarge the holes using a #28 drill and countersink to accommodate screw (NASS14P632-10) 4d, Remove the channel, deburr, and clean out all metal particles. Reposition the channel using screws (NAS514P632-10) as temporary dowel pins. Trim lower end of channel to clear ram air inlet grill as required, e. Remove the channel and apply sealant along its entire mounting surface to prevent water access between channel and the retainer. NOTE: Examine windshield —_retainer (206-032-118-18) for signs of separation from the windshields. If separation exists, remove the re- tainer and reseal using approved sealant. Allow sealant to cure in accordance with manufacturer's specifications. {Install channel using screws (NAS514P632- 10), nuts (MS21042L06), and washers (AN960-6). Startat the lower end of the channel and work up. g. Using a #28 dril, drill a new hole aft of the existing rivet under lower end of channel allowing sufficient edge distance. Countersink and install screw (NAS514P632-10), washer (AN960-6), and nut (MS21042L06), applying approved sealant under the head. fh Using a #27 dil, drill a new hole in the upper fend of the channel in line with the second rivet row and countersink. Install rivet (NAS173984-9), using the extension piece described in Figure 3-1. Apply sealant under the head. 3.4.4 Position lower angles (365-83025-1,-2) firmly against channel. Ensure that the end of channel does not protrude forward of angles. a. Using a hole finder, locate the six lower windshield retaining strip rivet positions where the rivets were removed (step 3.4.2e) and drill through using a #16 dril, Remove, clean, and cleco one angle into position and locate the three 0.165 - 0.169 inch holes in channel (pin 965-83008-13). Remove and drill through using a #19 extension dril. Repeat for other angle. b. Apply sealant to the angle mounting surfaces and rivet the angles into position using six vets (NAS1738B5-4), ensuring they are flush to aircraft and channel 3.4.5 Position the cutter assembly (365-83003-3) into the top end of the channel and proceed as fol- lows: a. Check the gap between the outer sides of the channel and the cutter assembly cheek plates. Shim as required, using shims (365-83024-13). Ensure that the cutter assembly is positioned centrally within the channel and perpendicular to the airframe. b. Ensure the back of the cutter is flush with the end of the channel and that the front end is Pushed down and bottoming in the channel. cc. Locate the second hole from the forward end of the cutter cheek plate and drill through the channel using a #19 extension drill. Align using screw (990-00026-3). . Pull the cutter back until it bottoms in the channel and, using a #19 extension drill, drill through the cutter cheek plates and channel at the aft lower hole position. Align using screw (990-00026-1) @. Drill the remaining cutter attachment holes, using a #19 extension drill, 1"CAPSCREW WASHER CUTTER ASSEMBLY WASHER o- SHIM GUIDE BLADE io BOLT / WASHER NUT WASHER Figure 3-2 (Sheet 1 of 2) Upper Cutter kit — Exploded View 12WASHER ~CUTTER ASSEMBLY CAPSCREW INSERT ASSEMBLY Soe Sat SCREW pees (oP capsorew CHANNEL. WASHER, = “ NUT ANGLE CLIPS Figure 3 -2 (Sheet 2 of 2) Upper Cutter Kit ~ Exploded View 133.4.5 Position doublers (365-83009-1, -2) so their flanges cover the five aft bolt holes in the channel. Ensure the correct edge distance is obtained atthe ends of the doubler flanges, a. Trim the doubler flanges as required to match Cutter assembly (365-83003-3) and to clear the transmission fairing retaining flange. b. Position one doubler and holding firmly in Place, dil the forward hole through the cutter Cheek plates using a #19 extension dil Repeat for other doubler. Secure doublers in place using screw (990-00026-1) and nut (821042108), c. From inside the cockpit area, mark all accessi- ble rivet hole positions. Locate all other rivet holes with a hole finder and dril, using a #30 dril, Enlarge the rivet holes using a #27 dri. d. Mark and drill two new hole positions in the doubler forward edges, and twelve new hole Positions in the doubler aft edges using a #30 Aril. See Bristol drawing 365-83035, fe. Remove one doubler, secure the other doubler with clecos and screw (990-00026-1), and drill the four remaining holes in the doubler flange by backdriling through the cutter cheek plates using a #19 extension dri. Repeat for other doubler. 1. Remove the cutter and doublers, 9. Apply sealant between the cutter shims, cheek- Plates, channel, and both doubler airframe ‘mounting surfaces. Position all components and secure doublers with cleco fasteners. h. Secure the cutter and doubler flanges to the channel using five screws (990-00026-1), four screws (990-00026-3), washers (NAS620-8 or 8L) as required, and nine nuts (MS21042L08) Coat serews with sealant prior to installation, i, Rivet the doublers into position using eighteen rivets (NAS1738B4-3), twenty-eight rivets (NAS1738B4-4), twelve rivets. (NAS1739B4-3), "six rivets (MS20470AD4-5), nine rivets (MS20470AD4-4), and eight rivets (MS20426AD4-4) as per drawing, Do not rivet the strut assembly mounting positions. 14 NOTE: Due to differences in material thickness caused by sealing materials rivets of different lengths may be required. 3.4.6 Attach strut assemblies (365-83007-1, -2) to cutter assembly (365-89003-3) using bolt (NAS464P3A10), two washers (AN6O-10L), nut (MS21042L3) and proceed as follows: a. Locate each strut foot position over the remain- ing seven holes on each side and mark through from undemeath. Remove and drill holes using a #30 drill. Clean and debur. b. Apply sealant to the strut feet. Reposition the struts and rivet feet into position using six rivets (MS20470AD4-6) and -— eight rivets (MS20470AD¢-7). Coat the bolt with sealant. Install bolt, nut and washers, and tighten. NOTE: Ifthe existing forward commer rivet edge distance cannot be obtained on strut foot, install flush rivet. Mark and drill new rivet position main- taining proper edge distance. 