Eagle ICA-D212-725 Instructions Manual
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Eagle ICA-D212-725 Instructions Manual

Single engine conversion of bell model 212 helicopters
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ICA-D212-725
Eagle Copters Ltd.
823 McTavish Road NE
Calgary, AB, T2E 7G9
Canada
Tel: 1 403 250 7370
Fax: 1 403 250 7110
http://www.eaglecopters.com
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
ICA-D212-725
Eagle Single
SINGLE ENGINE CONVERSION OF BELL MODEL 212 HELICOPTERS
 COPYRIGHT
2007 BY DART AEROSPACE LTD 
THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED
OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
6
Revision:
Date: 13.08.26

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  • Page 1 ICA-D212-725 Eagle Copters Ltd. 823 McTavish Road NE Calgary, AB, T2E 7G9 Canada Tel: 1 403 250 7370 Fax: 1 403 250 7110 http://www.eaglecopters.com INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ICA-D212-725 Eagle Single SINGLE ENGINE CONVERSION OF BELL MODEL 212 HELICOPTERS ...
  • Page 3 ICA-D212-725 (01) Page 2 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) REVISION RECORD Revision Issue Date Description Date Inserted Inserted By 07.05.31 New Issue 07.11.30 Revision 08.12.01 Revision 09.05.20 Revision 11.06.01 Revision 12.06.20 Revision 13.08.26 Revision   COPYRIGHT 2007 BY DART AEROSPACE LTD ...
  • Page 4 ICA-D212-725 (01) Page 3 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) SERVICE BULLETIN RECORD SUBJECT REQUIREMENT NUMBER DSB-D212-725-1 FAA Certification Mandatory DSB-D212-725-2 LH Instruments Optional DSB-D212-725-3 AC Torquemeter Optional DSB-D212-725-4 Interconnect Valve Replacement Optional DSB-D212-725-5 Alternative Altimeter Optional DSB-D212-725-6 Pilot Collective Cable...
  • Page 5 ICA-D212-725 (01) Page 4 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) LIST OF EFFECTIVE PAGES Section Page Revision # Section Page Revision # Section Page Revision #   COPYRIGHT 2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 6 ICA-D212-725 (01) Page 5 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) LIST OF EFFECTIVE PAGES Section Page Revision # Section Page Revision # Section Page Revision #   COPYRIGHT 2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 7 ICA-D212-725 (01) Page 6 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) LIST OF EFFECTIVE PAGES Section Page Revision # Section Page Revision # Section Page Revision #   COPYRIGHT 2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 8 ICA-D212-725 (01) Page 7 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) LIST OF EFFECTIVE PAGES Section Page Revision # Section Page Revision # Section Page Revision #   COPYRIGHT 2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 9 ICA-D212-725 (01) Page 8 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) LIST OF EFFECTIVE PAGES Section Page Revision # Section Page Revision # Section Page Revision #   COPYRIGHT 2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 10 ICA-D212-725 (01) Page 9 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) LIST OF EFFECTIVE PAGES Section Page Revision # Section Page Revision # Section Page Revision #   COPYRIGHT 2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 11 ICA-D212-725 (01) Page 10 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) Table of Contents Chapter 01 – Introduction ....................... (01-00-00) Chapter 04 – Airworthiness Limitations ..................(04-00-00) Chapter 05 – Inspection and Component Overhaul Schedule ............(05-00-00) Chapter 06 – Dimensions and Areas ....................(06-00-00) Chapter 07 –...
  • Page 12 Use of the Manual 1.2.1 General This Chapter provides a general description of the contents and use of this ICA and the Eagle “Single” Helicopter. Generally, maintenance procedures for components or assemblies which have been removed from the helicopter are contained in either BHT-212-CR&O Component Repair & Overhaul Manual or BHT-205A1- CR&O.
  • Page 13 If confusion regarding applicability exist when new Bell 212, 205, or Honeywell T5317 series ADs are issued the operator/maintainer should contact Eagle Copters for clarification. Owner/operators of aircraft incorporating this STC will be notified of Airworthiness Directives that may apply to their helicopter because of this STC but may not appear on the Transport Canada website because of their airframe applicability.
  • Page 14 ICA-D212-725 (01) Page 13 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) 1.2.7 Terminology Warnings, cautions, and notes are used throughout this manual to emphasize important and critical instructions as follows: WARNING AN OPERATING PROCEDURE, PRACTICE, ETC., WHICH, IF NOT CORRECTLY FOLLOWED, COULD RESULT IN PERSONAL INJURY OR LOSS OF LIFE.
  • Page 15 1.2.12 Description of Helicopter Dart Aerospace Ltd and Eagle Copters have developed Canadian STC SH07-28/SR02831NY to convert the twin engine Bell 212 to a single engine aircraft powered by the Honeywell T5317A/B/BCV engine. The purpose of this conversion is to reduce the empty weight and maintenance/operating costs of the Bell 212 aircraft.
  • Page 16 Hydraulic System Cyclic Control Tail Rotor Control The “Eagle Single” helicopter (Figure 1-1) consists of two major assemblies: The forward fuselage and tailboom. The forward fuselage is semi-monocoque and reinforced shell construction with transverse bulkheads and metal and fiberglass covering.
  • Page 17 ICA-D212-725 (01) Page 16 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) Figure 1-1. Eagle Single Helicopter (typical)   COPYRIGHT 2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 18 ICA-D212-725 (01) Page 17 of 17 CHAPTER 01 – INTRODUCTION (01-00-00) Customer Feedback Return via email to dshepherd@dartaero.com Manual Title: Date of latest Revision: Section; Chapter; Paragraph Affected: Your feedback: Now Reads: Should Read: Your Name: Address: Position: Company: Phone:...
  • Page 19  ...

  • Page 20: Airworthiness Limitations

    ICA-D212-725 (04) Page 1 of 2 CHAPTER 04 – AIRWORTHINESS LIMITATIONS (04-00-00) CHAPTER 04 AIRWORTHINESS LIMITATIONS (04-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 21 ICA-D212-725 (04) Page 2 of 2 CHAPTER 04 – AIRWORTHINESS LIMITATIONS (04-00-00) AIRWORTHINESS LIMITATIONS SCHEDULE 4.1.1 The airworthiness limitations in Chapter 04 of BHT-212-MM apply except as noted in 4.1.2 and 4.1.3 below. 4.1.2 Refer to the following Honeywell T5313B/T5317 Service Bulletins for airworthiness limitations associated with the T5317A or T5317B engine.
  • Page 22 ICA-D212-725 (05) Page 1 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) CHAPTER 05 INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 23: Table Of Contents

    ICA-D212-725 (05) Page 2 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) TABLE OF CONTENTS   Table of Contents ............................2   LIST OF FIGURES ............................2   LIST OF TABLES ............................2     General .............................. 3  ...
  • Page 24 ICA-D212-725 (05) Page 3 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) GENERAL The inspection schedules noted in Chapter 05 of the BHT-212-MM apply to this helicopter. In addition the inspections listed in section 5.2 – 5.16 of this chapter supplement those of the helicopter manufacturer.

  • Page 25: Daily Inspection - Part A

    ICA-D212-725 (05) Page 4 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) DAILY INSPECTION – PART A Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the Daily Inspection – Part A requirements. Those requirements must be supplemented to include the following items 5.2.1...
  • Page 26 ICA-D212-725 (05) Page 5 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) DAILY INSPECTION – PART A Initial Inspection Task Description Data Reference Mech Other 5.2.4.5 Oil and fuel hoses and tubes for chafing, leaking, and security.

  • Page 27: 100 Hour/12 Calendar Months - Part A

    ICA-D212-725 (05) Page 6 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 100 HOUR/12 CALENDAR MONTHS – PART A Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the 100 Hour/12 Month Inspection –...
  • Page 28 ICA-D212-725 (05) Page 7 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 100 HOUR/12 CALENDAR MONTHS – PART A Initial Inspection Task Description Data Reference Mech Other 5.3.5.1 Starter – generator cooling duct for obstruction, kinking, and security.

  • Page 29: 25 Hours/30 Days - Part B

    ICA-D212-725 (05) Page 8 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 25 HOURS/30 DAYS – PART B Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the 25 Hour/30 Day Inspection –...
  • Page 30 ICA-D212-725 (05) Page 9 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 25 HOURS/30 DAYS – PART B Initial Inspection Task Description Data Reference Mech Other 5.4.3.5.4 Proper oil level. Chapter 26 5.4.3.6 Engine compartment fire extinguisher container for proper charge, condition, and mounting.
  • Page 31 ICA-D212-725 (05) Page 10 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 25 HOURS/30 DAYS – PART B Initial Inspection Task Description Data Reference Mech Other 5.3.6.3 Nicks, scratches, and corrosion damage up to 0.020” (0.50mm) deep is acceptable but must be polished out to a maximum depth of 0.020”...

  • Page 32: 300 Hours - Part B

    ICA-D212-725 (05) Page 11 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 300 HOURS – PART B Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the 300 Hour Inspection –...

  • Page 33: 600 Hours/12 Months - Part B

    ICA-D212-725 (05) Page 12 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 600 HOURS/12 MONTHS – PART B Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the 600 Hour/12 Month Inspection –...

  • Page 34: Each 500 Hours Of Component Operation

    ICA-D212-725 (05) Page 13 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) EACH 500 HOURS OF COMPONENT OPERATION Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the 500 Hours of Component Operation Inspection requirements.

  • Page 35: 600 Hours Of Component Operation Or Anytime Driveshaft Is Removed

    ICA-D212-725 (05) Page 14 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 600 HOURS OF COMPONENT OPERATION OR ANYTIME DRIVESHAFT IS REMOVED Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the 600 Hours of Component Operation Inspection requirements.

  • Page 36: 3100 Hours Of Component Operation

    ICA-D212-725 (05) Page 15 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 3100 HOURS OF COMPONENT OPERATION Initial Inspection Task Description Data Reference Mech Other NOTE This inspection applies to 205-040-250-ALL clutches installed in 212-040-001-059/-137 and subsequent transmissions 5.9.1...
  • Page 37 ICA-D212-725 (05) Page 16 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 3100 HOURS OF COMPONENT OPERATION Initial Inspection Task Description Data Reference Mech Other 5.9.1.4 Inspect lower flange surface and pilot diameter of ring gear 205-040-231, and mating surfaces of bevel gear support case 204-040-386 for fretting and wear.
  • Page 38 ICA-D212-725 (05) Page 17 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 3100 HOURS OF COMPONENT OPERATION Initial Inspection Task Description Data Reference Mech Other 5.9.1.10 Remove tail rotor drive quill 212-040-365-025 to gain access to accessory drive and sump gears. Visually...

  • Page 39: Figure 5-1 D212-725-1-901 Bellcrank Control Component Damage And Repair (25/100 Hours)

    ICA-D212-725 (05) Page 18 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) CRITICAL PART Careful maintenance and inspection of this part is critical to continued flight safety rotorcraft. Unauthorized repairs modifications may have hazardous consequences. This part must be...

  • Page 40: After Hard Landing

    ICA-D212-725 (05) Page 19 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 5.10 AFTER HARD LANDING Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the After Hard Landing Inspection requirements. Those requirements must...

  • Page 41: After Blade Strike Or Other Rotating System Torque Spike

    ICA-D212-725 (05) Page 20 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 5.11 AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the After Blade Strike or other rotating torque spike Inspection requirements.

  • Page 42: After Overspeed

    ICA-D212-725 (05) Page 21 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 5.12 AFTER OVERSPEED Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the After Overspeed Inspection requirements. Those requirements...

  • Page 43: After Over-Torque

    Series 5.13.2 Overtorque inspections Bell Maintenance Manual that are required when overtorque “does not exceed 104%” must be accomplished on the Eagle Single when overtorque has not exceeded 58 psi. 5.13.3 Overtorque inspections Bell Maintenance Manual that are required when overtorque “exceeds 104% but does not exceed 112%”...

  • Page 44: After Engine Compressor Stall Or Surge

    ICA-D212-725 (05) Page 23 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 5.14 AFTER ENGINE COMPRESSOR STALL OR SURGE Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the After Engine Compressor Stall or Surge Inspection requirements.

  • Page 45: After Lightning Strikes

    ICA-D212-725 (05) Page 24 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 5.15 AFTER LIGHTNING STRIKES Initial Inspection Task Description Data Reference Mech Other NOTE Refer to the Bell 212 Maintenance Manual for the After Lightning Strike Inspection requirements. Those...

  • Page 46: Component Overhaul Schedule

    ICA-D212-725 (05) Page 25 of 25 CHAPTER 05 – INSPECTION AND COMPONENT OVERHAUL SCHEDULE (05-00-00) 5.16 COMPONENT OVERHAUL SCHEDULE 5.16.1 Refer to the following Honeywell Service Bulletins for limitations on the engine/engine components: T5313B/17-0001 Time Between Overhaul/Time Between Inspection T5313B/17-0020 Life Limits 5.16.2...
  • Page 47  ...

  • Page 48: Dimensions And Areas

    ICA-D212-725 (06) Page 1 of 6 CHAPTER 06 – DIMENSIONS AND AREAS (06-00-00) CHAPTER 06 DIMENSIONS AND AREAS (06-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 49 ICA-D212-725 (06) Page 2 of 6 CHAPTER 06 – DIMENSIONS AND AREAS (06-00-00) TABLE OF CONTENTS Table of Contents ..............................2 Airframe Principal Dimensions ........................ 3 Stations, Waterlines, and Buttock Lines ....................3 6.2.1 General ............................... 3 6.2.2 Station Lines (F.S.) ..........................3 6.2.3...
  • Page 50 ICA-D212-725 (06) Page 3 of 6 CHAPTER 06 – DIMENSIONS AND AREAS (06-00-00) AIRFRAME PRINCIPAL DIMENSIONS helicopter Water line (0) is a plane below the lowest point on the fuselage. Water lines can be used to Figure 6-1 depicts the major dimensions of the measure locations as described for station lines.
  • Page 51 ICA-D212-725 (06) Page 4 of 6 CHAPTER 06 – DIMENSIONS AND AREAS (06-00-00) Figure 6-1. Principal dimensions  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 52 ICA-D212-725 (06) Page 5 of 6 CHAPTER 06 – DIMENSIONS AND AREAS (06-00-00) Figure 6-2. Station diagram (sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 53 ICA-D212-725 (06) Page 6 of 6 CHAPTER 06 – DIMENSIONS AND AREAS (06-00-00) Figure 6-2. Station diagram (sheet 2 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 54 ICA-D212-725 (07) Page 1 of 1 CHAPTER 07 – LIFTING AND JACKING (07-00-00) CHAPTER 07 LIFTING AND JACKING (07-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 55  ...
  • Page 56 ICA-D212-725 (08) Page 1 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) CHAPTER 08 WEIGHT AND BALANCE (08-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 57 ICA-D212-725 (08) Page 2 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) TABLE OF CONTENTS Table of Contents ..............................2 List of Figures ............................... 2 Weight and Balance ..........................3 Leveling ..............................3 Weighing ..............................3 Determining Center of Gravity Location ....................4 Determining Amount of Ballast Required ....................
  • Page 58 ICA-D212-725 (08) Page 3 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) WEIGHT AND BALANCE The center of gravity (CG) is considered to be the WEIGHING balancing point of a body for weight and balance Purposes. The helicopter can be compared to a...
  • Page 59 ICA-D212-725 (08) Page 4 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) Figure 8-1. Leveling the individual net scale weights. 8.3.8 Lower helicopter to surface. Weigh jacks, blocks, and any other equipment used between scales and helicopter. Deduct this weight...
  • Page 60 ICA-D212-725 (08) Page 5 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) 8.4.1 This distance from F.S. 0.0 to a line 8.4.3 Multiply total net weight of aft scales by through centers of forward jack pads is called the aft arm.
  • Page 61 ICA-D212-725 (08) Page 6 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) DETERMINING AMOUNT OF 8.5.3 Check derived weight plus ballast and BALLAST REQUIRED resultant CG on the Gross Weight vs Center of Gravity Chart provided in the FMS-D212-725-1;...
  • Page 62 ICA-D212-725 (08) Page 7 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) Figure 8-3. Nose Ballast  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 63 ICA-D212-725 (08) Page 8 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) check. NOSE BALLAST INSTALLATION AND REMOVAL NOTE Ballast weights (2 and 3) shall be installed in 8.6.1 Determine amount of ballast to be combination with washers (1) and clamps (4) on added or removed and moment arm.
  • Page 64 ICA-D212-725 (08) Page 9 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) Figure 8-4. Tail Skid Ballast  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 65 ICA-D212-725 (08) Page 10 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) WEIGHT AND BALANCE SAMPLE PROBLEM 8.8.1 The sample Actual Weight Record (see below) can be used as a guide to follow a helicopter from weighing to weight and balance check with intermediate steps to change adjust ballast.
  • Page 66 ICA-D212-725 (08) Page 11 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) Longitudinal Lateral Weight Moment Moment 5673.0 147.03 834112.07 0.39 2190.0 As weighed: Add: Unusable fuel 28.3 142.8 4041.2 Undrainable oil 230.7 1638.0 Engine Oil 24.5 169.1 4143.0 M/R G/B oil 27.3...
  • Page 67 ICA-D212-725 (08) Page 12 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) NOTE Since it is impossible to operate helicopter without engine oil, it has been added to the derived weight of the aircraft.  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...
  • Page 68 ICA-D212-725 (08) Page 13 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) Empty Weight and Balance before Ballast 12000 11500 11000 10500 10000 9500 9000 8500 132.58 8312.80 8000 144.55 7500 7550.00 7000 6500 6000 5500 5000 Station (Inches) 8.8.5...
  • Page 69 ICA-D212-725 (08) Page 14 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) Longitudinal Lateral Weight Moment Moment 5970.8 145.26 867309.46 0.36 2160.0 Derived Weight: Add: Ballast 108.0 -4.5 -486.0 6078.8 142.60 866823.46 0.36 2160.0 Weight Empty after ballast Longitudinal...
  • Page 70 ICA-D212-725 (08) Page 15 of 15 CHAPTER 08 – WEIGHT AND BALANCE (08-00-00) Empty Weight and Balance after Ballast 12000 11500 11000 10500 10000 9500 9000 130.82 8500 8420.80 8000 142.45 7658.00 7500 7000 6500 6000 5500 5000 Station (Inches) 8.8.7...
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  • Page 72 ICA-D212-725 (09) Page 1 of 1 CHAPTER 09 – TOWING (09-00-00) CHAPTER 09 TOWING (09-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
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  • Page 74 ICA-D212-725 (10) Page 1 of 1 CHAPTER 10 – PARKING AND MOORING (10-00-00) CHAPTER 10 PARKING AND MOORING (10-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
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  • Page 76 ICA-D212-725 (11) Page 1 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) CHAPTER 11 PLACARDS AND MARKINGS (11-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 77 ICA-D212-725 (11) Page 2 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) TABLE OF CONTENTS Consumable Material List ............................. 2 11.0 Placards and Markings ..........................3 11.1 Placards ..............................3 11.2 Decals – Application ..........................3 LIST OF FIGURES Figure 11-1.
  • Page 78 ICA-D212-725 (11) Page 3 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) 11.0 PLACARDS AND MARKINGS (C-305) evaporates. 11.1 PLACARDS CAUTION Decals, stencils, and markings used on Model 212 helicopters are shown on Figure 11-1. The first part of this figure shows sections, views, and DO NOT ALLOW TOLUENE (C-306) TO MAKE details on the helicopter.
  • Page 79 ICA-D212-725 (11) Page 4 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) with your finger or a squeegee to remove the air. 11.2.3.2 For the sealing of exterior decals, 11.2.3 Edge seal or fully coat the decal with the...
  • Page 80 ICA-D212-725 (11) Page 5 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) Figure 11-1. Placards and Markings  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 81 ICA-D212-725 (11) Page 6 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) RADIO CALL Radio Call Plate 11200 11000 10500 10000 9500 9000 8500 8000 7500 95 100 105 110 115 120 125 130 Indicated Airspeed - Knots DECREASE V 3 KNOTS PER 1000 FT.
  • Page 82 ICA-D212-725 (11) Page 7 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) MAXIMUM GAS PRODUCER SPEED TAKEOFF POWER = 105.0% MAX. CONT. POWER = 101.0% D212-725-6-003 Operating Limitations EGT VS OAT LIMITS (T5317A ONLY) VFR OPERATIONS ONLY CAP. 270 LBS...
  • Page 83 ICA-D212-725 (11) Page 8 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) HEAT SELECTOR Bell Helicopter TEXTRON  A Subsidiary of Textron Inc. Bell Insignia Illuminated Sign STRUCTURAL PANEL REQUIRED GROUND RUN AND FLIGHT This panel must be installed for all flights ...
  • Page 84 ICA-D212-725 (11) Page 9 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) INSTALL SHAFT CLAMPS INDEXED 90° TO EACH OTHER TORQUE TO 30-35 IN-LB Torque Limits, Tail Rotor Driveshaft Clamps SERVICE WITH MIL-L-7808 OIL OR MIL-L-23699 OIL DO NOT MIX...
  • Page 85 ICA-D212-725 (11) Page 10 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) EMERGENCY EXIT EMERGENCY EXIT PUSH WINDOW AT PUSH WINDOW AT LOWER CORNER LOWER CORNER View A EMERGENCY EXIT EMERGENCY EXIT PUSH WINDOW AT PUSH WINDOW AT LOWER CORNER...
  • Page 86 ICA-D212-725 (11) Page 11 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) Decal – 2 Required Structural Panel Requirements Door Lock LOCKED Door Lock  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 87 ICA-D212-725 (11) Page 12 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) OPEN Door Lock Fire Extinguisher Fire Extinguisher (31-043-14CGL) Turn and Pull EMERGENCY EXIT Emergency Exit PULL Pull  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 88 ICA-D212-725 (11) Page 13 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) MAXIMUM ALLOWABLE BALLAST LEFT SIDE 82 POUNDS RIGHT SIDE 82 POUNDS Maximum Allowable Ballast 28 Volt D.C. Max. Allowable Weight Door Lock Emergency Exit  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...
  • Page 89 ICA-D212-725 (11) Page 14 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) Fuel Sump Drain Ground Here Fuel System Capacity FOR OPERATING TEMPERATURES BELOW 40°F OAT, FUEL USED MUST CONTAIN PFA-55MB ADDITIVE, CONCENTRATION TO BE .06% - .15% BY VOLUME Decal –...
  • Page 90 ICA-D212-725 (11) Page 15 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) Decal – 2 Required MAXIMUM ALLOWABLE  WEIGHT 400 LBS  100 LBS. PER SQ FT. Maximum Allowable Weight RIVET R Rigging Rivet RIVET S Rigging Rivet 42º GEARBOX OIL  CAPACITY 0.2 US QTS = 0.2 LITERS Capacity  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...
  • Page 91 ICA-D212-725 (11) Page 16 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) RIVET P Rigging Rivet CLOSE OPEN Close and Open CARGO MUST BE SECURED  IN ACCORDANCE WITH  FLIGHT MANUAL INSTRUCTIONS Cargo Securing Hydraulic Reservoir Inside Transmission Oil Access  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...
  • Page 92 ICA-D212-725 (11) Page 17 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) TRANSMISION OIL  CAPACITY 11.0 US QTS =10.4 LITERS Capacity 205-075-058 RESERVOIR TOTAL SYSTEM CAP. 10 US PTS – 4.7 LITERS RESERVOIR CAP. 5.3 US PTS – 2.5 LITERS REFILL LEVEL CAP. 2.5 US PTS – 1.2 LITERS...
  • Page 93 90° GEARBOX OIL CAPACITY 0.4 US QTS – 0.4 LITERS 90° Gearbox Capacity Eagle Single Identification Placard (Mounted above Aircraft Data Plate)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 94 ICA-D212-725 (11) Page 19 of 19 CHAPTER 11 – PLACARDS AND MARKINGS (11-00-00) Applicable for helicopters Pre TB 212-12-213. Applicable for helicopters Post TB 212-12-213. Applicable for helicopters Post TB 212-12-213 equipped with hydraulic reservoir P/N 205-076-058-XXX (PEEK plastic). Applicable for helicopters Pre TB 212-12-213 equipped with hydraulic reservoir P/N 205-076-135-XXX (magnesium alloy) Applicable for helicopters Pre.
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  • Page 96 ICA-D212-725 (12) Page 1 of 24 CHAPTER 12 – SERVICING (12-00-00) CHAPTER 12 SERVICING (12-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 97 ICA-D212-725 (12) Page 2 of 24 CHAPTER 12 – SERVICING (12-00-00) TABLE OF CONTENTS   Table of Contents ............................... 2   Consumable Materials List ..........................3     12.1 Servicing ............................... 4     12.1A servicing tolerance ..........................4  ...
  • Page 98 ICA-D212-725 (12) Page 3 of 24 CHAPTER 12 – SERVICING (12-00-00) CONSUMABLE MATERIALS LIST The following consumable materials are required to perform the maintenance procedures within this chapter. ITEM NOMENCLATURE GAGE/FSCM/ SOURCE C-009 Lubricating Oil, Grade 1010, MIL-L-6081 Commercial  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...
  • Page 99 ICA-D212-725 (12) Page 4 of 24 CHAPTER 12 – SERVICING (12-00-00) 12.1 SERVICING The following is only applicable for those operators whose governing aviation authority requires to specifically approve the servicing tolerance. CAUTION If approval of the servicing tolerance is required by...
  • Page 100 ICA-D212-725 (12) Page 5 of 24 CHAPTER 12 – SERVICING (12-00-00) OCCURS WHICH REMOVES NATURAL FATS kg) 002 fire extinguisher with an extension AND OIL WHICH MAY EXPOSE SKIN TO assembly in an accessible place. Make sure fire INFECTIOUS DERMATOSES.
  • Page 101 ICA-D212-725 (12) Page 6 of 24 CHAPTER 12 – SERVICING (12-00-00) 12.4.7 Install filler cap and nozzle dust cap. 12.4.3 Confirm fuel in fueling vehicle is correct type prior to refueling. Refer to Table 12-1 12.4.8 Place BATTERY BUS switches and for list of approved fuels.
  • Page 102 ICA-D212-725 (12) Page 7 of 24 CHAPTER 12 – SERVICING (12-00-00) 12.5 MAIN FUEL SYSTEM - DEFUELING 12.5.9 Remove access plates under fuel cell 12.5.1 Comply with requirements sumps. paragraph 12.3. NOTE 12.5.10 Position suitable container under helicopter. If helicopter is being defueled with defueling type vehicle, accomplish step 12.5.2 through step...
  • Page 103 ICA-D212-725 (12) Page 8 of 24 CHAPTER 12 – SERVICING (12-00-00) 12.6 MAIN FUEL SYSTEM - PURGING than 20%. If reading is more than 20%, repeat step FUEL CELLS 12.6.2.1 through step 12.6.2.4 until reading is less than 20%. MATERIALS REQUIRED 12.6.3...
  • Page 104 ICA-D212-725 (12) Page 9 of 24 CHAPTER 12 – SERVICING (12-00-00) Inspect and clean filter and strainers as required. 12.7 OIL SYSTEM 12.8.2.2 Fill oil system with specification of engine, transmission, tail rotor drive lubricating oil to be used. gearboxes and main rotor hub may be serviced with MIL-PRF-7808, MIL-PRF-23699, or DOD- 12.8.2.3...
  • Page 105 ICA-D212-725 (12) Page 10 of 24 CHAPTER 12 – SERVICING (12-00-00) gearbox. 12.10 TRANSMISSION OIL SYSTEM 12.14 MAIN ROTOR HUB The transmission sump case serves as the reservoir for this system. The filler is located on Transparent plastic sight gauges are on grip and the upper right side of the transmission and is pillow block reservoirs for checking oil level.
  • Page 106 ICA-D212-725 (12) Page 11 of 24 CHAPTER 12 – SERVICING (12-00-00) of hydraulic fluid used in the system, refer to system, refer to paragraph 12-17A. paragraph 12.18. 12.17.4 If fluid level is low, replenish with Filters may be checked from inside cabin through hydraulic fluid (C-002) or hydraulic fluid (C-072).
  • Page 107 ICA-D212-725 (12) Page 12 of 24 CHAPTER 12 – SERVICING (12-00-00) Complete each of the three hydraulic fluid 12.17A.2.5 Move the collective stick, cyclic stick, conversion phases as follows: and pedals to operate all the flight control actuators through full travel for a minimum of five cycles.
  • Page 108 ICA-D212-725 (12) Page 13 of 24 CHAPTER 12 – SERVICING (12-00-00) hydraulic test couplings of the hydraulic system No. step 2 for the hydraulic system No. 2. 1 and No. 2. 12.17A.4.1 Fully drain the hydraulic cart. 12.17A.6 For the rotor brake do as follows: 12.17A.4.2 Fill the hydraulic cart to 75% of the...
  • Page 109 ICA-D212-725 (12) Page 14 of 24 CHAPTER 12 – SERVICING (12-00-00) reservoirs and drain the hydraulic fluid in a OFF positions five times in approximately 2-second suitable container. intervals. 12.17A.8.3 Connect the hose to the suction outlet 12.17A.8.11 Let the hydraulic cart run for 1 minute.
  • Page 110 45 days without operation or service, the acceptable limit replace with a serviceable purge-lubricate all bearings. unit. The 2241-009 Fire Bottle must be charged with 6 lbs of Halon for installation on the Eagle Single. WARNING PRIOR LUBRICATION, VERIFY 12.19.2...
  • Page 111 ICA-D212-725 (12) Page 16 of 24 CHAPTER 12 – SERVICING (12-00-00) SEPARATION LUBRICATION 12.22 LUBRICATION - LUBRICANT FROM THE THICKENING AGENT, OIL MAY BE RESTRICTIONS (204-040-755-005) REMIXED THOROUGHLY WITH THICKENING AGENT RESTORE MATERIALS REQUIRED ORIGINAL LOAD CARRYING CAPABILITIES. IF Refer to BHT-ALL-SPM for specification and THERE IS A LOSS OF LUBRICATING OIL FROM source.
  • Page 112 ICA-D212-725 (12) Page 17 of 24 CHAPTER 12 – SERVICING (12-00-00) 040-755-005 lubricant goes into service, the re- 12.23 FLEXIBLE COUPLING LUBRICATION lubrication interval is dictated by the calendar and service-time schedule whether the component is MATERIALS REQUIRED NUMBER NOMENCLATURE...
  • Page 113 ICA-D212-725 (12) Page 18 of 24 CHAPTER 12 – SERVICING (12-00-00) Table 12-2. Flex couplings lubrication log (EXAMPLE ONLY) Part Number Nomenclature Date Airframe Date Airframe Lubricated Hours Lubricated Hours Transmission Tail Rotor Drive Output Coupling Tail Rotor Driveshaft Hanger (8)
  • Page 114 ICA-D212-725 (12) Page 19 of 24 CHAPTER 12 – SERVICING (12-00-00) Figure 12-1. Servicing Points  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 115 ICA-D212-725 (12) Page 20 of 24 CHAPTER 12 – SERVICING (12-00-00) Figure 12-2. Rotor Brake Servicing  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 116 ICA-D212-725 (12) Page 21 of 24 CHAPTER 12 – SERVICING (12-00-00) Figure 12-3. Lubrication Chart (Sheet 1 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 117 ICA-D212-725 (12) Page 22 of 24 CHAPTER 12 – SERVICING (12-00-00) Figure 12-3. Lubrication Chart (Sheet 2 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 118 ICA-D212-725 (12) Page 23 of 24 CHAPTER 12 – SERVICING (12-00-00) Figure 12-3. Lubrication Chart (Sheet 3 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 119 ICA-D212-725 (12) Page 24 of 24 CHAPTER 12 – SERVICING (12-00-00) Figure 12-3. Lubrication Chart (Sheet 4 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 120 ICA-D212-725 (18) Page 1 of 1 CHAPTER 18 – VIBRATION AND NOISE ANALYSIS (18-00-00) CHAPTER 18 VIBRATION AND NOISE ANALYSIS (18-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
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  • Page 122 ICA-D212-725 (21 Page 1 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) CHAPTER 21 AIR DISTRIBUTION (VENTILATION) (21-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 123 ICA-D212-725 (21 Page 2 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) TABLE OF CONTENTS Table of Contents ..............................2 Consumable Material List ............................. 3 21.1 Air Distribution (Ventalation) ........................4 21.2 Troubleshooting ............................5 21.3 Bleed Air Heating System Components ....................7 21.4...

  • Page 124: Consumable Material List

    ICA-D212-725 (21 Page 3 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) CONSUMABLE MATERIAL LIST The following consumable materials are required to perform the maintenance procedures within this chapter. ITEM NOMENCLATURE GAGE/FSCM/ SOURCE C-300 Adhesive, 299-947-152, Type I, Class I...

  • Page 125: Air Distribution (Ventalation)

    ICA-D212-725 (21 Page 4 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) 21.1 AIR DISTRIBUTION The temperature selecting dial, through an electrical (VENTALATION) positioning motor, controls a remote sensor which is mounted on plenum chamber in the compartment on The cabin air distribution system includes two right side below engine deck.

  • Page 126: Troubleshooting

    ICA-D212-725 (21 Page 5 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) 21.2 TROUBLESHOOTING Troubleshoot bleed air heating system in accordance with table 21-1. Table 21-1. Troubleshooting Indication of trouble Probable cause Corrective action No bleed air flow to variable mixture Restricted or no flow Clear lines —...
  • Page 127 ICA-D212-725 (21 Page 6 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) Figure 21-1. Air distribution system schematic (typical)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 128: Bleed Air Heating System Components

    ICA-D212-725 (21 Page 7 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) 21.3 BLEED AIR HEATING SYSTEM COMPONENTS 21.5 VARIABLE CONTROL MIXING VALVE The following paragraphs provide maintenance The mixing valve (5, Figure 21-2 and 21-3) is information various miscellaneous installed on the right side below the engine deck.
  • Page 129 ICA-D212-725 (21 Page 8 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) Figure 21-2. Bleed air heating system (S/N 30504 through 30553)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 130 ICA-D212-725 (21 Page 9 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) Figure 21-3. Bleed air heating system (S/N 30554 and sub.)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 131: Installation

    ICA-D212-725 (21 Page 10 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) 21.5.2 Installation 21.7 SELECTOR 21.5.2.1 Position valve (5, Figure 21-2 or 21.7.1 Removal Figure 21-3) in heater system and secure in place with clamp and large B nut. Torque nut 40 to 58 21.7.1.1...

  • Page 132: Outlet Control Valve

    ICA-D212-725 (21 Page 11 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) 21.7.2.8 Install four mount screws securing be removed. selector to control valve. 21.9.1.2 Remove necessary clamps, couplings, 21.7.2.9 Perform operational check to ensure and/or tape wrapping securing component to proper operation of cabin heater valve.
  • Page 133 ICA-D212-725 (21 Page 12 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) 21.9.2.2.1 Clean circumference duct 21.9.3 Installation damaged area with toluene (C-306) or xylene (C- 347). Allow area to air dry for at least 30 minutes. MATERIALS REQUIRED...
  • Page 134 ICA-D212-725 (21 Page 13 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) Figure 21-4. Outlet control valve  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 135: Ventilation/Defog System

    ICA-D212-725 (21 Page 14 of 14 CHAPTER 21 – AIR DISTRIBUTION (VENTILATION) (21-00-00) 21.10 VENTILATION/DEFOG SYSTEM each end of blower (33, Figure 21-2) and slide ducts back clear of blower. Ventilation/defog system delivers outside air to windshield nozzles and nozzles on sides of 21.11.1.2...
  • Page 136 ICA-D212-725 (25 Page 1 of 1 CHAPTER 25 – EQUIPMENT AND FURNISHINGS (25-00-00) CHAPTER 25 EQUIPMENT AND FURNISHINGS (25-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 137  ...
  • Page 138 ICA-D212-725 (26) Page 1 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) CHAPTER 26 FIRE PROTECTION (26-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 139 ICA-D212-725 (26) Page 2 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) TABLE OF CONTENTS Table of Contents ..............................2 26.1 Fire Protection ............................3 26.2 Engine Fire Detection System ....................... 3 26.3 Test Switch ............................. 3 26.4 Testing – Fire Detection System ......................3 26.5...

  • Page 140: Fire Protection

    ICA-D212-725 (26) Page 3 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) 26.1 FIRE PROTECTION Check that FIRE CAUTION lights illuminated. Fire protection consists of fire detection systems which give warning of fire in the engine 26.4.2 Push FIRE DET TEST #1 switch.

  • Page 141: Fire Detector Control Amplifier

    ICA-D212-725 (26) Page 4 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) 26.5.12 Place the remote system test switch in 26.5.5 Check all detector circuits by pushing the first position. the DETECTOR TEST switches (4), one at a time. No increased voltage should be noted from 26.5.13...
  • Page 142 ICA-D212-725 (26) Page 5 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) Figure 26-1. Fire Detection System Tester  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 143: Cargo Compartment Smoke Detection System

    ICA-D212-725 (26) Page 6 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) 26.7 CARGO COMPARTMENT SMOKE 26.8.1.4 Disconnect electrical connector (5), DETECTION SYSTEM 26.8.1.5 Remove screws (3) and washers (2). The cargo compartment smoke detector is a Remove smoke detector (4).
  • Page 144 ICA-D212-725 (26) Page 7 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) Figure 26-2. Cargo Compartment Smoke Detector  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 145: Fire Extinguisher

    ICA-D212-725 (26) Page 8 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) 26.9 FIRE EXTINGUISHER In the event a container is subjected to excessive heat, the fill and thermal relief fitting will open and hand type, manually operated, fire allow the extinguishing agent to escape. During this extinguishers are furnished with the helicopter.

  • Page 146: Engine Fire Extinguisher

    ICA-D212-725 (26) Page 9 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) NOTE: The manifold (1, Figure 26-3) must be free of dents and other mechanical damage, except as noted below. It must be kept clear of dirt and debris internally and the discharge holes must be open.

  • Page 147: Removal

    ICA-D212-725 (26) Page 10 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) 26.10.3.3 Connect tube assembly (2) to the extinguisher output connector. 26.11.2 Inspection 26.11.2.1 Inspect fire extinguisher (6, Figure 26-4) 26.10.3.4 Remove the bare electrical wire for state of charge by weight (or by visual indicator, if between the two electrical terminals and connect installed).
  • Page 148 ICA-D212-725 (26) Page 11 of 11 CHAPTER 26 – FIRE PROTECTION (26-00-00) Figure 26-4. Portable Fire Extinguishers and Brackets  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 149  ...

  • Page 150: Fuel System

    ICA-D212-725 (28) Page 1 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) CHAPTER 28 FUEL SYSTEM (28-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 151 ICA-D212-725 (28) Page 2 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) TABLE OF CONTENTS   Table of Contents ..............................2   List of Figures ..............................4   List Of Tables ..............................4   Consumable Material List ............................ 5  ...
  • Page 152 ICA-D212-725 (28) Page 3 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00)     28.17 Flapper Valve ............................ 31     28.17.1 Removal ............................ 31     28.17.2 Inspection ..........................32     28.17.3 Installation ..........................32     28.18 Low Fuel Level Warning Switches ....................
  • Page 153 Eagle ‘S’ Fuel system ......................8     Figure 28-1. Detail A.- Siphon Breaker Valve ..................... 9     Figure 28-2. Eagle ‘S’ Fuel System Schematic ..................10     Figure 28-3. Forward fuel cell ........................14     Figure 28-4.