3.4.7 Align blade (365-83006-5) with the mounted blade (365-83006-3) in the channel. Use shim (865-83024-5) as required. Ensure that the forward end of the blade is bottomed in the channel and drill through the two pilot holes in the cheek plates using a #19 extension dll 2, Remove the blade and shims. Place the blade ‘on the outside of the cheek plate, align with the ‘existing holes and temporarily pin into position. Using the biade as a dril jg, dil the last hole using a #19 extension dri b. Remove the blade, clean and deburr as necessary. Apply sealant between the blade, shims, and channel, install the blade using two screws _(990-00026.3), washers (NAS620-8, or -8L) as required, two nuts (MS21042L08) in’ the aft holes. Screw (290-00026-7), washers (NAS620-8, or -BL) as required, and nut (MS21042L08) in the forward hole. Coat screws with sealant prior to installa- tion 3.4.8 Position insert assembly (365-83008-15) into the channel. If interference between the cutter blade and the insert assembly is encountered, re- ‘move sufficient material from the insert to obtain the necessary clearance. Ensure the assembly is bottomed in the channel and that the mounting holes are aligned. Trim parts as required to ensurelower end of insert does not protrude beyond end of channel, @. Remove, clean, and install the insert using three screws (MS27039-1-14), three nuts (MS2104213), six washers (AN960-10L), and three screws (MS27039-0817), three nuts (MS21042L08), and six washers (ANS6O-8) as shown on drawing 365-83035. 3.4.9 Install the cable clamps, using existing hard- ‘ware, and reposition the wire bundle, Remove the circuit breaker panel and glare shield covering and thoroughly clean cockpit interior to remove all met- al panicles. a. Refinish/touch up WSPS as required, . Install the sound-proofing blankets, speaker, interior tim, and circuit breaker panel. ©. Remove the windshield and overhead window coverings and install the outside air tempera- ture gauge, 4. Install the forward transmission fairing 3.5 Installation Procedure: Lower Cutter Kit 3.5.1 Installation procedure: Refer to Bristol Dwg No, 365-83037 and Figure No, 3-3. Procedure: ‘@. Remove door assembly (206-031-210-389) and retain mounting screws, pitot static drain line ‘Support, and battery vent tube grommets. b. Refer to drawing 365-83037 and using a #40 Grill, remove and discard the six nut plates located in the second, third, and fourth posi- tions from the front of the access opening, © Using a #40 drill, remove the forward center nutplate and flatten dimpled holes. 35.2 Locate stiffener assembly (365-89021-33) and attach loosely to the aircraft through the for- ward center hole position using screw (MS27039-1-10) and proceed as follows: ‘@. Transfer two additional nutplate holes to the aircraft structure using a hole finder and a #8 aril b. Transfer stiffener assembly mounting holes using a #40 drill, ©. Remove stiffener assembly and dimple two holes in the aircraft structure. ¢. Install stiffener assembly using rivets (CcR2648s3.3) 3.5.3, Locate door assembly mounting (206-031-210-389) and drainline holes on tem. late (965-83026-3) as follows: @. Cleco door assembly and template together through the forward center hole, clamp and check alignment. Transfer the door periphery ‘mounting hole locations to the template using a +#10 drill, Do not pick up locations for nutplates removed at para 3.5.1b above, . Scribe the drain hole locations, separate door from template, and dril holes. 3.5.4 Locate stiffener (365-83021-15) ints position on the aircraft. Trim as required, clamp into posi- tion, and backdrill mounting holes using a #40 Grill. Remove the stiffener, dimple the holes, and re- Place stifener, using Cleco fasteners, a. Locate brackets (365-83021-28) and trim lengths to suit. Mark bracket position, then remove brackets and stiffener. b. Drill out existing fasteners within bracket area using a #40 drill. space permits, drill one hole either side of the upper existing hole, inot, drill a single hole beside the existing hole. Enlarge ‘new holes using a #30 drill and deburr. . Reposition stiffener and brackets and cleco as required. Locate and drill flange attachment holes using a #40 dril (4 per bracket) 4d. Remove stiffener and brackets and drill out the holes using a #30 drill. Reposition stifener and install using four rivets (CCR2648S3-2). ©. Reposition brackets (365-83021-29) and se- cure with Cleco fasteners. backdill mounting holes (4 upper, 2 lower) into brackets using a #30 drill and deburr. Dimple four upper holes (2 per side) in aircraft structure and countersink our holes in backside of bracket to match dimpled holes. 1. Reposition brackets and install using four rivets (NAS1739B4-2) and two tivets. (NAS1738B4-2), Install four rivets (NAS1738B4-1) in flange attachment holes of bracket and stiffener. 