  • Page 154: Consumable Material List

    ICA-D212-725 (28) Page 5 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) CONSUMABLE MATERIAL LIST The following consumable materials are required to perform the maintenance procedures within this chapter. ITEM No. NOMENCLATURE CAGE/FSCM/ SOURCE C-008 Petrolatum, VV-P-236 Commercial C-016 Lubricating Oil, Jet Engine, MIL-O-6081, Grade 1005...

  • Page 155: General

    ICA-D212-725 (28) Page 6 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.1 GENERAL insufficient fuel will pass, a bypass valve will open and permit fuel to bypass the filter. A pressure This chapter provides instructions for maintenance transmitter (1) is mounted adjacent to the filter. The of the airframe-mounted fuel supply system.

  • Page 156: Fuel Storage And Distribution System

    ICA-D212-725 (28) Page 7 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.3 FUEL STORAGE AND 28.4.3 A governor bleed line equipped with a DISTRIBUTION SYSTEM check valve returns excess fuel from the power section fuel control to the aft center fuel cell.
  • Page 157 DSB-D212-725-4 has been incorporated. Figure 28-1. Eagle ‘S’ Fuel system  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 158 ICA-D212-725 (28) Page 9 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-1. Detail A.- Siphon Breaker Valve Figure 28-1. Detail B. - Siphon Breaker Valve Table 28-1. Siphon Breaker Valve Item Detail A and B Item Number Part Number...
  • Page 159 May have been replaced by D212-725-1-273 Hose Assembly per DSB-D212-725-4 Figure 28-2. Eagle ‘S’ Fuel System Schematic  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 160: Troubleshooting Fuel System

    ICA-D212-725 (28) Page 11 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.5 TROUBLESHOOTING FUEL SYSTEM Table 28-2. Troubleshooting fuel system. INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION FUEL FILTER caution panel Fuel filter is dirty. Replace filter. frequent filter segment illuminated.

  • Page 161: Operational Check

    ICA-D212-725 (28) Page 12 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.6 OPERATIONAL CHECK 28.8 FORWARD FUEL CELLS For operational check of fuel system components Two fuel cells are located under the cabin floor and indicators, refer to Chapter 96.
  • Page 162 ICA-D212-725 (28) Page 13 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.8.1.11 Remove 12 bolts and access bar (2) to 28.8.1.4 Disconnect electrical wiring between open access slit in top of forward compartment of cabin structure and fuel cell sump components: cell.
  • Page 163 ICA-D212-725 (28) Page 14 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-3. Forward fuel cell  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 164: Cleaning

    ICA-D212-725 (28) Page 15 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.8.2 Cleaning deterioration which can be detected visually shall be replaced. MATERIALS REQUIRED 28.8.3.6 Inspect any removed components for NUMBER NOMENCLATURE serviceability. C-302 Methyl Alcohol CAUTION 28.8.4 Installation...
  • Page 165 ICA-D212-725 (28) Page 16 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) cell vent port. 28.8.4.15 Position ejector pump (23) over inner 28.8.4.6 Position quantity gage probe (7) with end of cross-feed fitting. Install two bolts, with support clamps to threaded inserts on inboard wall washers under heads, through pump housing into of forward compartment.

  • Page 166: Aft Fuel Cells

    ICA-D212-725 (28) Page 17 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) position. Install twelve bolts with thin aluminum 28.8.4.19.3 Connect pump outlet hose (13) from washers. Torque bolts 40 to 50 in-lbs. (4.52 to 5.65 aft outlet crossover to inboard elbow on boost Nm).
  • Page 167 ICA-D212-725 (28) Page 18 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) block (24) on door. CAUTION 28.10.1.2.6.3 Remove bolts and washers around DO NOT HANDLE FUEL CELL WHEN CELL edge of door (20). Carefully remove door, packing TEMPERATURE IS BELOW 65°F (18°C).
  • Page 168 ICA-D212-725 (28) Page 19 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-5. Aft fuel cell  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 169: Cleaning

    ICA-D212-725 (28) Page 20 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.10.2 Cleaning MATERIALS REQUIRED CAUTION NUMBER NOMENCLATURE C-339 Ethyl Alcohol DO NOT HANDLE FUEL CELL WHEN CELL TEMPERATURE IS BELOW 65°F (18°C). CAUTION LEAVE FUEL CELL IN ORIGINAL SHIPPING...
  • Page 170 ICA-D212-725 (28) Page 21 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) length of lacing cord (C-471). Lace as shown on and thin aluminum washers. Torque bolts 40 to 50 Figure 28-6. in-lbs. (4.52 to 5.65 Nm). 28.10.4.2.4 Align bottom ports of cells to 28.10.4.2.5...

  • Page 171: Aft Center Cell

    ICA-D212-725 (28) Page 22 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) NOTE Fuel tank assemblies 212-360-602-101 (left side) 28.10.4.3.10 Pressure test fuel system and 212-360-602-102 (right side) do not have paragraph 28.7. lacing rings. Vent, interconnect, and filler fitting attachments will support tank position in airframe 28.10.4.4...

  • Page 172: Cleaning

    ICA-D212-725 (28) Page 23 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.11.1.4 Disconnect electrical wiring from two SOAPS STRONG DETERGENTS WHEN quantity gage connectors (23) and terminal block CLEANING CELL. SOAPS CAN REACT WITH (24) on door. FUEL TO FORM A COMPOUND WHICH TENDS TO PLUG FILTERS.
  • Page 173 ICA-D212-725 (28) Page 24 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) may be fabricated by cutting off heads of two AN4 from inside cell. Torque bolts 40 to 50 in-lbs. (4.52 bolts approximately 6 in. (15.24 mm) long. Grind to 5.65 Nm).

  • Page 174: Fuel Sump Assembly

    ICA-D212-725 (28) Page 25 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.12 FUEL SUMP ASSEMBLY 28.12.2.2 Inspect components for security of Fuel cell sump assemblies are mounted in mounting. openings on the underside of each forward fuel tank. Removal of sump assemblies from the cells 28.12.2.3...

  • Page 175: Flow Switches

    ICA-D212-725 (28) Page 26 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.12.3.10 Perform pressure test (paragraph install check valve (10) with packing in switch inlet, 28.7). and union (12) with packing in outlet. 28.12.3.11 Install sump access door to fuselage 28.13.2.2...

  • Page 176: Canister Type Boost Pump Cartridge

    ICA-D212-725 (28) Page 27 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) and pump outlet plug (19) with bolt, washer, and 28.15 CANISTER TYPE BOOST PUMP packings, and pump drain valve (20) with packing. CARTRIDGE 28.14.1.6 Cover pump openings The canister type boost pump incorporates an integral cartridge pumping element.

  • Page 177: Repair

    ICA-D212-725 (28) Page 28 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.15.4.7 Connect black positive (+) lead terminal 28.15.3 Repair to positive (+) terminal on cartridge; do not over- torque. For cartridge repair. return cartridge to: 28.15.4.8 Secure drain valve (6) to allen screw (2) Airborne Aviation Products Group with lockwire (C-405).
  • Page 178 ICA-D212-725 (28) Page 29 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-7. Fuel cell sump (left side typical)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 179 ICA-D212-725 (28) Page 30 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-8. Fuel boost sump cartridge replacement  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 180: Ejector Pump

    ICA-D212-725 (28) Page 31 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.16 EJECTOR PUMP 28.16.2.1 Remove any obstructions from opening of pump using compressed air. An ejector pump (Figure 28-9) is mounted in each forward fuel cell. The ejector pump is operated by 28.16.2.2...

  • Page 181: Inspection

    ICA-D212-725 (28) Page 32 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) forward fuel cell. Remove access bar (18, Figure 28.17.3 Installation 28-10), washers (19), and access bar (17). 28.17.3.1 Remove protective covers from cell 28.17.1.3 Remove cover to fuel cell sump openings.

  • Page 182: Removal

    ICA-D212-725 (28) Page 33 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.18 LOW FUEL LEVEL WARNING 28.18.1.4 To remove switch support, remove SWITCHES retaining nut and washer from lower side of sump base (3). Lift support (7) and packing from upper Float actuated low fuel level warning switches are side.
  • Page 183 ICA-D212-725 (28) Page 34 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-9. Ejector sump  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 184 ICA-D212-725 (28) Page 35 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-10. Flapper valve  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 185: Removal

    ICA-D212-725 (28) Page 36 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.19 FORWARD CELL FUEL QUANTITY Torque 40 to 50 in-lbs. (4.52 to 5.65 Nm). PROBES 28.19.2.3 Position fuel quantity probe (3) in aft Five electronic transmitter probes of the fuel section of fuel cell and install clamps (2 and 4) using quantity gage system are mounted in fuel cells;...
  • Page 186 ICA-D212-725 (28) Page 37 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-11. Fuel quantity probes — forward fuel cell  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 187: Sump Drain Valve

    ICA-D212-725 (28) Page 38 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.20.2 Installation retainer (4), and two Lock-O-Seals from sump base (3). 28.20.2.1 Place packing (1, Figure 28-12) in groove around center cell access port. 28.21.1.4 Remove retaining nut, packing, and drain valve.
  • Page 188 ICA-D212-725 (28) Page 39 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-12. Aft center fuel cell access door  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 189: Removal

    ICA-D212-725 (28) Page 40 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.22 INTERCONNECT VALVES 28.23.1.4 Disconnect fuel tube and hose from valve fittings. On aircraft serial numbers 30687, 30931, 30576, 30817, 30599, 30544, 30866, and 30826 that have 28.23.1.5...

  • Page 190: Removal

    ICA-D212-725 (28) Page 41 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.24.2 Installation 28.25.2.3 Install sump assembly (paragraph 28.24.2.1 Position aft interconnect valve (20, 28.12.3). During installation, attach crossover Figure 28-2) between flanges of crossover assembly (2) to mating flange of aft interconnect...
  • Page 191 ICA-D212-725 (28) Page 42 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) shutoff valve. The manifold contains two separate for parts replacement. valve elements at the inlet ports. Each consists of a check valve which prevents reverse flow except 28.27.1.8.3 Remove fitting (8) and flange (7) from through the thermal relief bypass of trapped fuel.
  • Page 192 ICA-D212-725 (28) Page 43 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) with clamp. 28.27.2.6 Install washer (15) and nut (14) on union (16). 28.27.2.10 Turn battery switch ON, turn both boost pump switches ON, move FUEL VALVE switch to 28.27.2.7...
  • Page 193 ICA-D212-725 (28) Page 44 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-13. Fuel shutoff valve and fuel valve manifold  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 194: Main Fuel Filter

    ICA-D212-725 (28) Page 45 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.28 MAIN FUEL FILTER shutoff valve of supply system, a drain line with manual valve, and an outlet coupling for engine fuel The main fuel filter has a micronic type element control hose.

  • Page 195: Removal

    ICA-D212-725 (28) Page 46 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.28.1 Removal body, seated firmly on boss. 28.28.1.1 Open engine cowling on the left side. 28.28.2.2.3 Install packing (9) around upper lip of filter body (11), next to flange.

  • Page 196: Removal

    ICA-D212-725 (28) Page 47 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) 28.29.1.6 Remove nut (9) and washer (8). 28.29.2.12 Close Engine cowling. 28.29.1.7 Remove pressure transmitter (4). applicable, remove plug (2) and packing (3). Discard packing. 28.30 GOVERNOR BLEED LINE CHECK VALVE 28.29.1.8...
  • Page 197 ICA-D212-725 (28) Page 48 of 48 CHAPTER 28 – FUEL SYSTEM (28-00-00) Figure 28-15. Fuel Pressure Transmitter  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 198 ICA-D212-725 (29) Page 1 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) CHAPTER 29 HYDRAULIC SYSTEM (29-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 199 ICA-D212-725 (29) Page 2 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) TABLE OF CONTENTS   Table of Contents ............................. 2   List of Figures ..............................3   List of Tables ..............................3     29.1 Hydraulic System ..........................4  ...
  • Page 200 ICA-D212-725 (29) Page 3 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) LIST OF FIGURES     Figure 29-1. Hydraulic schematic (sheet 1 of 4) ................... 6     Figure 29-1. Hydraulic schematic (sheet 2 of 4) ................... 7  ...

  • Page 201: Hydraulic System

    ICA-D212-725 (29) Page 4 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.1 HYDRAULIC SYSTEM switches located on both systems 1 and 2 reservoir inlets will illuminate a HYDRAULIC Two similar but separate hydraulic systems are caution segment located on the caution panel used to operate flight controls power cylinders when hydraulic fluid temperature reaches 190°F...
  • Page 202 ICA-D212-725 (29) Page 5 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) units such as viscous dampers, liquid springs, or surface often appears to be excessive, though oleo struts. actually being allowable. However, it is also possible to have enough components with 29.2.1.2...
  • Page 203 ICA-D212-725 (29) Page 6 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-1. Hydraulic schematic (sheet 1 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 204 ICA-D212-725 (29) Page 7 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-1. Hydraulic schematic (sheet 2 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 205 ICA-D212-725 (29) Page 8 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-1. Hydraulic schematic (sheet 3 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 206 ICA-D212-725 (29) Page 9 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-1. Hydraulic schematic (sheet 4 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 207 ICA-D212-725 (29) Page 10 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Table 29-1. Allowable leakage for in-service hydraulic components Component Function Leak Type Leakage Rate (Max) Flight Rod Seal 1 drop/20 full stroke cycles Controls Rod Seal 1 drop/15 minutes...

  • Page 208: Troubleshooting

    ICA-D212-725 (29) Page 11 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.2.2 Troubleshooting should be used with other sources of information such hydraulic schematic, electrical The following list of probable causes, isolation diagrams, operational check, and other detailed procedures, and remedies is intended to aid in procedures in this chapter.
  • Page 209 ICA-D212-725 (29) Page 12 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Table 29-2. Troubleshooting (Cont.) Indication of Trouble Probable Cause Corrective Action ONE SYSTEM LACKS POWER BUT PRESSURE IS NORMAL. Pressure operated valve in If system normal on test unit but Replace valve.
  • Page 210 ICA-D212-725 (29) Page 13 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Table 29-2. Troubleshooting (Cont.) Indication of Trouble Probable Cause Corrective Action FILTER INDICATORS TRIPPED Filters clogged. If indicator in cabin nose is red or Clean filter elements as required.
  • Page 211 ICA-D212-725 (29) Page 14 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Table 29-2. Troubleshooting (Cont.) Indication of Trouble Probable Cause Corrective Action HYDRAULICS AND MASTER CAUTION LIGHTS ON. System 1 or 2 overheating. Check temperature gage for Refer to EITHER HYDRAULIC temperature higher than 190°F...
  • Page 212 ICA-D212-725 (29) Page 15 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Table 29-2. Troubleshooting (Cont.) Indication of Trouble Probable Cause Corrective Action RESERVOIR OVERFLOWS WHEN USING GROUND TEST UNIT. Test unit pressure too low. Check test unit setting. Increase test unit pressure above 550 PSI (3792 kPa).
  • Page 213 ICA-D212-725 (29) Page 16 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Table 29-2. Troubleshooting (Cont.) Indication of Trouble Probable Cause Corrective Action MOTORING SERVO ACTUATOR IN TAIL ROTOR CONTROLS. Hoses restraining or causing Inspect hoses for position Position hoses for least restraint.

  • Page 214: Flushing

    ICA-D212-725 (29) Page 17 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.2.3 Flushing 29.2.3.1.7 Accomplish complete visual inspection of hydraulic system to ensure all MATERIALS REQUIRED components and lines are securely attached and appear capable of satisfactory operation. NUMBER...

  • Page 215: Operational Check

    ICA-D212-725 (29) Page 18 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) returns to test stand. 29.2.3.4 After flushing procedure is completed, remove dust caps from actuators. Reconnect 29.2.4.1.3 Capable of producing pressure to hoses cyclic, collective anti-torque 1400 PSIG, and a minimum flow rate of 6.0 actuators.
  • Page 216 ICA-D212-725 (29) Page 19 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) while performing the following: as follows: 29.2.4.5.1 Observe all parts of system for 29.2.4.8.1 With hydraulic test stand connected evidence of leakage, taking corrective action as to system 2 only, apply 1000 PSIG (6895 kPa) necessary.

  • Page 217: Operational Check (Helicopter Power)

    ICA-D212-725 (29) Page 20 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) opening between 1100 and 1300 PSIG (7585 and 8964 kPa), and being fully open by 1400 PSIG (9653 kPa). 29.2.5 Operational Check (Helicopter Power) CAUTION MATERIALS REQUIRED NUMBER...

  • Page 218: Reservoir Assemblies

    ICA-D212-725 (29) Page 21 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3 HYDRAULIC SYSTEM COMPONENTS other defects of transparency which could prevent proper observation of fluid level. 29.3.1 Reservoir Assemblies 29.3.1.2.3 Inspect vent screen for cleanliness, The reservoirs for system 1 and system 2 are damage, and corrosion.
  • Page 219 ICA-D212-725 (29) Page 22 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-2. Hydraulic system No. 1  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 220 ICA-D212-725 (29) Page 23 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-3. Hydraulic system No. 2  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 221: Integrated Valve And Filter Assemblies

    ICA-D212-725 (29) Page 24 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.1.3.2 If vent screen is unserviceable due drain plug to drilled head of aft outboard bolt to damage or clogging, replace as follows:. with lockwire (C-405). 29.3.1.3.2.1 Carefully drill out area where screen 29.3.1.4.5...

  • Page 222: Hydraulic Filter Assemblies

    ICA-D212-725 (29) Page 25 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.2.5). Reset clogged filter indicator. 29.3.2.1 Removal MATERIALS REQUIRED 29.3.2.4 Installation NUMBER NOMENCLATURE 29.3.2.4.1 Position valve and filter assembly C-428 Caps and/or Plugs (Item 13, Figure 29-2 or Item 5, Figure 29.3).
  • Page 223 ICA-D212-725 (29) Page 26 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.3.1.4 Remove retainer (3) and filter element general condition. Pay particular attention to (5). damage to the filtering surfaces and bonding of the end caps to the filtering core.
  • Page 224 ICA-D212-725 (29) Page 27 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) metal, brass, and aluminum contamination. NOTE 29.3.3.4.10 Replace non-cleanable filter Discard cleanable filter element P/N 205-076- element (12) 205-076-034-003 034-007 after three cleaning events contamination is found and flush the hydraulic system.
  • Page 225 ICA-D212-725 (29) Page 28 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.3.6 Hydraulic Filter Assemblies (P/N CAUTION 212-076-006-007) - Installation MATERIALS REQUIRED EXCESSIVELY TIGHTEN NUMBER NOMENCLATURE LOCKWIRE ON FILTER BODY AND FILTER BOWL. DAMAGE TO THE LOCKWIRE HOLES C-002 or C-072 Hydraulic Fluid CAN OCCUR.

  • Page 226: Hydraulic System Accumulators

    ICA-D212-725 (29) Page 29 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) accumulator. 29.3.3.7.5 Install filter element (12) into filter bowl (11). 29.3.4.1.3 Cover open lines with caps and/or plugs (C-428). 29.3.3.7.6 Fill filter bowl (11) half full with clean hydraulic fluid (C-002) or hydraulic fluid (C-072).
  • Page 227 ICA-D212-725 (29) Page 30 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) CAUTION 29.3.5.1.5 Disconnect hoses from pump, draining fluid from reservoir and hoses. DO NOT LUBRICATE SPLINES FOR PUMPS 29.3.5.1.6 Cap open lines and fittings. Cover P/N 731634 (PV3-044-8A) OR 212-076-010-101 open port in transmission case.

  • Page 228: Hydraulic Pump (System 2)

    ICA-D212-725 (29) Page 31 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.6 Hydraulic Pump (System 2) 29.3.6.4.1 If replacing pump, install 90° elbow fittings in suction port, and unions in pressure, System 2 pump is identical to system 1 pump.
  • Page 229 ICA-D212-725 (29) Page 32 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-4. Hydraulic Filter Assemblies  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 230 ICA-D212-725 (29) Page 33 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-5. Hydraulic Pump and Reservoir Hose and Fittings  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 231: Pressure Transmitter

    ICA-D212-725 (29) Page 34 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.7 Pressure Transmitter 29.3.7.3.1 Place pressure transmitter Figure 29-6) into lift beam bracket (5) and Hydraulic system No. 1 (Figure 29-6) and secure with screws (7) and thin aluminum hydraulic system No.
  • Page 232 ICA-D212-725 (29) Page 35 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-6. Pressure Transmitter  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 233: Collective Hydraulic Cylinder

    ICA-D212-725 (29) Page 36 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.8 Collective Hydraulic Cylinder 29.3.8.2 Repair A dual hydraulic cylinder, located in left aft pylon MATERIALS REQUIRED area is used to assist collective control of main NUMBER NOMENCLATURE rotor and reduce feed back forces.
  • Page 234 ICA-D212-725 (29) Page 37 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-7. Collective Hydraulic Cylinder  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 235 ICA-D212-725 (29) Page 38 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-8. Hydraulic cylinder boot 29.3.8.3.1 Coat threads of clevis (8, Figure 29- 29.3.8.2.2.6 Remove bolt attaching lower or end 7) with corrosion preventive compound (C- 101). bearing (19) to support (20) and ensure no side loads have been induced into lower piston rod.
  • Page 236 ICA-D212-725 (29) Page 39 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.8.3.5 Place boot (6) over end of control tube loads have been induced into lower piston rod. If (5). Fill cavity of housing (9) with corrosion necessary, loosen and retighten bearing nut (11) preventive compound (C-104).

  • Page 237: Cyclic Hydraulic Cylinder

    ICA-D212-725 (29) Page 40 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.9 Cyclic Hydraulic Cylinder installed, cylinder assembly can be removed up through cylinder support (7). dual hydraulic cylinders mounted vertically in forward end of pylon support and are 29.3.9.1.7 Remove...
  • Page 238 ICA-D212-725 (29) Page 41 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-9. Cyclic Hydraulic Cylinder  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 239: Tail Rotor Hydraulic Cylinder

    ICA-D212-725 (29) Page 42 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.9.2.8 Install cylinder assembly as follows: using new packings. NOTE 29.3.9.2.10 Connect control tubes (3) and spring Cylinder assembly can be installed from the top if (2) to swashplate horns, and tubes (12) to input transmission is removed.
  • Page 240 ICA-D212-725 (29) Page 43 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-10. Tail Rotor Hydraulic Cylinder  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 241 ICA-D212-725 (29) Page 44 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-11. Tail Rotor Hydraulic Cylinder Lever Bearing  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 242 ICA-D212-725 (29) Page 45 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.3.10.1.5 Support cylinder and remove two 29.3.10.2.3.5 If bearing does not meet torque bolts through trunnion plates (10). Remove plates requirement, replace in accordance with HR and cylinder.

  • Page 243: Rotor Brake Hydraulic System

    ICA-D212-725 (29) Page 46 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.4 ROTOR BRAKE HYDRAULIC SYSTEM CAUTION 29.4.1 Rotor Brake System DO NOT ATTEMPT ANY ADJUSTMENT OF Hydraulic pressure to operate the rotor brake SERVO VALVE BYPASS VALVE system is provided by actuation of lever (5, HYDRAULIC CYLINDER.
  • Page 244 ICA-D212-725 (29) Page 47 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Table 29-3. Troubleshooting rotor brake system Indication of Trouble Probable Cause Corrective Action No braking action. Insufficient fluid in system. Fill and bleed system. Foreign substance in fluid.
  • Page 245 ICA-D212-725 (29) Page 48 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) Figure 29-12. Rotor Brake System  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 246: Servicing

    ICA-D212-725 (29) Page 49 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.4.3 Servicing should be drained from each valve before conducting bleeding operation. MATERIALS REQUIRED 29.4.4.6 Repeat steps 29.4.4.2 through NUMBER NOMENCLATURE 29.4.4.5 for other bleed valve (2). C-002 Hydraulic Fluid 29.4.4.7...
  • Page 247 ICA-D212-725 (29) Page 50 of 50 CHAPTER 29 – HYDRAULIC SYSTEM (29-00-00) 29.4.5.3 Installation 29.4.5.3.2 Apply bead of adhesive (C-308) to MATERIALS REQUIRED roof surface around master cylinder fill port. NUMBER NOMENCLATURE 29.4.5.3.3 Attach tubing to master cylinder. C-308 Adhesive 29.4.5.3.4 Bleed master cylinder (paragraph...
  • Page 248 ICA-D212-725 (30 Page 1 of 1 CHAPTER 30 – ICE AND RAIN PROTECTION (30-00-00) CHAPTER 30 ICE AND RAIN PROTECTION (30-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 249  ...

  • Page 250: Landing Gear

    ICA-D212-725 (32) Page 1 of 1 CHAPTER 32 – LANDING GEAR (32-00-00) CHAPTER 32 LANDING GEAR (32-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 251  ...
  • Page 252 ICA-D212-725 (52 Page 1 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) CHAPTER 52 DOORS AND WINDOWS (52-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 253 ICA-D212-725 (52 Page 2 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) TABLE OF CONTENTS   Table of Contents ............................2   List of Figures ..............................3   Consumable Materials List ..........................4     52.1 Doors ..............................6  ...
  • Page 254 ICA-D212-725 (52 Page 3 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) LIST OF FIGURES     Figure 52.1. Fuselage Access Doors, Covers, and Panels (Sheet 1 of 4) ..........8     Figure 52-1. Fuselage Access Doors, Covers, and Panels (Sheet 2 of 4) ..........9  ...

  • Page 255: Consumable Materials List

    ICA-D212-725 (52 Page 4 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) CONSUMABLE MATERIALS LIST The following consumable materials are required to perform the maintenance procedures within this chapter. Item No. Nomenclature Cage/FSCM Source C-004 Grease, Graphite, MIL-G-7178 Commercial...
  • Page 256 ICA-D212-725 (52 Page 5 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Item No. Nomenclature Cage/FSCM Source C-405 Lockwire, MS20995C32 (0.032 Inch Dia.) Commercial C-406 Aluminum Oxide Cloth. P-C-451 Commercial C-407 Abrasive Pad, Nylon Web (Scotchbrite) L-P-0050, Type I, Class 1, Size 1...

  • Page 257: Doors

    ICA-D212-725 (52 Page 6 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.1 DOORS NOTE It is necessary to thoroughly clean surfaces This chapter provides maintenance data for crew before sanding to preclude working any foreign doors, passenger/cargo doors, access doors and matter into pores of material.
  • Page 258 ICA-D212-725 (52 Page 7 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Press seal down to expel all air to ensure proper 52.1.2.7.1 Apply one even coat of adhesive (C- contact and adhesion. 300) to bond surfaces of seal and metal.
  • Page 259 ICA-D212-725 (52 Page 8 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52.1. Fuselage Access Doors, Covers, and Panels (Sheet 1 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 260 ICA-D212-725 (52 Page 9 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) DIMENSIONS RETAINER ITEM NOMENCLATURE ACCESSES (INCHES) TYPE QTY Nose Door (Lower) Inverters No. 1. 2, and DC Control 24 x 34 Camlock Panels No. 1 Hinge Access Panel RMI Adapter No.
  • Page 261 ICA-D212-725 (52 Page 10 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) DIMENSIONS RETAINER ITEM NOMENCLATURE ACCESSES (INCHES) TYPE QTY Door Assembly Driveshaft and Electrical Disconnect 6 x 8 Latch P/N 205-060-810-015 (L/H) Access Door Hinge P/N 205-060-810-016 (R/H)
  • Page 262 ICA-D212-725 (52 Page 11 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) DIMENSIONS RETAINER ITEM NOMENCLATURE ACCESSES (INCHES) TYPE QTY Door Pilot Cyclic Controls 7 x 11 Screw Door Pilot Cyclic Controls 8 x 12 Screw Door Heat Distribution Valve...
  • Page 263 ICA-D212-725 (52 Page 12 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-2. Lower Fuselage and Tailboom Access Doors, Covers, and Panels (Sheet 1 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 264 ICA-D212-725 (52 Page 13 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) DIMENSIONS RETAINER ITEM NOMENCLATURE ACCESSES (INCHES) TYPE QTY Panel Assembly Forward Electrical Compartment 14 x 30 Screw Door Anti-torque Controls 6.3 x 12.7 Screw Door Copilot Cyclic Controls...
  • Page 265 ICA-D212-725 (52 Page 14 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) DIMENSIONS RETAINER ITEM NOMENCLATURE ACCESSES (INCHES) TYPE QTY Door Fuel Boost Pump 12 x 16 Screw Door Anti-torque Lever 8 x 10 Screw Door Landing Gear Attach Structure...

  • Page 266: Crew Doors

    ICA-D212-725 (52 Page 15 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.2 CREW DOORS. aft end of rod from rod end on latch assembly (13). Remove rod through aft side of door. 52.2.1 Crew Doors – Description Maintenance 52.2.1.2.4 Remove screws (17) to detach latch...
  • Page 267 ICA-D212-725 (52 Page 16 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-3. Interior Cabin Access Doors, Covers, and Panels (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 268 ICA-D212-725 (52 Page 17 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) DIMENSIONS RETAINER ITEM NOMENCLATURE ACCESSES (INCHES) TYPE QTY Door Assembly Hydraulic Components, Lift Beam Link 15 x 28 Sleeve Bolt37 and Cargo Hook Door Assembly Cyclic Hydraulic Servos and Cargo...
  • Page 269 ICA-D212-725 (52 Page 18 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.2.1.3 Inspection 52.2.1.4.4 Repair damaged door windows (paragraph 52.7.4.2). 52.2.1.3.1 Perform operational check for both crew doors. 52.2.1.4.5 Install new door seals as required (paragraph 52.1.2). 52.2.1.3.2 Inspect...

  • Page 270: 52.2.2 Crew Door Jettison Mechanism

    ICA-D212-725 (52 Page 19 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.2.1.5.10 Position rod (21) clevis on bellcrank 52.2.1.6.3 Align hinge halves and release (20). Secure with pin (22) and cotter pin. jettison handle. 52.2.1.5.11 Position rod (9) in door and thread 52.2.1.6.4 Close door slowly and observe...
  • Page 271 ICA-D212-725 (52 Page 20 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) of latch striker (1) with pin (3) secured by cotter 52.2.2.1.5 Disassemble ejection mechanism as pin. Verify spring (2) is attached between striker follows: and bracket in door post.

  • Page 272: Crew Door Hinges

    ICA-D212-725 (52 Page 21 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) latching position, and tighten nut on swivel to hold 52.2.3 Crew Door Hinges end of cable securely. 52.2.3.1 Crew Door Hinges - Removal 52.2.2.2.6 Perform operational check (paragraph 52.2.2.3).
  • Page 273 ICA-D212-725 (52 Page 22 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) and 13) for excessive wear to the striker blocks. 52.2.3.4.1 Replace the bushings (14 and 15, 52.2.3.2.6 Replace the spring assemblies (11 Figure 52-6) as follows: or 13) if the rivets of the striker blocks are visible.
  • Page 274 ICA-D212-725 (52 Page 23 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) (7.925 to 7.950 mm). 52.2.3.4.2.5 Ream bushings (16) to have a NOTE diameter from 0.1880 to 0.1885 inch (4.778 to Make sure that the ends of the bushings are flush 4.788 mm).
  • Page 275 ICA-D212-725 (52 Page 24 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Upper Forward Striker 12. Latch Striker 23. Spring Latch Rod Roller 13. Latch Assembly 24. Pin Upper Window 14. Outer Handle 25. Latch Rod Doorpost 15. Latch Shaft 26.
  • Page 276 ICA-D212-725 (52 Page 25 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-5. Crew Door Jettison Mechanism  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 277 ICA-D212-725 (52 Page 26 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-6. Crew Door Hinges (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 278 ICA-D212-725 (52 Page 27 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Hinge half assembly, upper fixed Hinge half assembly, upper movable Hinge half assembly, lower fixed Hinge half assembly, lower movable Screw Washer Washer Screw Spring assembly, lower...

  • Page 279: Passenger/Cargo Area Access Doors

    ICA-D212-725 (52 Page 28 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.3 PASSENGER/CARGO AREA ACCESS DOORS 52.3.1.3 Repair or replacement The passenger/cargo area access doors consist of 52.3.1.3.1 Replace unserviceable parts in latch the sliding passenger/cargo door and the hinged mechanism (paragraph 52.3.2).

  • Page 280: Passenger/Cargo Door

    ICA-D212-725 (52 Page 29 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) (17) at aft end of lower track on fuselage. Install 52.3.2 Passenger/Cargo Door Latches inside handle and latch guards, if not previously accomplished. 52.3.2.1 Removal 52.3.1.4.5 Perform operational check (paragraph NOTE 52.3.1.5).

  • Page 281: Annual Functional Inspection For Crew And Passenger/Cargo Doors

    ICA-D212-725 (52 Page 30 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.3.3 Annual Functional Inspection for Crew and Passenger/Cargo Doors NOTE Corrosion pits shall be no larger than 0.060 in. MATERIALS REQUIRED (1.524 mm) in major surface dimension and 0.020 in.

  • Page 282: 52.3.4 Cargo Hinged Panels

    ICA-D212-725 (52 Page 31 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) METAL SHALL BE REMOVED. access opening at top of panel. 52.3.3.4.1 Abrade corrosion pits with aluminum 52.3.4.1.5.5 Remove cotter pin and pin (14) to oxide cloth (C-406) or abrasive pad (C-407) and detach tube (15) from spindle assembly (12).
  • Page 283 ICA-D212-725 (52 Page 32 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) pin (16) on tube. Insert pin through guide at 52.3.4.3.6.2 Operate handle (13) to open bottom of panel. Attach tube (15) to spindle panel. Verify upper and lower pins retract to assembly (12) using pin (14) and cotter pin.
  • Page 284 ICA-D212-725 (52 Page 33 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-7. Passenger/Cargo Door (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 285 ICA-D212-725 (52 Page 34 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-7. Passenger/Cargo Door (Sheet 2 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 286 ICA-D212-725 (52 Page 35 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-8. Passenger/Cargo Door Latch (Typical)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 287 ICA-D212-725 (52 Page 36 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-9. Cargo Hinged Panel Door  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 288: Cargo Compartment Door

    ICA-D212-725 (52 Page 37 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.4 CARGO COMPARTMENT DOOR The cargo compartment door is located on the 52.4.4 Installation forward right side of the tail boom. The door is hinged on the forward end and has a latch and 52.4.4.1...

  • Page 289: Electrical And Equipment Compartment Access Doors

    ICA-D212-725 (52 Page 38 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.5.1.2 Inspection 52.5.2.1 Removal 52.5.1.2.1 Inspect hinges cracks 52.5.2.1.1 Release spring loaded latches and distortion. hold door open. 52.5.1.2.2 Inspect latches for operation and 52.5.2.1.2 Remove hinge pins attaching doors security.

  • Page 290: Tail Rotor Driveshaft Access Covers

    ICA-D212-725 (52 Page 39 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 10) for missing, damaged, or loose studs. 52.5.3.3 Installation 52.6.2.2 Inspect covers for corrosion and Position door, panel, or fairing on helicopter and mechanical damage. fasten twist-type fastener or install screws, as applicable 52.6.2.3...
  • Page 291 ICA-D212-725 (52 Page 40 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-10. Tailboom Driveshaft Access Covers  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 292 ICA-D212-725 (52 Page 41 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7 WINDOWS AND WINDSHIELDS 52.7.1.1.5 Carefully remove windshield from The following paragraphs provide maintenance helicopter. instructions for the pilot and copilot windshields, cabin and nose section windows (upper and lower), crew door windows, passenger/cargo door 52.7.1.2...
  • Page 293 ICA-D212-725 (52 Page 42 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7.1.4 Installation (4.82 to 4.97 mm) drill. Temporarily attach with clecos. MATERIALS REQUIRED 52.7.1.4.9 Transfer remaining screw holes NUMBER NOMENCLATURE starting at the inboard corners, progressing C-305 Aliphatic Naphtha towards the outboard edge.
  • Page 294 ICA-D212-725 (52 Page 43 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7.1.4.15 Apply a small even bead of sealant 52.7.1.4.18 Remove excess sealant (C-328) (C-328) to window frame. from around windshield with aliphatic naphtha (C-305). Touch up paint if bare metal is evident.
  • Page 295 ICA-D212-725 (52 Page 44 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Scratches and pits may polished out to the extent that vision is not distorted. Distortion of vision is cause for replacement. Cracks, holes or other damage may be temporarily repaired, if vision of crew members will not be impaired by stop drilling, patching or other approved methods (refer to FAA Advisory Circular 43.13-1B.

  • Page 296: 52.7.2 Cabin Roof Windows

    ICA-D212-725 (52 Page 45 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7.2 Cabin Roof Windows CAUTION The cabin roof windows (Figure 52-11) are made of tinted acrylic. WHEN CLEANING WINDOWS MOUNTING FLANGE, USE ONLY ALIPHATIC NAPHTHA, TYPE II (C-305). DO NOT USE 52.7.2.1...
  • Page 297 ICA-D212-725 (52 Page 46 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7.2.3.9 Apply a 0.125 in. (3.18 mm) wide FLANGE, USE ONLY ALIPHATIC NAPHTHA bead of adhesive (C-308). TYPE II. DO NOT USE ALIPHATIC NAPHTHA. TYPE I AS IT WILL CLOUD WINDOWS.
  • Page 298 ICA-D212-725 (52 Page 47 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) Figure 52-13. Passenger/Cargo Door Windows (Doors Equipped with Push-out Style Windows)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 299: 52.7.3 Lower Nose Section Windows

    ICA-D212-725 (52 Page 48 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7.3 Lower Nose Section Windows window using naphtha. The lower nose windows (Figure 52-11) are made 52.7.3.3.4 Position window over of clear acrylic. opening. Trim surplus edge to permit window to be in mounting position against flange.
  • Page 300 ICA-D212-725 (52 Page 49 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) lower crew door window, and an upper crew door MATERIALS REQUIRED window. NUMBER NOMENCLATURE C-305 Aliphatic Naphtha 52.7.4.1 Removal C-308 Adhesive 52.7.4.1.1 Remove forward crew door window 52.7.4.3.1 Prior to installation of any crew door...

  • Page 301: Passenger/Cargo Door Windows (Doors Equipped With Push Out Windows)

    ICA-D212-725 (52 Page 50 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 0.50 in. (12.7 mm). WINDOWS, USE ONLY ALIPHATIC NAPHTHA, TYPE II (C-305). DO NOT USE ALIPHATIC 52.7.4.3.2.7 Remove all dust and foreign matter NAPHTHA, TYPE I, AS IT WILL CLOUD from window mating area and from window WINDOWS.
  • Page 302 ICA-D212-725 (52 Page 51 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7.5.1.3 Remove filler (lock strip) (3, Figure 52-13) from retainer. 52.7.5.2.2 Inspection (windows removed). 52.7.5.1.4 Push window out by pressing at lower 52.7.5.2.2.1 Mark both lower corners corners as directed by decal.
  • Page 303 ICA-D212-725 (52 Page 52 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) MATERIALS 52.7.5.3 Repair NOTE Repair windows in accordance with Figure 52-12 Helicopter finishes will not adhere to surfaces and FAA Publication 43.13-1B, Aircraft Inspection where primer and adhesive are applied.
  • Page 304 ICA-D212-725 (52 Page 53 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) 52.7.5.4.7.3 Position and hold retainer (seal) (6) 52.7.5.4.10 To avoid adhesive contact with in place with masking tape (C-426) so that it nests the painted surfaces of the door, verify in all four corners of the opening.