153.8.5 Locate stiffener (365-83021-21) inits position ‘on the template. Attach by picking up the stiffener ‘ut piates with screws (MS27039--08) through the cutter pre-drilled locating holes. NOTE: Due to the floating nut plates, the stiffen- er can move slightly on the template. Therefore, use a square to ensure correct 90 degree align: ‘ment between the stiffener and the template be- {ore tightening the retaining screws a. Refer to drawing and backdtil the relocated nut plate screw holes using a #10 drill. Remove stiffener and trim both ends sufficiently to allow proper fit to the aircratt, ensuring correct hole edge distance is maintained. b, Locate nut plates (MS21071L3) on stiffener as, shown and drill nut plate mounting holes using a #40 drill, Countersink holes and install two ‘ut plates using four rivets (CCR264SS3-4), 3.5.6 Locate stiffener (365-83021-3) as per draw- ing and trim both ends of stifener to allow for prop- er fit to aircratt a. Locate stiffener (365-83021-3) on the template as per drawing. Align with stiffener (865-83021-21) and clamp into position main- taining the 0.38 inch dimension on drawing Pick up the cutter assembly rear mounting holes using a #10 dri b. Remove stiffener (365-83021-3) from the tem- plate and mark and drill the nut plate mounting holes using a #40 dri. Countersink and install the two nut plates (MS21059L3) with rivets (CCR264SS3-3), . Attach stifener to the template by picking up the stiffener nut plates through the cutter pre-drilled locating holes with screws (MS27039-1-10). Check the alignment before tightening the screws. . Refer to drawing 3865-83037 and back drill the relocated nut plate holes through stifener using a #10 dell. Remove template. . Locate the nut plate mounting hole locations on stiffener and drill using a #40 dril. Countersink holes and install two nut plates (MS21071L3) using four rivets (CCR264SS-3-4). 16 1. Position template on aircraft and secure. Using ‘a #10 dill, locate new hole positions to aircraft. Remove template. 3.5.7 Attach stiffeners (865-83021-21, -3) to aircraft using existing hardware and two screws (MS27039-1-10) and locate rivet mounting holes approximately as. shown, maintaining adequate edge distance. Drill two holes for each stiffener us- ing a #27 dri a. Remove stiffeners and countersink holes in stiffeners. Dimple holes in aircraft. b. Install stiffeners (365-83021-21, -3) using two rivets (NAS1739B4-3) and two rivets (NAS1739B4-4) respectively. 3.5.8 Position cutter assembly (365-83013-11) on the template and cleco through the four mounting holes. Check the fore and aft alignment and clamp. a. Refer to drawing and locate and drill a new ‘screw hole position through each strut assem- bly foot using a #10 dri. Remove the cutter assembly and locate and drill the nut plate ‘mounting holes in the template using a #40 rit b. Transfer template hole locations to the airerat. Drill and dimple nut plate mounting holes and install nut plates (MS21069L3K) using rivets (CCR264883.3) 3.5.9 Position the template on top of panel (885-89026-5) and cleco together through the cut- ter mounting holes. Ensure the forward center hole is perfectly aligned. Drill the panel periphery holes using a #10 drill, Mark the drain holes and remove the panel. Drill holes, deburr, and prime cut edges. 3.5.10 Position the _cutter__assembly (885-83013-11) on panel (365-83026-5) and check fore and aft alignment. Secure with cleco fasten- ers. Pick up the panel periphery holes to match by back drilling through the panel into the cutter assembly doubler. Remove and deburr 3.5.11 Refer to drawing 365-83037 for installation ‘of vent tube (365-83027-1) and proceed as follows: a. Attach cutter assembly to its mounting stiffen- ers. b. Position vent tube through the existing hole in the aircraft pedestal floor and check for ade-quate clearance between the tube and the siiffener and the tube and the cutter assembly. Elongate the hole tothe leftas required to attain the necessary clearance. ©. Install bracket (AN743-12) and vent tube as per drawing and mark the location of the vent tube on the cutter assembly doubler. d. Remove the cutter assembly. Extend the vent tube to its permanent position and tighten the tube retaining clamp. ©. Transfer the vent tube hole location to panel (865-83026-1) and cut out and/or dril hole. 3.8.12 Loosely install panel (365-83026-1) with the att panel retaining screws and reposition the pitot static drain lines and battery vents through their re- spective holes. 3.5.13 Loosely mount cutter assembly (665-88013-11) and check the alignment. Tighten the panel forward center screw first to ensure that cutter alignment is maintained before tightening the balance of the panel and cutter retaining sorews. Trim parts as required to ensure cutter as- sembly forward end is flush on aircraft. Install the drain and vent line grommets, 3.6 Installation Procedures: Breakaway Tip Kit Extension NOTE To ensure the effectiveness of the WSPS on aircraft mounted on high skid gear, the Extension Breakaway Tip Kit (965-36504-005) must be installed. 3.6.1. Installation Procedure: Refer to Figure 5-3 and proceed as follows: a. Remove two bolts (ANS-6A) securing the standard breakaway tip ». Install Extension Breakaway Tip (965-83045-9) using two bolts (NAS6203-9), two nuts (MS21042L3) and two washers (AN960-10). ©. Touch up paint to match. CAUTION ‘The use of the cutter extension kit on standard (low) skid gear equipped hi opters is not permitted as insutti- cient ground clearance will result. NOTE Conversion of helicopter from high skid gear to standard (low) skid gear will necessitate removal of the exten- sion to ensure adequate cutter ground clearance. To accomplish this remove the extension breakaway tip and at- tachment hardware. Install the stan- dard breakaway tip using existing at- tachment hardware. 3.7 Final Clean-up a. Refinish WSPS as desired. b. Reconnect battery and perform functional test of radio systems. 