  • Page 305: 52.7.6 Cargo Hinged Panel Door Windows

    ICA-D212-725 (52 Page 54 of 54 CHAPTER 52 – DOORS AND WINDOWS (52-00-00) NOTE 52.7.6.2 Inspection and repair. Silicone adhesive (C-307) curing is obtained from moisture in the air. If window installation is Inspect and repair window as required. Refer to performed in a very dry environment, curing may FAA publication AC 43.13-1B, Aircraft Inspection...
  • Page 306 ICA-D212-725 (53) Page 1 of 19 CHAPTER 53 – FUSELAGE (53-00-00) CHAPTER 53 FUSELAGE (53-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 307: List Of Figures

        53.6 Generic Sheet Metal Part Replacement Procedure ................12 LIST OF FIGURES     Figure 53-1. Eagle Single Helicopter Fuselage and Major Components ............. 5     Figure 53-2. Forward Fuselage ........................6     Figure 53-3. Crew Seat Track Assemblies - Removal and Installation ............7  ...

  • Page 308: Fuselage

    ICA-D212-725 (53) Page 3 of 19 CHAPTER 53 – FUSELAGE (53-00-00) 53.1 FUSELAGE 53.3.1.2 Remove right-hand track The fuselage consists of forward fuselage and assemblies (3, Figure 53-3) as follows: tailboom. The forward fuselage (1, Figure 53-1) is of combined semi-monocoque and reinforced shell 53.3.1.2.1 Remove the screws (1), washers (2)

  • Page 309: 53.3.2 Crew Seat Tracks - Installation

    ICA-D212-725 (53) Page 4 of 19 CHAPTER 53 – FUSELAGE (53-00-00) 53.3.2 Crew Seat Tracks - Installation 53.3.2.3 Install the applicable crew seat (Chapter 25) 53.3.2.1 Install right hand track assemblies (3, Figure 53-3) as follows: 53.4 TENSION ROD ASSEMBLY 53.3.2.1.1 Make sure the mating surfaces are...
  • Page 310 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-1. Eagle Single Helicopter Fuselage and Major Components  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 311 ICA-D212-725 (53) Page 6 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-2. Forward Fuselage  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 312 ICA-D212-725 (53) Page 7 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-3. Crew Seat Track Assemblies - Removal and Installation  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 313 ICA-D212-725 (53) Page 8 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-4. Tension Rod Assembly - Removal and Installation  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 314 ICA-D212-725 (53) Page 9 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-5. Tension Rod Assembly - Damage Limits  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 315: Tailboom

    ICA-D212-725 (53) Page 10 of 19 CHAPTER 53 – FUSELAGE (53-00-00) 53.5 TAILBOOM 53.5.2 Inspection The tailboom (Figure 53-6) is of semi-monocoque MATERIALS REQUIRED construction. External components consist of NUMBER NOMENCLATURE formed aluminum alloy skins and driveshaft C-308 Sealant covers, a fiberglass fairing, aluminum honeycomb...
  • Page 316 ICA-D212-725 (53) Page 11 of 19 CHAPTER 53 – FUSELAGE (53-00-00) in area of splice. primer (C-222). Allow to dry 1 hour. Apply one coat of polyurethane enamel (C-233). 53.5.2.5.3 Report any cracks to Product Support Engineering. 53.5.3.3 Perform necessary structural repairs in accordance with BHT-MED-SRM-1.
  • Page 317 ICA-D212-725 (53) Page 12 of 19 CHAPTER 53 – FUSELAGE (53-00-00) 53.5.4.3 Place countersunk washer (Figure 53- NOTE 9) on each bolt with countersunk side of washer As no procedure can cover all sheet metal part toward bolt head. Install bolts using plain washers,...
  • Page 318 ICA-D212-725 (53) Page 13 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-6. Tailboom  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 319 ICA-D212-725 (53) Page 14 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-7. Control Disconnect Points for Tailboom Removal  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 320 ICA-D212-725 (53) Page 15 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-8. Tailboom Support Assembly, T102012  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 321 ICA-D212-725 (53) Page 16 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Figure 53-9. Tailboom Attaching Bolts  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 322 ICA-D212-725 (53) Page 17 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Inspection Characteristic Method Limit ZONE 1 Corrosion on one Measure For corrosion depth of <=0.020 inch (0.51 mm), remove twice lug face the depth of the corrosion. Do not remove more than 0.040 inch (1.02 mm) from the cross hatched area.
  • Page 323 ICA-D212-725 (53) Page 18 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Inspection Characteristic Method Limit Corrosion Measure For a corrosion depth of <=0.010 inch (0.25 mm), uniformly damage to the remove twice the depth of the corrosion around the periphery of lug hole (not the the hole.
  • Page 324 ICA-D212-725 (53) Page 19 of 19 CHAPTER 53 – FUSELAGE (53-00-00) Inspection Characteristic Method Limit Mechanical Measure For a mechanical damage of <=0.040 inch (1.02 mm), remove damage on one the depth of the damage. Do not remove more than 0.040 inch spot face (1.02 mm) from the cross hatched area.
  • Page 325  ...
  • Page 326 ICA-D212-725 (62) Page 1 of 1 CHAPTER 62 – MAIN ROTOR (62-00-00) CHAPTER 62 MAIN ROTOR (62-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 327  ...
  • Page 328 ICA-D212-725 (63) Page 1 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) CHAPTER 63 MAIN ROTOR DRIVE SYSTEM (63-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 329 ICA-D212-725 (63) Page 2 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) TABLE OF CONTENTS Table of Contents ..............................2   63.1 Main Rotor Drive System ........................6     63.1.1 Main Rotor Drive System ........................ 6  ...
  • Page 330 ICA-D212-725 (63) Page 3 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7 Transmission Quills ..........................96     63.7.1 Transmission Quills ........................96     63.7.2 Tail Rotor Drive Quill ........................96     63.7.3 Input Drive Quill ........................... 100  ...
  • Page 331 ICA-D212-725 (63) Page 4 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-8. Dimensional Check before Installing Mast ................21     Figure 63-9. Transmission ..........................27     Figure 63-10. Transmission Build up (Sheet 1 of 4) ..................28  ...
  • Page 332 ICA-D212-725 (63) Page 5 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-54. Transmission Pylon Mounts (Sheet 2 of 2) ................. 123     Figure 63-55. Isolation Mount Test Fixture ....................124     Figure 63-56. Rotor Brake Assembly (Sheet 1 of 2) .................. 136  ...
  • Page 333 ICA-D212-725 (63) Page 6 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.1 MAIN ROTOR DRIVE SYSTEM assembly transmission mounted accessories. This includes engine-to- 63.1.1 Main Rotor Drive System transmission (main) driveshaft, transmission and This Chapter contains maintenance information for...

  • Page 334: Main Rotor Drive System

    ICA-D212-725 (63) Page 7 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) component, see Figure 63-2. concentrated hydrochloric (muriatic) acid (C-431), 63.1.2.1 Identification and concentrated nitric acid (C-432). Proceed as follows: MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and source.

  • Page 335: Main Rotor Drive System

    ICA-D212-725 (63) Page 8 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) The information contained in this figure is provided 63.1.2.2.2 Foreign ferrous material for the evaluation of contamination found on the introduced into gearboxes is often much softer drive system chip detectors.
  • Page 336 ICA-D212-725 (63) Page 9 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) TYPICAL APPEARANCE DESCRIPTION SIGNIFICANCE A few moderately-sized and/or (SIGNIFICANT DEBRIS) numerous small nearly-flat flakes: This is a classic indication of Under magnification one side of rolling element bearing failure.
  • Page 337 ICA-D212-725 (63) Page 10 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) TYPICAL APPEARANCE DESCRIPTION SIGNIFICANCE Spiral curls or comma-shaped (INSIGNIFICANT DEBRIS) particles: Particles are fragments of chips or When examined under shavings produced during the magnification, particles are often machining of ferrous components.
  • Page 338 ICA-D212-725 (63) Page 11 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) TYPICAL APPEARANCE DESCRIPTION SIGNIFICANCE Irregular-shaped ferrous particles: (INSIGNIFICANT DEBRIS) Particles this type Usually triangular cross commonly result tool sections. Often spiked-like in slippage during assembly of the appearance.

  • Page 339: Main Driveshaft

    ICA-D212-725 (63) Page 12 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.2 MAIN DRIVESHAFT the end fittings (Figure 63-5). Tighten clamps to allow removal of shaft. Remove shaft assembly. 63.2.1 Main Driveshaft Remove clamp work aids. A main driveshaft with crowned tooth couplings is installed between an adapter on the engine output 63.2.1.1.4...

  • Page 340: 63.2.2 Engine Driveshaft Adapter

    ICA-D212-725 (63) Page 13 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Refer to paragraph 63.2.2.1 for engine driveshaft 63.2.1.4.2.4 Install opposite end clamp set, in adapter installation procedures. the same manner, positioned 90 degrees around shaft in relation to previously installed clamp set.
  • Page 341 ICA-D212-725 (63) Page 14 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-3. Main Driveshaft Assembly (204-040-433-101)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 342 ICA-D212-725 (63) Page 15 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-4. Main Driveshaft Installation and Removal Tool Figure 63-5. Workaid Tool Installed on Main Driveshaft  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 343 ICA-D212-725 (63) Page 16 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-6. Main Driveshaft Damage Limits  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 344: Main Rotor Mast

    ICA-D212-725 (63) Page 17 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.3 MAIN ROTOR MAST 63.3.2.1.9 Remove sealant from around 63.3.1 Main Rotor Mast base of retainer plate using a sharp, non-metallic The main rotor mast assembly is a tubular steel scraper.
  • Page 345 ICA-D212-725 (63) Page 18 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) nicks, scratches, and corrosion may be polished 63.3.2.3.2.2 If dimension is less than 2.570 out, provided cleanup does not exceed 0.005 inch inches (65.278 mm), examine upper and lower (0.127 mm) depth and is blended into surrounding...
  • Page 346 ICA-D212-725 (63) Page 19 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) on transmission. 63.3.2.3.8 Rotate transmission input quill, by 63.3.2.3.6 Install aluminum washer, a thin hand, to make sure there is no unusual noise or steel washer, and a nut on each of ten mounting evidence of binding.
  • Page 347 ICA-D212-725 (63) Page 20 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-7. Mast Assembly  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 348 ICA-D212-725 (63) Page 21 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-8. Dimensional Check before Installing Mast  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 349: Transmission

    ICA-D212-725 (63) Page 22 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.4 TRANSMISSION and nuts (1). 63.4.1 Transmission 63.4.2.3 Remove transmission from The transmission (Figure 63-9) is a mechanical shipping container position stand, reduction gearbox, attached on the fuselage SWE13875.

  • Page 350: 63.4.3 Troubleshooting

    ICA-D212-725 (63) Page 23 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) (paragraph 63.5.6.3). 63.4.2.9 Remove cap (22). Install oil pressure switch (36) and packing (38) (paragraph 63.4.2.10.7 For transmissions 212-040-001- 63.5.22). 059 and subsequent, and transmissions modified by TB.
  • Page 351 ICA-D212-725 (63) Page 24 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Table 63-1. Transmission Oil System Troubleshooting INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Clogged pump screen. Drain sump and remove pump screen, check for chips and oil contamination.

  • Page 352: Troubleshooting Transmission Oil System

    ICA-D212-725 (63) Page 25 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Table 63-1. Transmission Oil System Troubleshooting INDICATION OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Obstruction of air flow around Check for any obstruction of area transmission or through oil cooler;...

  • Page 353: Chapter 63 - Main Rotor Drive System

    ICA-D212-725 (63) Page 26 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) filter in external lines has a visual indicator which 63.4.4.3 Cumulative clogging of oil filters will extend when filter bypass conditions are will not show as a gradual drop in oil pressure...
  • Page 354 ICA-D212-725 (63) Page 27 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-9. Transmission  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 355 ICA-D212-725 (63) Page 28 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-10. Transmission Build up (Sheet 1 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 356 ICA-D212-725 (63) Page 29 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-10. Transmission Build up (Sheet 2 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 357 ICA-D212-725 (63) Page 30 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-10. Transmission Build up (Sheet 3 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 358 ICA-D212-725 (63) Page 31 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-10. Transmission Build up (Sheet 4 of 4)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 359: Maintenance

    ICA-D212-725 (63) Page 32 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) tachometer generator from drive quill 63.4.5 Maintenance (paragraph 63.7.5.1). Disconnect No. 2 hydraulic pump lines and cap fittings (Chapter 29). 63.4.5.1 Removal 63.4.5.1.5 Remove engine-to-transmission SPECIAL TOOLS REQUIRED (main) driveshaft (paragraph 63.2.1.1).
  • Page 360 ICA-D212-725 (63) Page 33 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.4.5.1.13 Remove stabilizer bar damper and INSTALLED. adapter (Chapter 62). 63.4.5.1.23 Install cover plate in transmission 63.4.5.1.14 Remove swashplate and scissors top case opening. and sleeve (Chapter 62).
  • Page 361 ICA-D212-725 (63) Page 34 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) oil lines for leaks. If main input quill is leaking, replace seal (paragraph 63.7.4.1 to 63.7.4.2). 63.4.5.3.6 Install a retaining bolt (3, Figure 63-11) with a countersunk washer and a large 63.4.5.2.11...
  • Page 362 ICA-D212-725 (63) Page 35 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) electrical wires (Chapter 96), if so equipped. proper operation. 63.4.5.3.17 Service transmission with NOTE (Chapter 12). Verify actual presence of oil in sight Throughout the entire procedure which follows, gage.
  • Page 363 ICA-D212-725 (63) Page 36 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) counterclockwise to decrease pressure. When leakage, replace defective parts. Repeat leak test required pressure is obtained, tighten jam nut. run. Start engine and gradually increase rotor rpm to 100% and recheck pressure.
  • Page 364 ICA-D212-725 (63) Page 37 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-11. Transmission Mounting Hardware  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 365: Transmission Oil System Components

    ICA-D212-725 (63) Page 38 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5 TRANSMISSION OIL SYSTEM COMPONENTS oil drains back into the sump case. temperature and pressure gage indications are 63.5.1 Transmission Oil System provided by a temperature bulb and a pressure The transmission is lubricated by an oil system transmitter.
  • Page 366 ICA-D212-725 (63) Page 39 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-12. Transmission Oil System Schematic  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 367 ICA-D212-725 (63) Page 40 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) secure with lockwire (C-405). 63.5.2 Transmission Oil Pressure Relief Valve 63.5.2.2.3 Check oil pressure in operation. The pressure relief valve (10, Figure 63-13) is mounted in the oil manifold located at right aft side 63.5.2.3...
  • Page 368 ICA-D212-725 (63) Page 41 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-13. Transmission Oil System (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 369 ICA-D212-725 (63) Page 42 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 1. Breather 12. Jet no. 3 23. Filler cap 2. Line to mast jet 13. Sump filter 24. Auxiliary jet 3. Jet no. 1 14. Inlet hose 25.
  • Page 370 ICA-D212-725 (63) Page 43 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-14. Oil Pressure Relief Valve  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 371: Transmission Oil Pump

    ICA-D212-725 (63) Page 44 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.3 Transmission Oil Pump 63.5.3.1.11 Cover opening in sump case (1). The oil pump (18, Figure 63-13) is mounted in the underside of transmission sump case, and is 63.5.3.2...
  • Page 372 ICA-D212-725 (63) Page 45 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.3.2.10 Secure screen (17) chip detector base with lockwire (C-405). 63.5.3.2.12 Install access door. 63.5.3.2.11 Service transmission (Chapter 63.5.3.2.13 Check for oil leaks at next 12).