7SCREW SCREWS SS Lf ANTENNA V ASSEMBLY STIFFENER s Figure 3-3 Lower Cutter Kit — Exploded View 184, Maintenance WARNING Ail hardware used on the WSPS is of approved aircraft grade. Bristol Se- ries 990 screws are heat treated to withstand projected cutting and im- pact loads and should not be replaced with any other type of screw. Maintenance procedures for the Wire Stike Pro- tection System (WSPS) will fall into two basic categories: preventative maintenance to offset deterioration caused by time or weather, and corrective procedures to repair units damaged through accidents. Refer to Paragraph 1.5 preced- ing, for parts ordering 4.1 Preventive Maintenance 4.1.1 Inspect condition and security of WSPS Upper Cutter Assembly, Lower Cutter Assembly, and Deflectors. Minor nicks and scratches to components may be dressed out, with the excep- tion of sawtooth and cutter blades. Replace any cracked or deformed components. Replace loose ‘or damaged fasteners. (See Paragraphs 4.3 and 44 following) 41.2 Inspect sawtooth blades and cutter blades for any deformation, corrosion, nicks, scratches, cracks, or gouges. Inspect blades for damage. Blades showing evidence of any type of damage must be replaced. Damaged or missing rubber coating may be repaired using approved sealant. (See Paragraph 4.5 following.) 4.1.3 Inspect strut assemblies as follows: for deformation at the strut and deflector attachment areas, and at the foot pad areas for cracks, especially in the welded areas and around the formed tab ends and for straightness. (Maximum allowable bow over strut length is 0.060 inches.) Strut assemblies showing permanent deforma- tion, cracks, or excessive bow must be replaced. (Gee Paragraph 4.6 following ) 4.1.4 Inspect and verity that lower cutter break- away tip is secure. Replace if loose or damaged. (Gee Paragraph 4.7 following.) 4.41.5 _ Inspect all components for surface finish deterioration and/or corrosion damage. Refinish areas where surface paint has been removed or damaged. Components showing evidence of light corrosion, except cutter blades, may be repaired and refinished. Replace components showing signs of moderate or heavy corrosion. NOTE: Evaluate corrosion as follows: Light corrosion: characterized by discoloration or pitting to a depth of approximately .001 inch maximum, Moderate corrosion: appears similar to light corrosion except that there may be some blisters or evidence of scaling and flaking. Pitting depth may be as deep as 0.010 inches. Heavy corrosion: general appearance may be similar to moderate corrosion with severe blister- ing, exfoliation, and scaling and flaking, Pitting depths will be deeper that 0.010 inches. 4,2 Damage Inspection and Repair 4.2.1. After a hard landing or after sustaining damage: a. Inspect upper cutter, lower cutter and wind- shield post deflector for obvious damage. b. Inspect attachment area for damage. 4.2.2 Aftera wire strike or suspected wire strike: fa. Inspect for damage to aircraft and external ‘components. Repair any damage to the aircraft in accordance with the aircraft manufacturer's instructions, 19Figure 4-1 Removal and Installation of Upper Cutter Assembly 20b. Inspect condition and security of WSPS. Minor nicks and scratches may be dressed out Replace any components showing evidence of cracks or permanent deformation. Replace loose or damaged fasteners, . Replace cutter blades. Refer to Paragraph 4.7. 4.2.3 Incase of lower WSPS ground contact: a. Inspect lower cutters and deftectors for visible damage and security. Replace any compo- ents showing evidence of deformation, . Inspect attachment area for damage and security. Replace loose and/or damaged fas- teners. c. Replace the breakaway tip, if required. 4.3 Inspection and Repair Procedures: Upper Cutter Assembly A Inspection: 43. . Inspect the assembly for paint deterioration, superficial paint scratches, and light corrosion, Note that no maderate or heavy corrosion is allowed. Scratches, nicks, or gouges toa depth of 0.010 inches may be repaired, b. Inspect the saw blade and cutter blades. (See Paragraph 4.7) cc. Inspect the deflector assembly for cracks and permanent deformation, Deflector assemblies showing evidence of any cracks or permanent deformation must be replaced, 4. Check security of the cutter assembly. Loose fasteners must be replaced, @. Inspect the surrounding support structure for evidence of permanent deformation. If perma- rent structural deformation exists, replace the entire cutter assembly. 4.3.2 Removal: (Refer to Figure 4-1.) a. Remove forward lower entry guide blade and shim b. Remove strut attachment bolt, washers, and ‘nut from deflector. ©. Remove upper cutter mounting capscrews, washers, and nuts. d. Remove the cutter assembly from the aircraft, ting position of shims, if installed. ©. Clean sealant from shims, mounting channel, and cutter assembly. 4.3.3. Repair: Clean and repair areas of light corrosion or deterioration. Use sandpaper to Femove scratches to a maximum depth of 0.010 inches. Prime and paint repaired areas and superficial paint scratches. 4.3.4 Installation: . Position the cutter assembly into the top end of, the channel. Check the gap between the outer sides of the channel and the cutter assembly cheek plates. Shim as required, NOTE: Ensure that the assembly is positioned centrally within the channel and perpendicular to the airframe. Ensure that the back of the cutter is flush to the end of the channel and that the front end is pushed down and bottomed in the channel, b. Apply sealant to cutter assembly, shims, and airframe mounting surfaces. Position cutter and shims. Install capscrews, washers, and nuts. ©. Clean off excess sealant, d. Install strut attachment bolt, washers, and nut. . Install forward lower entry guide blade and shim, Prime and paint as required, 4.4 Inspection and Repair Procedures: Doublers 4.4.1 _ Inspection: . Inspect doubiers for paint deterioration, super- ficial paint scratches, and light corrosion. No moderate or heavy corrosion is allowed. Scratches, nicks, or gouges to a depth of 0.010 in. may be repaired, 21WASHER, i CAPSCREW wa : CUTTER ASSEMBLY DOUBLER, RH RIVET- i STRUT ASSEMBLY: NUT WASHER Figure 4-2 Removal and Installation of Doublers 227 WASHER 29 SCREW Nut a I SCREW MOUNTING 8 CHANNEL: Ls 1 WASHER er NUT: Ta WASHER, NUT Figure 4-3 Removal and Installation of Windshield Deflectorb. Inspect doublers for cracks and permanent deformation. Doublers showing evidence of any cracks or permanent deformation must be replaced ©. Verify security of doublers. Loose fasteners must be replaced. 