  • Page 373: Transmission Main Input Gear Quill Electric Chip Detector

    ICA-D212-725 (63) Page 46 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.4.3.2 Inspect chip detector components 63.5.4 Transmission Mast Bearing in accordance with Figure 63-17. Electric Chip Detector (Transmissions 212-040- 001-059 and Subsequent and Transmissions modified by T.B. 212-80-35) 63.5.4.4...
  • Page 374 ICA-D212-725 (63) Page 47 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) from housing. 63.5.5.3.2 Inspect chip detector components in accordance with Figure 63-17. 63.5.5.2 Cleaning 63.5.5.4 Installation MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and 63.5.5.4.1 Coat new packing (6 and 8, Figure source.
  • Page 375 ICA-D212-725 (63) Page 48 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-16. Mast Bearing Electric Chip Detector  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 376 ICA-D212-725 (63) Page 49 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-17. Damage Limits – Electric Chip Detector (Typical)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 377 ICA-D212-725 (63) Page 50 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-18. Main Input Quill Electric Chip Detector  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 378 ICA-D212-725 (63) Page 51 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.6 Transmission Sump Case Electric Chip Detector 63.5.6.3 Inspection transmissions have electric chip 63.5.6.3.1 Inspect chip detector (4, Figure detector/drain plug located in the transmission 63-19) for presence of metal particles.
  • Page 379 ICA-D212-725 (63) Page 52 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-19. Sump Case Electric Chip Detector  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 380 ICA-D212-725 (63) Page 53 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-20. Damage Limits – Sump Case Electric Chip Detector  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 381 ICA-D212-725 (63) Page 54 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.7.2.1 Visually inspect filter screens for 63.5.7 Transmission Oil Sump Filter metal particles or other contamination. If metal An oil filter is located in upper right aft corner of particles are found, refer to paragraph 63.1.2.
  • Page 382 ICA-D212-725 (63) Page 55 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) mechanical and corrosion damage (Figure 63-23). 63.5.7.4.5 Install thin aluminum washer (7) next to filter housing and thin steel washer (8) 63.5.7.4 Installation adjacent to nut (9). Install nut.
  • Page 383 ICA-D212-725 (63) Page 56 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-22. Sump Internal Filter (pre TB 212-91-131)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 384 ICA-D212-725 (63) Page 57 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-23. Sump Internal Filter 63.5.8 Full Flow Debris Monitor MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and The following procedures are applicable to source. helicopters S/N 31312 and subsequent and 35026 and subsequent and helicopters modified by T.B.
  • Page 385 ICA-D212-725 (63) Page 58 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) is not acceptable. 63.5.8.4.6 Install brackets (1 and 3) using washers (4) and nuts (5). 63.5.8.4 Installation 63.5.8.4.1 Lubricate new packings (6 and 11, 63.5.8.4.7 Torque nuts (5) 50 to 70 inch-lbs.
  • Page 386 ICA-D212-725 (63) Page 59 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-24. Full Flow Debris Monitor  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 387 ICA-D212-725 (63) Page 60 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.9 Transmission External Oil Filter NUMBER NOMENCLATURE C-304 Solvent A second filter (25, Figure 63-13) in the transmission oil system is located inside the right 63.5.9.2.1...
  • Page 388 ICA-D212-725 (63) Page 61 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-25. Transmission External Oil Filter  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 389 ICA-D212-725 (63) Page 62 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.10 Transmission Planetary Oil Jets 63.5.10.3 Inspection Two oil jets (8, Figure 63-26) are installed in the 63.5.10.3.1 Inspect clogging. planetary gear case of transmission to provide passages are clogged, determine source(s) of positive lubrication to planetary gearing.
  • Page 390 ICA-D212-725 (63) Page 63 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-26. Planetary Oil Jet  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 391 ICA-D212-725 (63) Page 64 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.11 Transmission Oil Jet No. 1 63.5.11.5 Installation 63.5.11.1 Removal MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and 63.5.11.1.1 Remove screw (9, Figure 63-27) source. and pull out oil jet (6).
  • Page 392 ICA-D212-725 (63) Page 65 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-27. Transmission Oil Jet No. 1  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 393 ICA-D212-725 (63) Page 66 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.12 Transmission Oil Jet No. 2 63.5.12.5 Installation 63.5.12.1 Removal MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and 63.5.12.1.1 Remove screw (1, Figure 63-28) source. and pull out oil jet (4).
  • Page 394 ICA-D212-725 (63) Page 67 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-28. Transmission Oil Jet No. 2  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 395 ICA-D212-725 (63) Page 68 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.13 Transmission Oil Jet No. 3 MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and 63.5.13.1 Removal source. 63.5.13.1.1 Remove bolt (1, Figure 63-29), washer (2), and bracket (3).
  • Page 396 ICA-D212-725 (63) Page 69 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-29. Transmission Oil Jet No. 3  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 397 ICA-D212-725 (63) Page 70 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.14 Transmission Oil Jet No. 4 63.5.14.4 Repair 63.5.14.1 Removal Refer to paragraph 63.5.10.4. 63.5.14.1.1 Remove access door on right side of pylon support in cabin.
  • Page 398 ICA-D212-725 (63) Page 71 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-30. Transmission Oil Jet No. 4  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 399 ICA-D212-725 (63) Page 72 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.15 Transmission Oil Jet No. 5 MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and 63.5.15.1 Removal source. 63.5.15.1.1 Remove screw (4, Figure 63-31). NUMBER NOMENCLATURE 63.5.15.1.2...
  • Page 400 ICA-D212-725 (63) Page 73 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-31. Transmission Oil Jet No. 5  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 401 ICA-D212-725 (63) Page 74 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.16 Transmission Oil Jet No. 6 MATERIALS REQUIRED Refer to BHT-ALL-SPM for specification and source. 63.5.16.1 Removal 63.5.16.1.1 Remove screw (7, Figure 63-32). NUMBER NOMENCLATURE C-405 Lockwire 63.5.16.1.2...
  • Page 402 ICA-D212-725 (63) Page 75 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-32. Transmission Oil Jet No. 6  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 403 ICA-D212-725 (63) Page 76 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) source. 63.5.17 Transmission Oil Jet No. 7 63.5.17.1 Removal NUMBER NOMENCLATURE C-405 Lockwire 63.5.17.1.1 Remove valve (1, Figure 63-33) with packing (2). Discard packing. 63.5.17.5.1 Install screw (9, Figure 63-33) with new seal (10).
  • Page 404 ICA-D212-725 (63) Page 77 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-33. Transmission Oil Jet No. 7  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 405 ICA-D212-725 (63) Page 78 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.18.2.1 Rinse screen with solvent (C-304). 63.5.18 Transmission Oil Pump Screen The transmission oil pump intake screen is a wire 63.5.18.2.2 Dry using filtered, compressed air.
  • Page 406 ICA-D212-725 (63) Page 79 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-34. Transmission Oil Pump Screen Figure 63-35. Damage Limits – Oil Pump Inlet Screen  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 407 ICA-D212-725 (63) Page 80 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.19.2.3 Lubricate new packings (1 and 3) 63.5.19 Oil Temperature Manifold and install on tube (2). Install tube in manifold (24) 63.5.19.1 Removal 63.5.19.2.4 Lubricate new packings (4 and 5) 63.5.19.1.1...
  • Page 408 ICA-D212-725 (63) Page 81 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-36. Oil Temperature Manifold  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 409 ICA-D212-725 (63) Page 82 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.20 Oil Pressure Transmitter 63.5.20.3 Installation 63.5.20.1 Removal MATERIALS REQUIRED 63.5.20.1.1 Disconnect electrical connector (5, Refer to BHT-ALL-SPM for specification and Figure 63-37). source. 63.5.20.1.2 Remove pressure transmitter (4)
  • Page 410 ICA-D212-725 (63) Page 83 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-37. Transmission Oil Pressure Transmitter  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 411 ICA-D212-725 (63) Page 84 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.21 Oil Pressure Switch 63.5.21.3 Installation 63.5.21.1 Removal MATERIALS REQUIRED 63.5.21.1.1 Disconnect electrical connector (5, Refer to BHT-ALL-SPM for specification and Figure 63-38). source. 63.5.21.1.2 Remove pressure switch (4) with...
  • Page 412 ICA-D212-725 (63) Page 85 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-38. Transmission Oil Switch  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 413 ICA-D212-725 (63) Page 86 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.22 Oil Pressure Manifold 63.5.22.3 Inspection 63.5.22.1 Removal Inspect manifold (4, Figure 63-39) for damaged 63.5.22.1.1 Remove pressure switch threads and for mechanical or corrosion damage.
  • Page 414 ICA-D212-725 (63) Page 87 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-39. Oil Pressure Manifold  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 415 ICA-D212-725 (63) Page 88 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) surface finish restored. 63.5.23 Filler Neck, Scupper and Mounting Bracket 63.5.23.3.2 Inspect bracket (5) and tube (13) for damage such as distortion and cracks. Loose 63.5.23.1...
  • Page 416 ICA-D212-725 (63) Page 89 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.23.4.11 Check for leaks at next helicopter twisting clockwise to engage lock. ground run. Figure 63-40. Filler Neck, Scupper and Mounting Bracket  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...
  • Page 417 ICA-D212-725 (63) Page 90 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.5.24.2.2 Dry with filtered, compressed air. 63.5.24 Transmission Sight Glasses NOTE 63.5.24.3 Inspection The following maintenance procedures are 63.5.24.3.1 Inspect glass (3, Figure 63-41) for detailed for indicator (4, Figure 63-41).
  • Page 418 ICA-D212-725 (63) Page 91 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-41. Transmission Sight Glass  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 419 ICA-D212-725 (63) Page 92 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.6 TRANSMISSION OIL COOLING SYSTEM 63.6.1.2 Inspection Repair – Transmission Oil Cooler 63.6.1 Transmission Oil Cooling System 63.6.1.2.1 Inspect oil cooler support for damage. The transmission oil system cooler is mounted in the bottom of the rear fuselage compartment, in 63.6.1.2.2...
  • Page 420 ICA-D212-725 (63) Page 93 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) bolt head and nut. 63.6.2 Oil Cooler Blower Oil cooler blower is located in the aft fuselage, 63.6.2.2.5 Attach blower to support bracket below the engine tailpipe.
  • Page 421 ICA-D212-725 (63) Page 94 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) end fitting engages the coupling body seldom poppets increase, reducing volume of the flow occurs. In the event it does occur, the end fitting cavity or allowing fluid to push the valves seal is the most probable cause.
  • Page 422 ICA-D212-725 (63) Page 95 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.6.4 Transmission Oil System Tubes 63.6.4.1 Inspection – Transmission and Hoses System Tubes and Hoses The transmission oil system has various tube and 63.6.4.1.1 Inspect tubes for nicks, scratches, hose assemblies for transfer and return of oil from dents, bent areas, and corrosion.

  • Page 423: Transmission Quills

    ICA-D212-725 (63) Page 96 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7 TRANSMISSION QUILLS NUMBER NOMENCLATURE C-304 Solvent 63.7.1 Transmission Quills 63.7.2 Tail Rotor Drive Quill CAUTION A drive quill equipped with a flexible spherical toothed coupling...
  • Page 424 ICA-D212-725 (63) Page 97 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) QUILL. reason for removal, i.e., overtorque, sudden stoppage, etc. 63.7.2.3.1.1 Wipe grease from coupling (10) and adjacent parts with clean cloths. 63.7.2.4.4 If no unacceptable defects are found, install tail rotor drive quill and return 63.7.2.3.1.2...
  • Page 425 ICA-D212-725 (63) Page 98 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7.2.6.4 Apply heat lamp (or 250 watt light 63.7.2.6.7 Apply a bead of adhesive (C-308) bulb) to mounting port in sump case until case is in gap around edge of quill sleeve where flange hot to the touch with bare hands.
  • Page 426 ICA-D212-725 (63) Page 99 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-42. Tail Rotor Drive Quill  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 427: Input Drive Quill

    ICA-D212-725 (63) Page 100 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7.3 Input Drive Quill 63.7.3.2.2 Remove cover from unused An input drive quill equipped with a freewheeling mounting port at left side of transmission. coupling is located on the aft side of the transmission main case.
  • Page 428 ICA-D212-725 (63) Page 101 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) positions. Install the T101586-5 studs into quill other studs. Install nuts and torque 160 to 190 mounting studs finger tight. inch-pounds. 63.7.3.2.8 Install input quill onto the studs far 63.7.3.2.12...
  • Page 429 ICA-D212-725 (63) Page 102 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-44. Work Aid for Lubrication of Tail Rotor Drive Coupling  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 430 ICA-D212-725 (63) Page 103 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-45. Input Drive Quill (205-040-263-003)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 431: Input Drive Quill Seal

    ICA-D212-725 (63) Page 104 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7.4 Input Drive Quill Seal 63.7.4.1.5 Inspect new seal wear sleeve (19) and mating surface on coupling outer race for TOOLS REQUIRED damage. Any nicks or dents on OD of wear...
  • Page 432 ICA-D212-725 (63) Page 105 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) SPECIAL ATTENTION SHOULD BE GIVEN TO 63.7.4.2.1 Remove cowling and main ASSURE NO EXCESSIVE BONDING MATERIAL driveshaft in accordance with paragraph 63.2.1.1. IS LEFT BETWEEN THE WEAR SLEEVE AND COUPLING RACE, AS IT TENDS TO BECOME 63.7.4.2.2...
  • Page 433 ICA-D212-725 (63) Page 106 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) in accordance with paragraph 63.2.1.4. Figure 63-46. Input Quill Seal Wear Sleeve Work Aid  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 434 ICA-D212-725 (63) Page 107 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-47. Input Drive Quill (205-040-263-101)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 435: Hydraulic Pump And Tachometer Drive Quill

    ICA-D212-725 (63) Page 108 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7.5 Hydraulic Pump and Tachometer 63.7.5.2 Cleaning Drive Quill MATERIALS REQUIRED A drive quill located on right side of transmission Refer to BHT-ALL-SPM for specification and sump case drives No 1 hydraulic pump by splined source.
  • Page 436 ICA-D212-725 (63) Page 109 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7.5.4.2 Replace seals (2 and 9, Figure source. 63-49) as follows: NUMBER NOMENCLATURE 63.7.5.4.2.1 Remove nuts (12), washers (11 C-007 Bearing Grease and 10), bolt (5) with washers (6 and 8), and...
  • Page 437 ICA-D212-725 (63) Page 110 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) on forward drive pad with four nuts and washers. of pylon support. Torque nuts 50 to 70 inch-lbs. (5.65 to 7.91 Nm). Connect electrical cable plug.
  • Page 438 ICA-D212-725 (63) Page 111 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-48. No. 1 Hydraulic Pump and Rotor Tachometer Drive Quill  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 439 ICA-D212-725 (63) Page 112 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-49. No. 1 Hydraulic System and Rotor Tachometer Drive Quill Assembly  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 440: No. 2 Hydraulic Pump Drive Quill

    ICA-D212-725 (63) Page 113 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7.6 No. 2 Hydraulic Pump Drive Quill 63.7.6.3 Inspection A drive quill located on the front of the transmission main case drives the no. 2 hydraulic 63.7.6.3.1...
  • Page 441 ICA-D212-725 (63) Page 114 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) teeth. If necessary, tap on quill using a soft face mallet as an aid to installation. Tap only on quill 63.7.6.5.6 Check quill pinion by hand for sleeve.

  • Page 442: Rotor Brake Quill

    ICA-D212-725 (63) Page 115 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.7.7.2.1 Clean sealant residue from both 63.7.7 Rotor Brake Quill quill and mating surface of transmission using a For helicopters so equipped, the rotor brake quill is...
  • Page 443 ICA-D212-725 (63) Page 116 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) oil to bore of transmission quill port and to mating diameter of quill assembly. 63.7.7.5.7 Install aluminum washers against flange of quill, steel washers (4) under 63.7.7.5.5...
  • Page 444 ICA-D212-725 (63) Page 117 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-51. Rotor Brake Quill  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 445: Transmission Quill Port Covers

    ICA-D212-725 (63) Page 118 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.8 TRANSMISSION QUILL PORT COVERS 63.8.1.7 Remove and discard packing (1). NOTE Removal and installation procedures for left and right quill port covers are identical. The following 63.8.2...
  • Page 446 ICA-D212-725 (63) Page 119 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-52. Quill Port Covers  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 447: Transmission Mounts

    ICA-D212-725 (63) Page 120 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.9 TRANSMISSION MOUNTS pylon support. 63.9.1 Pylon Mounts 63.9.2.2 Inspection Five vibration isolating mounts located on the support structure of the fuselage (Figure 63-53) 63.9.2.2.1 Replace pylon mounts, (5, 9, and are provided to mount the transmission.
  • Page 448 ICA-D212-725 (63) Page 121 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) mount with press ram so as to deflect mount in a bushing is properly seated on bolt and mount. vertical plane, not to exceed 0.25 inch (6.35 mm) Position bushing (20) on bolt and mount.
  • Page 449 ICA-D212-725 (63) Page 122 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-53. Transmission Pylon Mounts (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 450 ICA-D212-725 (63) Page 123 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-53. Transmission Pylon Mounts (Sheet 2 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 451 ICA-D212-725 (63) Page 124 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-54. Isolation Mount Test Fixture  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 452: Friction Dampers

    ICA-D212-725 (63) Page 125 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.9.2.3.2.4 Make sure lift link lower end is securely attached in fitting on lift beam with bolt, 63.9.3.3 Installation washers, nut, and cotter pin. 63.9.3.3.1 Install bolt, washers, and nut 63.9.2.3.2.5...
  • Page 453 ICA-D212-725 (63) Page 126 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Keep attaching parts with link. NOTE Ensure bolt assembly (11 or 14, Figure 63-11) has 63.9.4.1.4.2 Transmissions with lift link fitting a bushing bonded to shank.

  • Page 454: Serviceability Checks

    ICA-D212-725 (63) Page 127 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) reinstall all firewalls, baffles, fairings, cowlings, and access doors. 63.10.1.8 After five hours of operation, inspect sump filter and chip detector. 63.10 SERVICEABILITY CHECKS 63.10.1.9 If the number of particles has increased, or if there are particles that can be 63.10.1...

  • Page 455: Rotor Brake System

    ICA-D212-725 (63) Page 128 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.11 ROTOR BRAKE SYSTEM For maintenance procedures applicable to rotor The rotor brake system is an optional equipment brake master cylinder, quill assembly and brake kit.

  • Page 456: Bleeding

    ICA-D212-725 (63) Page 129 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.11.3.8 Repeat step 63.11.3.2 through 63.11.2 Bleeding step 63.11.3.6 until discharged fluid is free of air. NOTE Bleeding is invalid if hydraulic quick disconnect is 63.11.4 Bleeding - Brake Assembly P/N removed.

  • Page 457: Rotor Brake System Components

    ICA-D212-725 (63) Page 130 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.12 ROTOR BRAKE SYSTEM 63.12.1.7 Remove bolts, nuts and washers COMPONENTS attaching master cylinder (6) to roof structure 63.12.1 Master Cylinder - Removal 63.12.1.8 Remove master cylinder (6).

  • Page 458: Brake Assembly - Removal (P/N 9450103-1)

    ICA-D212-725 (63) Page 131 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.12.4.3 Remove bolts (12, Figure 63-56), 63.12.5.6 Remove bolts (12, Figure 63-56), washers, and outboard brake assembly half (11). washers (13), and outboard brake assembly half (11).

  • Page 459: Brake Assembly - Installation (P/N 9450103)

    ICA-D212-725 (63) Page 132 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.12.8.1 Install microswitch (8, Figure 63-55) on inboard brake assembly half (5, Figure 63-56) NUMBER NOMENCLATURE using screws (9, Figure 63-55) and washers (10). Commercial 400 Grit Aluminum Oxide Cloth 63.12.8.2...

  • Page 460: Brake Assembly - Installation (P/N 9450103-1)

    ICA-D212-725 (63) Page 133 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) 63.12.9.7 Insert brake oil transfer tube (14) 63.12.8.13 Torque bolts (12) to 120 to 130 in-lbs through packing (22) in inboard brake assembly (13.56 to 14.69 Nm) and secure with lockwire (C- half (5) until it bottoms out in hole in inboard brake 405).

  • Page 461: Rotor Brake Disc - Inspection

    ICA-D212-725 (63) Page 134 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) transmission cowling gain access between lathe centers. transmission. 63.12.11.3 While rotating disc, measure run-out 63.12.10.2 Remove outboard brake assembly as indicator probe is swept across full radical width half (11, Figure 63-56).

  • Page 462: Flange Adapter - Removal

    ICA-D212-725 (63) Page 135 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) requires brake disc to be inspected for warpage. 63.12.13 Flange Adapter - Removal 63.12.13.3.1 To prevent inadvertent separation of the assembly (6) and washers (7). SPECIAL TOOLS REQUIRED...
  • Page 463 ICA-D212-725 (63) Page 136 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-55. Rotor Brake Assembly (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 464 ICA-D212-725 (63) Page 137 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-55. Rotor Brake Assembly (Sheet 2 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 465 ICA-D212-725 (63) Page 138 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-56. Rotor Brake Assembly (Sheet 1 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 466 ICA-D212-725 (63) Page 139 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-56. Rotor Brake Assembly (Sheet 2 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 467 ICA-D212-725 (63) Page 140 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-56. Rotor Brake Assembly (Sheet 3 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 468 ICA-D212-725 (63) Page 141 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-57. Rotor Brake Assembly - Damage Limits (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 469 ICA-D212-725 (63) Page 142 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-57. Rotor Brake Assembly - Damage Limits (Sheet 2 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 470 ICA-D212-725 (63) Page 143 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-58. Rotor Brake Disc  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 471 ICA-D212-725 (63) Page 144 of 144 CHAPTER 63 – MAIN ROTOR DRIVE SYSTEM (63-00-00) Figure 63-59. Rotor Brake Disc Inspection Arbor  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 472 ICA-D212-725 (64) Page 1 of 1 CHAPTER 64 – TAIL ROTOR (64-00-00) CHAPTER 64 TAIL ROTOR (64-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 473  ...
  • Page 474 ICA-D212-725 (65) Page 1 of 1 CHAPTER 65 – TAIL ROTOR DRIVE SYSTEM (65-00-00) CHAPTER 65 TAIL ROTOR DRIVE SYSTEM (65-00-00) REFER TO BHT-212-MM  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 475  ...
  • Page 476 ICA-D212-725 (67) Page 1 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) CHAPTER 67 FLIGHT CONTROLS (67-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 477 ICA-D212-725 (67) Page 2 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) TABLE OF CONTENTS   LIST OF FIGURES ............................3     67.1 Flight Controls ..........................4     67.1.1 Introduction ..........................4     67.1.2 Troubleshooting ........................4  ...
  • Page 478 ICA-D212-725 (67) Page 3 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) LIST OF FIGURES     Figure 67-1. Collective Controls ......................6     Figure 67-2. Collective Bellcrank ......................7     Figure 67-3. Cyclic Controls (Sheet 1 of 2) ..................... 9  ...

  • Page 479: Flight Controls

    ICA-D212-725 (67) Page 4 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.1 FLIGHT CONTROLS 67.1.1 Introduction 67.1.4.1 Perform all checks and rigging This chapter contains instructions for maintenance with hydraulic boost off and hydraulic systems of the flight control systems. Mechanical linkage properly bled (Chapter 29).