4.4.2 Removal: (Refer to Figure 4-2.) a. Remove strut assemblies. b. Remove five aft capscrews, washers, and nuts, ©. Remove the LH and RH upper soundproofing blankets, 4. Cover windshield and overhead windows with suitable material to prevent damage. Mask edges, e. Cover back of circuit breaker panel with Suitable material to prevent metal particles from entering electrical area. Mask over cable ac- cess holes to instrument panel and the ram air inlet grit Remove doubler rivet fasteners, CAUTION Care must be exercised when drilling out rivets to prevent damage to electri- cal wiring. g. Remove doubler and clean sealant from ai craft. 4.4.3 Repair: Clean and repair areas of light corrosion and deterioration. Use sandpaper to Temove scratches to a maximum depth of 0.010 Inches. Prime and paint repaired areas and superficial paint scratches, 4.4.4 Installation: . Position doublers so that flanges cover the five aft bolt holes in the cutter assembly. b. Apply seaiant to the base of the doubler and Position using Cleco fasteners. Install the five att capscrews, washers, and nuts. Install rivet fasteners. 24 cc. Clean excess sealant from the doubler periph- ery. d. Install the FM ARC1 14 antenna, Apply sealant around the base of the antenna. e. Install strut assemblies, Prime and paint as required 1. Remove the protective coverings an the circuit breaker panel and the glareshield and thor- oughly clean up the cockpit interior. 9. Remove the protective coverings on the wind- shield and overhead window, close the circuit breaker panel, and install the soundproofing blankets, 4.5 Inspection and Repair Procedures: Windshield Deflector Assembly 4.5.1 Inspection: a. Inspect the detiector assembly for paint deteri- oration, superficial paint scratches, and light corrosion. No moderate or heavy corrosion is allowed. Scratches, nicks, or gouges in the channel and insert to a maximum depth of 0.010 in. may be repaired. ». Inspect the security of the windshield deflection system, paying particular attention to the clips fat the base of the windshield, If clips or windshield defiector components show evi- dence of any cracking or permanent deforma- tion due to impact, they must be replaced Inspect for gaps between the clips and the base of the windshield. No gaps are permitted, and replace as required, 45.2 Removal: (Refer to Figure 4.3.) a. Cover windshield and overhead windows with Suitable material to prevent damage. Mask edge, b. Remove insert retaining screws, washers, and nuts. ¢. Remove insert assembly from channel d. Remove upper cutter assembly as per Para- graph 4.3.2. e. Remove all cable clamps from the wire bundles running down the inside of the windshieldcenter post and the forward clamp on the circuit breaker panel. Lower bundles as far as possi- ble without disconnecting, 1. Cover back of circuit breaker panel to prevent metal particles trom entering electrical area. Mask over cable access holes to instrument panel and the ram ai inlet gril. g. Remove rivet at lower end and rivets at upper end of channel hh. Remove channel attachment screws, washers, and nuts. Remove channel. i. Remove rivets retaining lower angle clips and remove clips. i. Clean sealant from aircratt, angle clips, and channel. 4.5.3 Installation: a. Apply a bead of sealant along the entire deflector assembly mounting surface to pre- vent entry of water between the channel and the retainer. NOTE: Examine windshield retainer for signs of separation from the windshields. It separation exists, remove the retainer and reseal using approved sealant. Allow sealant to cure in accor- dance with manufacturer's instructions. b. Install the channel using screws, washers, and ruts. Start at the lower end of the channel and ‘work upward. . Install rivet at lower end of the channel, applying sealant under the head, 4. Install rivets at the upper end of the channel using extension piece. Apply sealant under the heads. e. Position lower angles firmly against the chan- nel. Apply sealant to the angle mounting surfaces and install the angles. 4. Clean excess sealant from channel and angle clips. Q. Install upper cutter assembly as per Paragraph 43.4 h. Install insert assembly. i. Prime and paint as required. k. Install cable clamps using existing hardware and reposition the wire bundle. Remove the Protective coverings from the circuit breaker panel and glareshield and thoroughly clean up ‘the cockpit interior to remove all metal particles. m. Remove the protective coverings from wind- shield and close the circuit breaker panel, 4.6 Inspection and Repair Procedure: Lower Cutter Assembly 46.1 Inspection: fa. Inspect the assembly for paint deterioration, ‘superficial paint scratches, and light corrosion. Note that no moderate or heavy corrosion is allowed. Scratches, nicks, or gouges to a maximum depth of 0.010 inches may be repaired. b. Inspect the sawblade and cutter blades. (See Paragraph 4.7) . Inspect the deflector assembly for cracks and permanent deformation. Deflector assemblies showing evidence of any cracks or permanent deformation must be replaced. 4d. Check security of the cutter assembly. Loose fasteners must be replaced. €. Inspect the surrounding support structure for evidence of permanent deformation. If perma- Tent structural deformation exists, replace the entire cutter assembly. 4.6.2 Removal: (Refer to Figure 4-4) a. Remove screws holding cutter assembly in place. CAUTION ‘Support cutter when last few fasteners are removed to prevent damage to the support structure and to prevent cut- ter from dropping from aircraft. b. Remove panel assembly. 25PANEL ASSEMBLY STIFFENER SCREW. CUTTER ASSEMBLY ‘SCREWS, ANTENNAE Figure 4-4 Removal and Installation of Lower Cutter Assembly 2646.3 Repair Clean and repair areas of light corrosion or deterioration. Use sandpaper to Femove scratches to a depth of 0.010 inches. Prime and paint areas of deterioration and superfi- cial paint scratches. 4.6.4 Installation: Paragraph 4.6.2, Reverse the procedures in 4.7 Inspection and Repair Procedure: Sawtooth/Cutter Blades 4.7.1 Inspection: Sawtooth Blade. Inspect the sawtooth blades for impact damage and shedding of the rubber coating. Sawblades with missing or deformed teeth (one or more) must be replaced. 4.7.2 Removal: (Refer to Figure 4-5.) a. Carefully remove rivets that hold sawblades, b. Remove sawblades and clean sealant from deflector, 47.3 Repair: a. Replace damaged or missing rubber coating using sealant, . Mask off deflector on each side of saw blades and apply a minimal coating of sealant to the cutting edge. Allow sealant to set before removing masking, 4.7.4 Installation: a, Install sawtooth blades with teeth facing the cutter throat, b. Install rivets, . Mask aluminum deflector on each side of sawblade and apply a minimal coating of sealant to the teeth. Allow sealant to set before removing masking, 4, Prime and paint as required. 4.7.5 Inspection: Cutter Blades. Inspect the cutter blades for evidence of nicks, abrasions and shedding of rubber coating, 4.7.6 Removal: (Refer to Figure 4-5.) a. Remove nuts, washers, and capscrews of blade to be removed. b. Remove cutter blade. If shims are used to center blade, note their position. NOTE: Removal of a cutter blade may require removal of entry guide blade. c. Clean sealant from shim(s) and retain for installation of replacement blade. 47.7 Repair: NOTE: Blades with nicks or abrasions on the cutting edge must be replaced. . To repair damaged rubber coating, mask off deflector and cheekplates on each side of cutter blades and apply a minimal coating of sealant to the cutter edge. Allow sealant to set before removing masking, bb. Prime and paint as required. 4.7.8 Installation: WARNING All hardware used on the WSPS is of approved aircraft grade. Bristol Se- ries 990 screws are heat treated to withstand projected cutting and im- pact loads and should not be replaced with any other type of screw. ‘a. Apply sealant to the cutter biade(s) and shims. Position in cutter assembly. Note that shims must be installed as per original positions. . Install new capscrews, washers, and retaining nuts. Where cutter throat blades have been removed, check gap of aft portion of cutter ‘throat blades. Maximum allowable gap is .020 inches with blades forced against the retaining screws. 4.8 Inspection and Repair Procedures: Strut Assemblies 4.8.1 _ Inspection: a. Inspect strut assemblies for paint deterioration, superficial paint scratches, and light corrosion. No moderate or heavy corrosion is allowed. b. Inspect strut assemblies for cracks, particularly in the welded areas and around the formed tab ends. Strut assemblies. showing evidence of any cracks must be replaced. 27UPPER SAW TOOTH BLADE UPPER ENTRY. GUIDE BLADES INSERT ASSEMBLY ® UPPER CUTTER ASSEMBLY LOWER ENTRY GUIDE BLADES BREAKAWAY TIP. LOWER SAWTOOTH LOWER CUTTER BLADE ASSEMBLY Figure 4-5 Removal and Installation of WSPS Blades 28UPPER STRUT ASSEMBLY WASHER LOWER STRUT ASSEMBLY WA NuT WASHER fs) Figure 4-6 Removal and Installation of Strut AssembliesWASHER oS, BOLT BREAKAWAY TIP ASSEMBLY Figure 4-7 Removal and Installation of Breakaway Tip 30cc. Inspect strut assemblies for deformation at the strut/ deflector area and the foot pad area Assemblies. showing evidence of permanent deformation must be replaced. d. Inspect assemblies for tube straightness, Maxi- mum allowable bow over strut length is 0.060 inches. Strut assemblies exceeding this maxi- mum must be replaced. . Inspect the security of the strut assemblies ‘Loose fasteners must be replaced 4.8.2 Removal: (Refer to Figure 4-6) NOTE: To facilitate removal of the lower struts, the cutter assembly must be removed from’ the aircratt. Refer to Paragraph 4.6.2. a. Remove rivets securing strut assembly foot pads to the aircraft, b. Remove strut attachment bolt, washers, and nuts from the deflector. . Clean sealant from strut assembly foot pads. 4.8.3. Repair Clean and repair areas of light corrosion. Paint areas of deterioration and superti- cial paint scratches. 4.8.4 Installation: a. Attach strut assemblies to cutter assembly with bolt, washers, and nut b. Apply sealant to the strut fest. Reposition the struts and rivet the feet into position. Reinstall and tighten strut attachment bolt, washers, nuts, and rivets, . Reinstall lower cutter assembly. d. Prime and paint as required. 4.9 Inspection and Repair Procedures: Breakaway Tips 4.9.1 Inspectior a. Inspect tip assembly for paint deterioration, superficial paint scratches, and light corrosion. No moderate or heavy corrosion is allowed Scratches, nicks, or gouges toa depth of 0.010 in. may be repaired. b. Inspect the security of the breakaway tip, paying particular attention to the rivet fasteners, there is evidence of loose or deformed rivets, replace the entire tip assembly. 4.9.2 Removal: (Refer to Figure 4-7.) Remove bolts, washers, and nuts, and drop tip assembly free of cutter. 