  • Page 480: Collective Controls

    ICA-D212-725 (67) Page 5 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.1.5 Collective Controls NOTE Maximum exposed thread dimension on control tube (6) is 1 .0 in. (25.4 mm) (detail B). MATERIALS REQUIRED NUMBER NOMENCLATURE 0-308 Adhesive CAUTION C-405...
  • Page 481 ICA-D212-725 (67) Page 6 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-1. Collective Controls  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 482: Cyclic Controls (Helicopters Prior To S/N 30850)

    ICA-D212-725 (67) Page 7 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-2. Collective Bellcrank 67.1.6 Cyclic Controls (Helicopters Prior NOTE to s/n 30850) For rigging procedures if dual control kits is installed, refer to appropriate MATERIALS REQUIRED Service Instruction.
  • Page 483 ICA-D212-725 (67) Page 8 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) to fit on cyclic lever of jackshaft (26) plus two 67.1.6.4 Position pilot cyclic stick turns, for approximately 0.30 in. (7.62 mm) perpendicular to deck within 1/2 degree.
  • Page 484 ICA-D212-725 (67) Page 9 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-3. Cyclic Controls (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 485 ICA-D212-725 (67) Page 10 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-3. Cyclic Controls (Sheet 2 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 486: Cyclic Controls (Helicopter S/N 30850 And Subsequent)

    ICA-D212-725 (67) Page 11 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.1.7 Cyclic Controls (Helicopter s/n 67.1.7.9 Adjust control tube (9) to fit then 30850 and subsequent). shorten tube by three turns of rod end bearing and install. MATERIALS REQUIRED 67.1.7.10...
  • Page 487 ICA-D212-725 (67) Page 12 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) of longitudinal magnetic brake (17) against aft stop. Adjust force gradient (18) to fit. Extend clevis on force gradient (18) two turns and install. For initial installation, install spring (35) in fourth hole in plate (34).
  • Page 488 ICA-D212-725 (67) Page 13 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-4. Swashplate Pre-tilt Settings  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 489: Anti-Torque Controls (Helicopters Prior To S/N 31175)

    ICA-D212-725 (67) Page 14 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.1.8 Anti-Torque Controls (Helicopters Prior to s/n 31175) CAUTION MATERIALS REQUIRED DO NOT MEASURE BETWEEN CROSSHEAD NUMBER NOMENCLATURE AND WEAR INDICATOR, IF INSTALLED. C-405 Lockwire MEASUREMENT SHALL BE TAKEN BETWEEN CROSSHEAD AND TRUNNION.
  • Page 490 ICA-D212-725 (67) Page 15 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.1.8.12 If clearance is less than 0.010 in. (0.254 mm), verify rigging procedures have been performed correctly. NOTE Maximum exposed thread length on fixed control rod clevis is 1.00 in. (25.4 mm).
  • Page 491 ICA-D212-725 (67) Page 16 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-5. Anti-Torque Controls (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 492: Anti-Torque Controls (212-011-701 Hub And Blade) (Helicopter S/N 31175 And Sub.)

    ICA-D212-725 (67) Page 17 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-5. Anti-Torque Controls (Sheet 2 of 2) 67.1.9.1.4 Force gradient (31) from pedal 67.1.9 Anti-Torque Controls (212-011-701 Hub and Blade) (Helicopter s/n 31175 and Sub.) adjuster (28).
  • Page 493 ICA-D212-725 (67) Page 18 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) obtain dimension of 4.334 ±0.010 in. (110.084 (32) at center of travel (detail B). ±0.254 mm) between inboard face of crosshead and outboard face of trunnion journal (Figure 67-6, 67.1.9.11.3...
  • Page 494 ICA-D212-725 (67) Page 19 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-6. Anti-Torque Rigging (212-011-701 Hub and Blade) (Helicopter s/n 31175 and Subsequent) Figure 67-7. Tail Rotor Blade to Yoke Clearance  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...

  • Page 495: Synchronized Elevator Controls

    ICA-D212-725 (67) Page 20 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.1.10 Synchronized Elevator Controls 67.1.10.1.3 Verify control tube disconnected from bellcrank (5). SPECIAL TOOLS REQUIRED NUMBER NOMENCLATURE 67.1.10.1.4 Set right elevator (1) so upper T101330 Cyclic Stick Fixture...
  • Page 496 ICA-D212-725 (67) Page 21 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.1.10.2.6.1 Place pilot cyclic stick NOTE extreme forward position against stick stop. All rigging to be accomplished with hydraulic boost Readjust control tube (16), if necessary, to align on, boost cart connected and operating, or with right elevator upper surface on rivet R.
  • Page 497 ICA-D212-725 (67) Page 22 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-8. Synchronized Elevator Controls Rigging  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 498: Collective Flight Controls

    ICA-D212-725 (67) Page 23 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.2 COLLECTIVE FLIGHT CONTROLS attaching housing (5) to structural intercostal. 67.2.1 Collective Controls Remove collective stick (3) and housing (5). The collective control system consists of a 67.2.2.1.5...
  • Page 499 ICA-D212-725 (67) Page 24 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) for proper operation. follows: 67.2.2.2.5 Inspect throttle controls grips 67.2.2.3.2.1 Pilot collective: retaining pin, both pilot and, if installed copilot stick, for looseness. Also inspect throttle(s) for 67.2.2.3.2.1.1 Remove collective switch box smoothness of operation.
  • Page 500 ICA-D212-725 (67) Page 25 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.2.2.3.4 Repair of corrosion damage shall 67.2.2.3.6.11 Apply primer (C-204) to all bare be twice depth of corrosion damage but not metal. exceeding mechanical damage limits for depth or width.

  • Page 501: Collective Friction Clamp

    ICA-D212-725 (67) Page 26 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.2.2.4.4 Align tube (10) with elbow (12) 70 in-lbs (5.6 to 7.9 Nm). After torqueing, the and attach with tapered bushings of correct size tapered bushings must protrude within the 0.030 and two bolts with steel washers under bolt heads to 0.060 inch (0.761 to 1.525 mm) limits shown in...
  • Page 502 ICA-D212-725 (67) Page 27 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) both clamp halves (5 and 8) and to dacron (pink) surface of liner material. Install liner material in 67.2.3.2 Inspection clamp halves. 67.2.3.2.1 Inspect clamp assembly for cracks 67.2.3.3.7...

  • Page 503: Minimum Collective Friction Adjustment

    ICA-D212-725 (67) Page 28 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) check for 0.003 to 0.008 in. (0.076 to 0.203 mm) backlash of each gear sector with mating gear, 67.2.4 Minimum Collective Friction measured at control tube attach point of sector Adjustment arm in neutral position.

  • Page 504: Miscellaneous Control Components

    ICA-D212-725 (67) Page 29 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) disconnected. 67.2.5.6.3 Increase decrease shim between gear sector and support until backlash is 67.2.6.1.1 Remove covers access 0.003 to 0.008 in. (0.076 to 0.203 mm). panels as required.
  • Page 505 ICA-D212-725 (67) Page 30 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.2.6.4.4 Install position support collective lever (1) and universal (3). Install bolts assembly (4) on lift beam and attaching brackets. washers and nuts. Tighten and install cotter pin.
  • Page 506 ICA-D212-725 (67) Page 31 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-9. Collective Stick and Jackshaft  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 507 ICA-D212-725 (67) Page 32 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-10. Collective Stick and Jackshaft Installation  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 508 ICA-D212-725 (67) Page 33 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-11. Friction Clamp Assembly  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 509 ICA-D212-725 (67) Page 34 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-12. Throttle Control Gear Sectors Shimming and Backlash  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 510: Cyclic Flight Controls

    ICA-D212-725 (67) Page 35 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.3 CYCLIC FLIGHT CONTROLS 67.3.1 Cyclic Controls 67.3.2.1.3 Disconnect fore-aft and lateral control tube assemblies (5 and 7) from lever, The cyclic control system consists of pilots cyclic below stick support, by removing bolts (6 and 8).

  • Page 511: Cyclic Control Force Gradient

    ICA-D212-725 (67) Page 36 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.3.4 Cyclic Control Force Gradient 67.3.4.2.1.3 Adjust nuts (6) to hold 2.5 to 3.0 lbs. (11.1 to 13.3 N) force against spring (1) on The force gradient is a link equipped with an lateral force gradient.

  • Page 512: Miscellaneous Control Components

    ICA-D212-725 (67) Page 37 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Lift magnetic brake from helicopter. 67.3.6 Miscellaneous Control 67.3.5.1.4 If force gradient is to be replaced, Components remove arm for use on replacement. Cyclic control components include push-pull tubes, bellcranks, jackshaft, mixing lever, and 67.3.5.2...
  • Page 513 ICA-D212-725 (67) Page 38 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) from each side of control lever. Remove each jackshaft by removing four bolts attaching bearing 67.3.6.3 Repair housing to beam, withdrawing assembly through access opening inside of cabin lower skin.

  • Page 514: Cyclic Jackshaft

    ICA-D212-725 (67) Page 39 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.3.7 Cyclic Jackshaft 67.3.6.4.3 Install the support assembly (37) on the airframe with bolts (38), washers (39) and 67.3.7.1 Replacement cyclic nuts (40). Torque the nuts. jackshaft 67.3.6.4.4...
  • Page 515 ICA-D212-725 (67) Page 40 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.3.7.1.11 Disassemble and remove burrs 67.3.7.1.15 Insert right left tube and metal particles. assemblies, with bearings and supports in place, through access openings at sides of cabin lower 67.3.7.1.12...
  • Page 516 ICA-D212-725 (67) Page 41 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-13. Cyclic Control Stick  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 517 ICA-D212-725 (67) Page 42 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-14. Force Gradient  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 518 ICA-D212-725 (67) Page 43 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-15. Cyclic Control Mixing Lever Assembly  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 519 ICA-D212-725 (67) Page 44 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-16. Cyclic Jackshaft  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 520: Anti-Torque Control

    ICA-D212-725 (67) Page 45 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.4 ANTI-TORQUE CONTROL 67.4.4.1 Removal 67.4.1 Anti-Torque Control System 67.4.4.1.1 Remove pilot seat. 67.4.2 Anti-Torque Controls 67.4.4.1.2 Remove flight control access The anti-torque control system. includes control doors.

  • Page 521: Force Trim

    ICA-D212-725 (67) Page 46 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) and secure with cotter pins. 67.4.6.1.4 Remove from stud magnetic brake arm and remove force gradient. 67.4.4.2.4 Apply a coat of primer (C-201) to mounting surface of pedal support, position on bulkhead with the word TOP up.

  • Page 522: Magnetic Brake

    ICA-D212-725 (67) Page 47 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.4.7 Magnetic Brake 67.4.8 Miscellaneous Control Components 67.4.7.1 Removal Control components between tail rotor control 67.4.7.1.1 Remove pilot seat. pedals and pitch change mechanism mounted on tail rotor gearbox includes control tubes, 67.4.7.1.2...
  • Page 523 ICA-D212-725 (67) Page 48 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.4.8.3 Installation support (19). If lever has side play in support (19), a maximum of two shim washers (18) may MATERIALS REQUIRED be used, one each side of lever (17). One shim washer (18) may be used on one side only.
  • Page 524 ICA-D212-725 (67) Page 49 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-17. Anti-Torque Control Pivot Bolts  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 525: Synchronized Elevator

    ICA-D212-725 (67) Page 50 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 67.5 SYNCHRONIZED ELEVATOR 67.5.2.1.5.3 Remove bolts and washers 67.5.1 Synchronized Elevator attaching retainers (7) and shim sets (9) to tailboom support brackets (10). Remove synchronized elevator consists retainers and shim sets.
  • Page 526 ICA-D212-725 (67) Page 51 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) accordance with following steps 67.5.2.2.3 and 68.5.2.2.8 For structural repair of elevator, 67.5.2.2.4. refer to FAA Aircraft Inspection and Repair Manual AC 43.13-1 A. 67.5.2.2.3 Inspect elevator for loose rivets, damage, dents, cracks, and worn spar tube 67.5.2.2.9...
  • Page 527 ICA-D212-725 (67) Page 52 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) 0.312 to 0.313 inch (7.92 to 7.95 mm) diameter. Deburr holes. 67.5.2.3.5.1 With one support retainer set (7) loosely installed, peel or add to shims (8) on 67.5.2.2.9.8 Apply primer (C-204) to holes and opposite set to obtain 13 to 16 lb.
  • Page 528 ICA-D212-725 (67) Page 53 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-18. Synchronized Elevator  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 529 ICA-D212-725 (67) Page 54 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-19. Elevator Spar Damage  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 530 ICA-D212-725 (67) Page 55 of 55 CHAPTER 67 – FLIGHT CONTROLS (67-00-00) Figure 67-20. Elevator Horn Hole Location  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 531  ...
  • Page 532 ICA-D212-725 (71) Page 1 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) CHAPTER 71 POWER PLANT SYSTEM (71-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 533 ICA-D212-725 (71) Page 2 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) TABLE OF CONTENTS   LIST OF FIGURES ............................2     71.1 Power Plant System .......................... 3     71.1.1 Power Plant – General ......................3  ...

  • Page 534: Power Plant System

    ICA-D212-725 (71) Page 3 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.1 POWER PLANT SYSTEM electrical connectors and engine controls as follows: (Refer to Figures 71-1 and 71-2.) 71.1.1 Power Plant – General 71.1.1.1.5.1 When disconnecting fuel and oil...
  • Page 535 ICA-D212-725 (71) Page 4 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.1.1.1.11 Hoist engine from helicopter, 71.1.1.1.12 Remove all engine QEC parts carefully guiding engine nose out of forward (hoses, brackets, wiring, etc.) except those firewall bellmouth. Install engine in suitable which are a part of the basic engine.
  • Page 536 ICA-D212-725 (71) Page 5 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 1. Oil Tank 2. Bipod 3. EGT/MGT Firewall Connector 4. V Band Coupling (FWD) Figure 71-2. Engine (Right Side)  COPYRIGHT  2007 BY DART AEROSPACE LTD. ...
  • Page 537 ICA-D212-725 (71) Page 6 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-3. Engine Stand  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 538 ICA-D212-725 (71) Page 7 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.1.1.2 Installation – Power Plant and bolt are located at the 3:00 position. Refer to Figure 72-2 (4). This procedure applies to engine built up with adapting parts to constitute a quick change 71.1.1.2.6...
  • Page 539 ICA-D212-725 (71) Page 8 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.1.1.2.8.7 Connect bleed air hose (3) to coupling on selector valve at left side of deck. 71.1.1.3.1.1 Main driveshaft inspection reveals excessive wear of coupling spline. NOTE Route bleed air hose as shown in Figure 71-1 (3).
  • Page 540 ICA-D212-725 (71) Page 9 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) freely moved with the fingers. NOTE Use shim plates on jacks to obtain necessary height. 71.1.1.3.4 Install target plate T101419 engine-to-transmission driveshaft 71.1.1.3.3.4 With maintenance hoist alignment tool set on the transmission input quill detached, and nut and washer removed from coupling.
  • Page 541 ICA-D212-725 (71) Page 10 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) o’clock position. Re-zero indicator at 3 o’clock position. Read +0.006 ± 0.004 at 9 o’clock 71.1.1.3.9 Correct engine alignment per position. section 71.1.1.4. Figure 71-4. Positioning Pylon for Driveshaft Alignment 71.1.1.4...
  • Page 542 ICA-D212-725 (71) Page 11 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) as shown in Figure 71-7 using lockwire P/N 71.1.1.5.2.3 Deburr drilled holes. MS20995C41. Reassemble the firewall assembly using AN970- 3 washers over the enlarged holes and under 71.1.1.4.8...
  • Page 543 ICA-D212-725 (71) Page 12 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-5. Engine Mount Fittings  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 544 ICA-D212-725 (71) Page 13 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-6. Typical Leg Assembly  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 545 ICA-D212-725 (71) Page 14 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-7. Lockwire Details  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 546 ICA-D212-725 (71) Page 15 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-8. Use of Alignment Tool Set T101419  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 547: Cowling And Fairings

    ICA-D212-725 (71) Page 16 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.2 COWLING AND FAIRINGS and damage. 71.2.1 Cowling and Fairings – General 71.2.2.2.2 Inspect latches for serviceability. Cowling and fairings are used to protect and provide easy maintenance access to engine 71.2.2.3...

  • Page 548: Transmission Cowling

    ICA-D212-725 (71) Page 17 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.2.4.3.2 Swing cowling closed 71.2.3.3 Installation – Engine Intake position. Check alignment for secure latching Fairing and for clearance with control linkages or other parts on transmission pylon.
  • Page 549 ICA-D212-725 (71) Page 18 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-9. Location of Airframe Components  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 550: Engine Mounts

    ICA-D212-725 (71) Page 19 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.3 ENGINE MOUNTS bolts as required. 71.3.1 Engine Mounts 71.3.1.2.3 Inspect rod end bearings for play as follows: The engine is supported on the service deck with one bipod and one tripod mount located on NOTE the right and left side of the engine combustor.
  • Page 551 ICA-D212-725 (71) Page 20 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.3.1.3.7 Accomplish main driveshaft the assembly. alignment check, if required. (Refer to paragraph 71.1.1.3.) 71.3.1.5.3 Ensure the stud threads are well lubricated with TECTYL 502C Class I, MIL-PRF- 71.3.1.3.8...
  • Page 552 ICA-D212-725 (71) Page 21 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-10. Engine Mounts  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 553 ICA-D212-725 (71) Page 22 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) Figure 71-11. 204-060-743-005 Lever Assembly Installation Detail  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 554: Power Plant Buildup

    ICA-D212-725 (71) Page 23 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.4 POWER PLANT BUILDUP 71.4.1 Remove engine from shipping container 71.4.2.9 Linear actuator. in accordance with the following: 71.4.2.10 Power turbine tachometer 71.4.1.1 Release pressure from generator engine shipping container.
  • Page 555 ICA-D212-725 (71) Page 24 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.4.3.2 Install tailpipe as follows: 71.4.3.5.3 Torque bolts 160 to 190 inch- 71.4.3.2.1 Position tailpipe onto rear of pounds and lockwire (C-405). combustion section. Align dowel pins on rear face of combustion section to matching indents 71.4.3.5.4...
  • Page 556 ICA-D212-725 (71) Page 25 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.4.3.7 Install throttle governor lever as 71.4.3.10.3 Install gasket using engine follows: supplied hardware; install turbine tachometer generator with electrical receptacle toward top of 71.4.3.7.1 Position governor shaft at mid engine, point between stops.
  • Page 557 ICA-D212-725 (71) Page 26 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) ports. Tighten securely and lockwire (C-405). 71.4.3.14 Install oil pressure switch as 71.4.3.12.8 Install reducer fitting with follows: packing into starter-generator pad drive seal drain port located on lower side forward of 71.4.3.14.1...
  • Page 558 ICA-D212-725 (71) Page 27 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) 71.4.3.17.3 Install four mounting nuts and 71.4.3.16.3 Install cooling air inlet shroud on torque 50 to 70 inch-pounds. starter-generator with the flanged side toward the mounting flange of the generator. Move 71.4.3.18...
  • Page 559 ICA-D212-725 (71) Page 28 of 28 CHAPTER 71 – POWER PLANT SYSTEM (71-00-00) adapter located at top of engine, forward of the compressor section. Torque hose-to-fitting combustion chamber. Route the hose assembly locking nut 750 to 850 inch-pounds. Position aft and downward across the combustion shroud over connection and secure with clamp.
  • Page 560 ICA-D212-725 (76) Page 1 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) CHAPTER 76 ENGINE CONTROLS (76-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 561 ICA-D212-725 (76) Page 2 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) TABLE OF CONTENTS List of Figures ..............................2 76.1 Engine Controls ..........................3 76.1.1 Engine Controls ........................3 76.2 Droop Compensator Controls ......................3 76.2.1 Droop Compensator Controls ....................3 76.2.2...