4.9.3 Repair: Clean and repair areas of light corrosion or scratches. Use sandpaper to remove scratches to a maximum depth of 0.006 inches. Prime and paint repaired areas and superticial paint scratches. 49.4 Installation: a. Position tip assembly and install bolts, wash- ers, and nuts. b. Prime and paint as required. 4.10 Inspection and Repair Proce- dures: Lower Cutter Stiffeners 4.10.1 Inspection: NOTE: To facilitate inspection of the stiffeners, the lower cutter assembly must be removed from the aircraft. (Refer to Paragraph 4.6.2.) a. Inspect stiffeners for cracks and permanent deformation. Stifeners showing evidence of ‘cracks or deformation must be replaced b. Inspect security of stifeners, and replace all loose fasteners. ©. Inspect the surrounding support structure for cracks and deformation. Suppor. structures showing evidence of cracks or permanent deformation must be replaced. 4.10.2 Removal: a. Remove lower cutter assembly as per Para- graph 4.6.2. b. Remove rivets retaining corresponding stiffen- er and remove stiffener. 4.10.3 No repair of Stifeners is authorized. 4.10.4 Installation: a. Refer to Paragraphs 3.5.4 through 3.5.7. b. Reinstall lower cutter assembly. 3123 = 36 24 Figure 5-1 Upper Cutter Kit 32Indentured Parts List 965-36502-002 Bell 206 Model Helicopter Wire Strike Protection System —— Wire Strike Protection System Upper Cutter Kit (Fig. 5-1) uns tom 365-83035-611 Pen | NOTE Number ren PART NUMBER 1234567 NOMENCLATURE 365-83035.611 kit — Cutter Installation Upper 1 365-83035-1 Cutter Installation Upper 1 1 385-83003-3 Cutter Assembly, Upper 1 2 365-83003-5 Deflector Assembly 1 5 3 990-00026.3 Screw 5s | 5 4 MS27039-1-18 Screw 2] 5 5 NAS620-8 Washer 10 | 35 6 ‘AN960-10 Washer 2) 45 rm Ms21042L08 Nut 5] 5 8 MS2108213 Nut 2] 5 9 365-83006-1 Blade +] 8 10 365-83006-3 Blade 2} 5 1 365-83023-1 Sawblade 1 5 12 365-83024-1 Shim 2 | 59 13 365-83024-3 Shim 4 | 59 14 990-00026-3 Screw 10 | 5 18 NAS620-8 Washer 20 | 35 16 ms2t0s2L08 Nut to | 5 7 MS20470AD4-8 Rivet 7] 5 18 | 365-83006-5 Blade 1 19 | 365-83007-1 Strut Assembly 1 20 365-83007-2 Strut Assembly 1 21 365-83008-13 Channel Assembly 1 22 365-83008-15 Insert Assembly 1 23 365-83009-1 Doubler 1 24 365-83009-2 Doubler 1 25 | 365-89024-5 Shim 3] 9 26 | — 365-83024-13 Shim 4 27 | 365-89025-1 Angie 1 28 365-83025-2 Angle 1 29 365-83041-1 Template 1 | 69 30 990-00026-1 Screw 5 3 990-000263 Screw 6 32 990-00026-7 Screw 1 33 | —ANo60-10L Washer 8 34 | ANg60-6 Washer 44 35 | ANg60-8 Washer 8 36 MS20470AD4-4 Rivet 9 37 MS20470AD4-6 Rivet 6 38 MS21042L06 ‘Nut 44 39 MS21042L08, Nut 15 40 Ms21042L3 Nut 4 41 Ms27099-1-14 Screw 3 42 MS27039-0817 ‘Screw 3 33Indentured Parts List 965-36502-002 Bell 206 Model Helicopter Wire Strike Protection System Wire Strike Protection System ten Upper Cutter Kit (Fig. 5-1) uns 365-83035-611 wer | nore PART NUMBER 12.3 4 5 6 7 NOMENCLATURE 43 NASt738B4-3, Rivet ne la 44 NAS1738B4-4 Rivet 28 7 45 NAST738B5-4 Rivet 6 | 7 46 NAS1739B4-2 Rivet 3 8 47 NAS1739B4.3 + Rivet 13 | 8 48 NAS1729B5-2 Rivet 1/9 49 NAS4B4P3A10 Bott 1 50 NAS514P692-10 Screw a | 2 51 NAS620-8 Washer 2a | 3 Or NAS620-8L Washer at | 3 52 MS20426AD4-4 Rivet 8 53 MS20470AD4-5 Rivet i 54 Ms20470aD4-7 | | Rivet 8 All non-standard parts are CAGE Code 35951 ‘Screw MS24693-S29 may be substituted for NAS514P632-10. Use of NAS620-8L washers is allowed where space is limited. Use of AN960-10L washers is allowed where space is limited, This item is supplied as part of an assembly but may be procured separately. ‘Supplied as a work-aid for installation only. (©RG243 Cherry Max rivets may be substituted for NAS1738 rivets. (©R3242 Chenry Max rivets may be substituted for NAS1739 rivets Not shown.Figure 5-2 (Sheet 1 of 2) Lower Cutter Kit 35Figure 5-2 (Sheet 2 of 2) Lower Cutter Kit 36Indentured Parts List 965-36502-002 Bell 206 Model Helicopter Wire Strike Protection System Wire Strike Protection System Lower Cutter Kit (Fig 5-2) 365-83037-611 1234567 NOMENCLATURE, 365-83037-611 365-83037-5 365-89013-11 385-83013-17 365-83015-1 365-89015-2 965-83017-1 385-83017-3 965-83017-5 385-83018-1 965-83019-1 1965-83020-1 '385-83006-3 965-83023.5 Kit, Cutter Installation, Lower Cutter installation, Lower Cutter Assembly, Lower Tip Assembly Strut Assembly Strut Assembly Blade Blade Blade Doubler Angle Channel Blade Sawblade 365-83024.3 Shim 965-83024.7 Shim 965-83024.9 Shim 965-83024-11 + Shim 365-83024-15 ‘990-00026-1 '990-000263 ‘AN960-10L_ MS20426AD4-4 MS20426AD4-5 MS20426AD4-9 Ms21042L08 Ms21042L3 MS27039-1-18 NAS464P3A7 NAS464P3A10 NAS620-8 365-83021-3 965-83021-15 365-83021-21 365-83021-29 365-83021.33, 365-83026-3 365-83026-5 '365-83027-1 '365-83028-1 AN742-46 AN743-12 ‘AN960-10L AN3-3A, CCR264883-2 Shim Screw Screw Washer Rivet Rivet Rivet Nut Nut Screw Bott Bolt = Washer Stiffener Stiffener Stitfener Assembly Bracket Stiffener Assembly Template Panel Tube Screen Clamp Bracket 1 1 1 1 1 1 1 1 2 1 1 1 2 2 2 2 2 5 7 0 9 4 WVVYVYNNNYNVVAA®ANYYVYNVNYVOVN Fes ae ea eee rains onl Sen‘tem Number Indentured Parts List 965-36502-002 Bell 206 Model Helicopter Wire Strike Protection System Wire Strike Protection System Lower Cutter Kit (Fig 5-2) 365-83037-611 PART NUMBER 1234567 NOMENCLATURE CcRe64s83-3 Rivet CCR264S83-4 Rivet Ms2104213 Nut MS2105913 Nutplate MS21069L3k Nutpiate Ms2107113 Nutplate MS27039-1-09 Screw MS27039-1-10 Screw Ms27030-1-11 : Screw NAS1738B4-1 Rivet NAS1738B4-2 Rivet NAS1739B4.2 Rivet NAS1739B4.3 + Rivet NAS1739B4-4 + Rivet ROEK@NaRENDNOS 38 NOTES All non-standard parts are CAGE Code 35951 This item is supplied as part of an assembly but may be procured separately. ‘Supplied as a work-aid for installation only. (CR3243 Cherry Max rivets may be substituted for NAS1738 rivets. (CR9242 Cherry Max rivets may be substituted for NAS1739 rivets, Not shown, Use of AN3-6A bolt is allowed. Use of NAS620-8L washers is allowed where space is limited,Figure 5-3 Extension Breakaway Tip Kittom Indentured Parts List 965-36502-002 Bell 206 Model Helicopter Wire Strike Protection System Wire Strike Protection System Extension Breakaway Tip Kit (Fig. 5-3) 16504-00: oe aie 965-36504-005 ER | wore PART NUMBER 1234567 NOMENCLATURE 1 365-89045.3 Extension Breakaway Tip Assembly 1 2 NASE203-9 Bok 2 3 MS21042L3 Nut 2 4 ANQ6O-10 Washer 2ADDENDUM‘Bniced Soares of America Department of Transporcation —Federal Apiation Administration Supplemental Type Certificate MNeamberesesoass Thivcontjicaly sssuedlo Bristol Aerospace, Ltd Winnipeg, Canada serif that the change in the typ design fer the following product swithithe limitations and conditions Aarefor au specified harcore the ainworthinassmeguirementiref Part © fithy CANAL Ade igulations Oipinal Product Ippo oortsfcate Namen: 4251 Make: Bell Medel: 2066, 2068 Daonyption of Type Dasign Change: tnstallation of wize strike protection system according to Drawing List AA 1-80 dated 2/9/80, or later FAA approved revision. Lorilations and Condationsy: Compatibility of this modification with other previously approved modifications must be determined by the installer. This cotsfcateand the supporting dale shish:is the basis for approval shall remain infect until sum ronclored, suspended meveked, om.a:lonrmination, dale is etherevise sslablished bythe Mebnimisiraton of the Date ofapplsation: November 16, 1979 Doteweisued: June 23, 1981 Datoofissmance: February 16, 1980 Dota amended By city otha ferns TSignlen] in P. Watson Chief, Engineering and Manufacturing Branch Trae ‘Any alteration of this eartifeate ts punishable by a fina of rat exceeding $1,000, of imprizonment not exceeding 3 years, or bath, ‘This certsficate may be transfered in acordance with FAR 21.47. Pia tom enton2iien6ey 42,‘Baied Beas of Serica Department of Transportation —Federal Aviation Administration Supplemental Type Certificate Bristol Aerospace, Ltd. P.O. Box 3689 Bristol, Tennessee 37625 antjiss that the change in the lype dusign for the flicuing product uith the limilalionsrand conditions arfor as specified hereon snails the ainuerthiness riguirerants if Pant ofthe Regulations: Goiginal Product — This carbificals, issued lo civil Air Uype Cerificate Ninber’ 39 54 Beil Med 206L, 206L-1, 206L-3, 206L-4 g Snel Dasorption f ype Laign Change: rygrariation of a Wize Strike Protection system in accordance with Aeronautical Accessories, Ine- Drawing List AA 1-80, dated Raguat 21, 1980 or later FAA approved revision. Lonitationsand Conditions: This approval should not be extended to other rotorcraft of this model on which other previously approved modifications are incorporated unless it is determined by the installer that the interrelationship between this change and any of those other previously approved modifications will produce no adverse effect upon the airvorthiness of that rotorcraft. This certificate and the supporting dats which is the basts fin approval shall remain: tr iffiel until sum crendlered, suspended, revoked, ora larminalion dale is wharwise cilablished by the Hebrninistrater of the Leleval Leialion Mdeninisteation, g g Deaefayplentim — sary 28, 1980 Late risen: Dial of suance! g st ae 4 October 8, 1980 Got amend’ sane 4, 1962, ip aoton of BEE ind? Siphatare c. sconyets”” Acting Manager, Atl ci Aircraft (Tey “iy alicration of this certificate ts punishable by 0 ine of not exceeding $1,000, or impritonment nat exceeding 3 pears, oF both Ths cerfiee may be transfered ve acordance with FAR 2.47 4344 THIS PAGE LEFT BLANK INTENTIONALLYWSPS Equipped Helicopter Wire Strike Report For statistical purposes, please report all wire strikes on this form and return to Bristol Aerospace Limited, RO. Box 874, Winnipeg, Canada R3C 284. by Fax or Mail Helicopter Owner — Address Date of Wire Stake Fimo of Day Heicopter Miz and Model | Registration Number Tocation and Type of Terrain Fype of Operation wire Height No. ofWires [Wire Type |Wre Material Wire Diameter | Stike Postion | WSPS Gutter Used Tvsibity | Sky Condition | Preciptation [ArTemparature | Wind Speed/bvecton No, of Occupants] Injuries | Helicopter Damage [Approx Repair Gost Description of Wire Strike ‘Do You Wish To Receive A Summary of WSPS Statistics? Yes No Bristol Aerospace Limited, Telex 07—57774, Fax 204-885-3195, Telephone (204) 775-8031Bristol Aerospace Limited Attention: PO. Box 874 WSPS Contracts Dept Winnipeg, Manitoba, Canada R3C 284WSPS Equipped Helicopter Wire Strike Report For statistical purposes, please report all wire strikes on this form and return to Bristol Aerospace Limited, P.. Box 874, Winnipeg, Canada R&C 2S4. by Fax or Mail Helicopter Owner — Address Date of Wire Stike Time of Day [Helicopter Mir. and Model] Registration Number Location and Type of Terrain Fizpe of Operation Wire Height No. of Wires [Wire Type [Wire Material [Wire Diameter | Strike Position | WSPS Cutter Used Visibility ‘Sky Condition | Precipitation [Air Temperature Wind SpeediDirection INo. of Occupants] Injuries Helicopter Damage [Approx Repair Cost Description of Wire Strike Do You Wish To Receive A Summary of WSPS Statistics? Yes No Bristol Aerospace Limited, Telex 0757778, Fax 204-885-3195, Telephone (204) 775-8001Bristol Aerospace Limited Attention: PO. Box 874 WSPS Contracts Dept Winnipeg, Manitoba, Canada R8C 284Bristol Aerospace Limited PO Box 874 Winnipeg, Manitoba, Canada R3C 2S4 Telephone : (204) 775-8331 Telex : 07-57774 Fax : (204) 885-3195 ‘ARolls—Royce Company Printed in Canada DR No. 921549