  • Page 562: Engine Controls

    ICA-D212-725 (76) Page 3 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) 76.1 ENGINE CONTROLS 76.2.1.1.2.1 Control lever (16, Figure 76-1). 76.1.1 Engine Controls The engine controls consist of the droop 76.2.1.1.2.2 Hardware connecting actuator compensator controls and the power lever (15) to control lever (16).
  • Page 563 ICA-D212-725 (76) Page 4 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) 76.2.1.1.7.1 Lock collective control stick in 76.2.1.1.4.4 Set actuator travel to 0.50 inches full up position. (1.27 mm). 76.2.1.1.7.2 Electrically operate the actuator 76.2.1.1.4.5 When actuator travel has been (15) to full increase position.
  • Page 564 ICA-D212-725 (76) Page 5 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) be made as required in ground run or flight: washer, and bolts. 76.2.1.1.9.1 Readjust actuator stroke 76.2.1.2.5 Remove bellcrank (6), torque necessary to maintain 97% to 101.5% ± 0.75% tube (4), and associated parts as follows: range with collective stick full down.
  • Page 565 ICA-D212-725 (76) Page 6 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) 76.2.1.6.1.3 Position bellcrank (6) on shaft of 76.2.1.4.2 Inspect cambox for security of shear fitting (5), align shear pin holes and install parts and smooth operation. Check that shims shear pin (7).
  • Page 566 ICA-D212-725 (76) Page 7 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) Figure 76-1. Droop Compensator Controls  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 567 ICA-D212-725 (76) Page 8 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) Figure 76-2. Rigging N2 Governor Actuator (Sheet 1 of 2)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 568: Cambox And Linear Actuator

    ICA-D212-725 (76) Page 9 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) Figure 76-2. Rigging N2 Governor Actuator (Sheet 2 of 2) 76.2.2 Cambox and Linear Actuator The electrically operated linear actuator (15, CAUTION Figure 76-1) is controlled by the GOV RPM INCR/DECR switch on the pilots collective pitch control stick.
  • Page 569 ICA-D212-725 (76) Page 10 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) bellcrank and housing before torqueing pivot bolt 76.2.2.2 Installation – Cambox and and forward bolt. Linear Actuator 76.2.2.2.2 Install actuator (15) as follows: 76.2.2.2.1 Install cambox (14, Figure 76-1) as follows: 76.2.2.2.2.1...

  • Page 570: Power Lever Controls

    ICA-D212-725 (76) Page 11 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) 76.3 POWER LEVER CONTROLS NOTE The idle stop plunger will not retract 76.3.1 Power Lever Controls if excessive pressure is applied by the twist grip toward the closed The engine fuel and power control system position.
  • Page 571 ICA-D212-725 (76) Page 12 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) tubes have inspection holes, threads shall Do not accomplish step 76.3.1.2.3.6. Proceed engage sufficiently to cover holes. to step 76.3.1.2.3.7. 76.3.1.2.1.4 Apply corrosion preventive 76.3.1.2.3.6 If dual controls are not installed,...

  • Page 572: Removal - Power Lever Controls

    ICA-D212-725 (76) Page 13 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) NOTE and bolt. If twist grip overtravel is not equal, an increase or decrease in the length of 76.3.1.3.5 Remove tube assembly (12) either of the adjustable rods (14 and from bellcrank (11) and bellcrank (13) by 35) will have to be accomplished.

  • Page 573: Cleaning - Power Lever Controls

    ICA-D212-725 (76) Page 14 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) assemblies if cracked, distorted, or loose rod 76.3.1.3.11.5 Remove housing (25) from ends or bearings. engine service deck by removing five bolts and five washers. 76.3.1.6.2 Replace bellcranks, torque tube, and levers if damaged.
  • Page 574 ICA-D212-725 (76) Page 15 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) around tube assembly (32) and in opening of retainer (30) and secure with retainer ring (29). 76.3.1.7.8 Install bellcranks (11, 13, and 15) respective mounts and secure with washers, 76.3.1.7.5.4...
  • Page 575 ICA-D212-725 (76) Page 16 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) Figure 76-3. Power Lever (N1) Controls Rigging (Sheet 1 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 576 ICA-D212-725 (76) Page 17 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) Figure 76-3. Power Lever Control System (Sheet 2 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 577: Flight Idle Solenoid

    ICA-D212-725 (76) Page 18 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) Figure 76-3. Power Lever (N1) Control Rigging (Sheet 3 of 3) 76.3.2 Flight Idle Solenoid 76.3.2.1.1 Disconnect terminals of wires from solenoid (19, Figure 76-3) and stow cable A spring loaded, electrically actuated flight idle assembly.

  • Page 578: Installation - Flight Idle Solenoid

    ICA-D212-725 (76) Page 19 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) 76.3.2.1.3 Remove four screws with four clearance between tip of plunger and projected shims securing solenoid (19) bracket surface of cam (24). Secure in place with four assembly (21).
  • Page 579 ICA-D212-725 (76) Page 20 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) PERSONNEL SHALL PERMITTED TO PERFORM THE CAUTION ADJUSTMENTS. RECORD ORIGINAL FUEL CONTROL ASSEMBLY SETTINGS BEFORE IF TOO MUCH ADJUSTMENT HAS MAKING ANY ADJUSTMENTS. BEEN MADE, IT IS POSSIBLE TO...
  • Page 580 ICA-D212-725 (76) Page 21 of 21 CHAPTER 76 – ENGINE CONTROLS (76-00-00) Figure 76-4. Fuel Control Adjustments  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 581  ...

  • Page 582: Engine Oil System

    ICA-D212-725 (79) Page 1 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) CHAPTER 79 ENGINE OIL SYSTEM (79-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 583 ICA-D212-725 (79) Page 2 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) TABLE OF CONTENTS List of Figures ..............................2 79.1 Engine Oil System – General ......................3 79.2 Engine Oil Cooler ..........................3 79.3 Engine Oil Tank ..........................8 79.4...
  • Page 584 ICA-D212-725 (79) Page 3 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) 79.1 Engine Oil System – General Engine lubricating oil is supplied from a tank 79.2 Engine Oil Cooler mounted on the forward firewall at right side of engine compartment.
  • Page 585 ICA-D212-725 (79) Page 4 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) Figure 79-1. Engine oil components  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 586 ICA-D212-725 (79) Page 5 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) 79.2.2 Cleaning – Oil Cooler 79.2.3.2 Inspect core assembly foreign matter, leakage, and scoring. When the oil cooler is removed from the helicopter after a prolonged period of service, it shall be cleaned both internally and externally as 79.2.4 Repair/Replacement...
  • Page 587 ICA-D212-725 (79) Page 6 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) air. If leakage is indicated, replace cooler. 79.2.5.5 Position duct between upper 79.2.6.2 Plug either inlet or outlet port, flanges of cooler and mount. Install eight bolts, and apply water at 75°F (24°C) at 400 psig to...
  • Page 588 ICA-D212-725 (79) Page 7 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) Figure 79-2. Engine oil system  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 589 ICA-D212-725 (79) Page 8 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) 79.3 Engine Oil Tank 79.3.4.1.1 Punctures or leaks. 79.3.1 Removal – Engine Oil Tank 79.3.4.1.2 Torn or punctured internal screens. 79.3.1.1 Open right engine cowling. Drain oil tank by opening valve in drain line 79.3.4.1.3...
  • Page 590 ICA-D212-725 (79) Page 9 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) 79.4 Engine External Oil Filter 79.4.1.11 Check for oil leaks and oil tank for servicing after next engine run-up. 79.4.1 Replacement – Engine External Oil Filter Element 79.4.2 Removal –...
  • Page 591 ICA-D212-725 (79) Page 10 of 10 CHAPTER 79 – ENGINE OIL SYSTEM (79-00-00) 79.5 Turbo Blower 79.5.2.4 Attach blower to duct with eight bolts, using thin aluminum alloy washer under 79.5.1 Removal – Turbo Blower and Duct each bolt head and nut.
  • Page 592 ICA-D212-725 (95) Page 1 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) CHAPTER 95 INSTRUMENT SYSTEM (95-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 593 ICA-D212-725 (95) Page 2 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) TABLE OF CONTENTS   LIST OF FIGURES ............................3     95.1 INSTRUMENT SYSTEM ........................ 4     95.1.1 Instrument System ........................4     95.1.2 Troubleshooting – Instrument System ..................4  ...
  • Page 594 95.8.8 Engine Hourmeter ........................20 LIST OF FIGURES     Figure 95-1. Eagle Single Instrument Panel (Page 1 of 2) ..............6   (S/Ns 30817, 30687, 30931, 30576 and 30599 only) ................... 6     Figure 95-1. Eagle Single Instrument Panel (Page 2 of 2) ..............7  ...

  • Page 595: Instrument System

    ICA-D212-725 (95) Page 4 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) instrument. Necessary access may be gained 95.1 INSTRUMENT SYSTEM through the nose access door. 95.1.1 Instrument System Maintenance information for flight, navigation, 95.1.4.2 Protect ends with electrical tape and...
  • Page 596 ICA-D212-725 (95) Page 5 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) facility for replacement of range marking if necessary. COPYRIGHT  2007 BY DART AEROSPACE LTD   THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 597 Page 6 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) Figure 95-1. Eagle Single Instrument Panel (Page 1 of 2) (S/Ns 30817, 30687, 30931, 30576 and 30599 only)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 598 ICA-D212-725 (95) Page 7 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) Figure 95-1. Eagle Single Instrument Panel (Page 2 of 2) (S/Ns 30817, 30687, 30931, 30576 and 30599 only) COPYRIGHT  2007 BY DART AEROSPACE LTD   THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 599 Cargo Fire Light Engine Fire Switchlight Cargo Release Armed Light Figure 95-2. Eagle Single Instrument Panel (Page 1 of 3) (All S/Ns except 30817, 30687, 30931, 30576 and 30599) COPYRIGHT  2007 BY DART AEROSPACE LTD   THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 600 Heater Switch MGT Indicator Instrument Panel, Center Figure 95-2. Eagle Single Instrument Panel (Page 2 of 3) (All S/Ns except 30817, 30687, 30931, 30576 and 30599) COPYRIGHT  2007 BY DART AEROSPACE LTD   THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 601 Engine Fire Switchlight Cargo Release Armed Light Placard Figure 95-2. Eagle Single Instrument Panel (Page 3 of 3) (All S/Ns except 30817, 30687, 30931, 30576 and 30599) COPYRIGHT  2007 BY DART AEROSPACE LTD   THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 602: Installation - Instruments

    ICA-D212-725 (95) Page 11 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) 95.1.8 Instrument Panel 95.1.7 Installation – Instruments Instrument panel contains all flight, propulsion, navigation and miscellaneous instruments except CAUTION standby magnetic compass, engine hourmeter, free temperature indicator. ENSURE ALL ELECTRICAL...

  • Page 603: Adjustment - Instrument Panel

    ICA-D212-725 (95) Page 12 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) 95.1.10.5 Connect battery quick disconnect. indicators. 95.1.11 Adjustment – Instrument Panel 95.2.2.1 Connect the pitot-static tester hoses to the appropriate connectors on the test set. Connect the pitot line to the pitot tube, and Two adjustment tube assemblies located behind connect the static line to the lower RH static port.
  • Page 604 ICA-D212-725 (95) Page 13 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) 95.2.2.6 Slowly open pressure vent valve. that after 1 minute, indicated loss of altitude shall Check that airspeed indication returns to a not exceed 100 feet. Check that vertical speed minimum limit.
  • Page 605 ICA-D212-725 (95) Page 14 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) Figure 95-3. Pitot-Static System COPYRIGHT  2007 BY DART AEROSPACE LTD   THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 606: Inspection - Pitot-Static System

    ICA-D212-725 (95) Page 15 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) Figure 95-4. Pitot-Static System 95.4 PITOT TUBE 95.2.3 Inspection – Pitot-Static System 95.4.1 Removal – Pitot Tube 95.2.3.1 Inspect pitot tube for clogged or obstructed inlet opening. 95.4.1.1 Ensure all electrical power is OFF 95.2.3.2...

  • Page 607: Flight Instruments

    ICA-D212-725 (95) Page 16 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) indicator virtual sphere can be adjusted for zero 95.4.2.4 Connect pitot line tubing to pitot tube pitch indication by using the 2 position switch in upper nose area.

  • Page 608: Navigation Instruments

    ICA-D212-725 (95) Page 17 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) 95.6 NAVIGATION INSTRUMENTS 95.7 PROPULSION AND HYDRAULIC INSTRUMENTS 95.6.1 Navigation Instruments 95.7.1 Propulsion Hydraulic The navigation instruments consist of the pilot Instruments gyro directional indicator and the standby magnetic compass (M28).

  • Page 609: Fuel Quantity Indicator

    ICA-D212-725 (95) Page 18 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) 30931, 30576, 30817 and 30599 the system is powered from the 26 VAC buss # 1. For all S/Ns 95.7.8 Transmission Oil Temperature and except 30687, 30931, 30576, 30817 and 30599 Pressure Indicator the system is powered from the 28 VDC buss.
  • Page 610 ICA-D212-725 (95) Page 19 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) Engine exhaust gas temperature indicator (M23) monitoring current at the generator shunt. In all registers exhaust gas air temperature received S/Ns except 30687, 30931, 30576, 30817 and from bayonet type thermocouples mounted at the 30599 a newer style indication combines the DC output of the power turbine.
  • Page 611 ICA-D212-725 (95) Page 20 of 20 CHAPTER 95 – INSTRUMENT SYSTEM (95-00-00) 95.8.7 Installation – Free Air Temperature Indicator 95.8.7.1 Place rubber washer over probe of thermometer with flat side of washer next to indicator case. Insert probe through mounting hole from inside the windshield.
  • Page 612 ICA-D212-725 (96) Page 1 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) CHAPTER 96 ELECTRICAL SYSTEM (96-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.

  • Page 613: Copyright  2007 By Dart Aerospace Ltd

    ICA-D212-725 (96) Page 2 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) TABLE OF CONTENTS   LIST OF FIGURES ............................7   LIST OF TABLES ............................. 7     96.1 ELECTRICAL SYSTEM ........................9     96.1.1 Electrical Systems ........................9  ...
  • Page 614 ICA-D212-725 (96) Page 3 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00)     96.3.8 External Power ........................33     96.3.9 Removal – External Power Receptacle ................... 33     96.3.10 Installation – External Power Receptacle ................34  ...
  • Page 615 ICA-D212-725 (96) Page 4 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00)     96.6.5 Operational Check – Transmission Oil Temperature Indicator ..........51     96.6.6 Engine Hourmeter ........................51     96.6.7 Operational Check – Engine Hourmeter ................. 51  ...
  • Page 616 ICA-D212-725 (96) Page 5 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00)     96.8.1 Caution and Warning System ....................62     96.8.2 Operation – Caution and Warning System ................62     96.8.3 Operational Test – Caution Panel Light .................. 62  ...
  • Page 617 ICA-D212-725 (96) Page 6 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00)     96.9.9 Operational Check – Searchlight System ................77     96.9.10 Landing Light ........................... 77     96.9.11 Operational Check – Landing Light System ................77  ...
  • Page 618 ICA-D212-725 (96) Page 7 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) LIST OF FIGURES     Figure 96-1. Track Mounted Relay - Removal/Installation (Typical) ............28     Figure 96-2. Starter/Generator Brush Wear ..................... 35     Figure 96-3.
  • Page 619 ICA-D212-725 (96) Page 8 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) CONSUMABLE MATERIALS LIST The following consumable materials are required to perform the maintenance procedures within this chapter. ITEM NOMENCLATURE GAGE/FSCM/ SOURCE C-237 Varnish, Alkaline Resistant, TT-V-119 Commercial C-489...

  • Page 620: Electrical System

    ICA-D212-725 (96) Page 9 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.1 ELECTRICAL SYSTEM 96.1.2.2 Verify that switches, relays, and diodes are functioning properly. 96.1.1 Electrical Systems Maintenance of electrical circuitry, electrical 96.1.2.3 Check that wiring, connectors, equipment, and electrical components with the and connections are in normal condition.
  • Page 621 ICA-D212-725 (96) Page 10 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Panel Overhead Console, left Panel Overhead Console, right Panel, Engine Fuel and Control Pedestal, forward Panel, Master Caution...
  • Page 622 ICA-D212-725 (96) Page 11 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION CR32, CR33 Diode, Main DC Buss # 2 Overhead Console, right CR39 Diode, Non-essential Buss Relay...
  • Page 623 ICA-D212-725 (96) Page 12 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION DS32 Light, Engine RPM, Pilot Instrument Panel, left DS37 Light, Master Caution, Copilot Instrument Panel, right...
  • Page 624 ICA-D212-725 (96) Page 13 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Relay, Starter Control Nose Compartment, lower Relay, Battery Buss Nose Compartment, lower Relay, AC Buss Control...
  • Page 625 ICA-D212-725 (96) Page 14 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Indicator, Pilot Clock Instrument Panel Indicator, Pilot Airspeed Instrument Panel Indicator, Pilot Vertical Speed Instrument Panel...
  • Page 626 ICA-D212-725 (96) Page 15 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Connector, Engine Control Panel Pedestal, forward Connector, Pilot Cyclic Stick Cyclic Stick, Pilot Connector, Copilot Cyclic Stick...
  • Page 627 ICA-D212-725 (96) Page 16 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Connector, Fuel Quantity Coupler Cabin Floor, Station 63, center 134A, B Connector, Fuel Quantity Probe Fuel Cell, right...
  • Page 628 ICA-D212-725 (96) Page 17 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Connector, Anti-collision Light, Lower Fuselage, underneath Connector, # 2 Hydraulic Temperature Bulb Pylon Compartment Connector, # 1 Hydraulic Temperature Bulb...
  • Page 629 ICA-D212-725 (96) Page 18 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Transistor, Pedestal Lights Cabin Roof, Station 92, left Transistor, Overhead Console Lights Cabin Roof, Station 92, right...
  • Page 630 ICA-D212-725 (96) Page 19 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Switch, Engine Start Pilot Collective Stick Switch, Searchlight Control Pilot Collective Stick Switch, Transmission Oil Temperature...
  • Page 631 ICA-D212-725 (96) Page 20 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION S105 Switch, External Power Door Nose Compartment, forward S106 Switch, Fire System Test # 2 Instrument Panel...
  • Page 632 ICA-D212-725 (96) Page 21 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-1. Equipment Reference Designator, Nomenclature, and Location REF DES NOMENCLATURE LOCATION Ignition Unit Engine Compartment Amplifier, Smoke Detector Nose Compartment Smoke Detector Cargo Compartment Ice Detector Probe...

  • Page 633: Power Source Component Data

    ICA-D212-725 (96) Page 22 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.1.5 Primary Secondary Electrical Power Analysis Operational checks should be performed using The helicopter is equipped with a 28 volt direct external power whenever possible. After repair current electrical system. Power for this system...

  • Page 634: Summary Of System Analysis

    ICA-D212-725 (96) Page 23 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.1.7 Summary of System Analysis generation of sparks in the presence of flammable vapors may cause explosions. Metallic objects The available excess capacities are as follows: that come in contact with the powered electrical...

  • Page 635: Standard Practices - Electrical Maintenance Or Repairs

    ICA-D212-725 (96) Page 24 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Make sure there is no tension on the test leads or 96.1.10.1.2 If a circuit breaker must remain the probes. open until a maintenance procedure is complete, install a clip or a plastic cable strap under the 96.1.9.1.7...

  • Page 636: Miscellaneous Electrical Tools

    ICA-D212-725 (96) Page 25 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) operational checks on battery power may deplete 96.1.12.1.1 Remove all protective caps from the charge in the battery. equipment or electrical equipment. Perform operational checks to ensure no new 96.1.12.1.2...

  • Page 637: Miscellaneous Electrical Components - Cleaning

    ICA-D212-725 (96) Page 26 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) wires, receptacles, shock mounts, capacitors, diodes, resistors and panel lights. 96.1.18 Miscellaneous Electrical Components - Cleaning 96.1.17 Miscellaneous Electrical 96.1.18.1 Remove all loose debris with a Components - Removal brush or clean cloth.
  • Page 638 ICA-D212-725 (96) Page 27 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-4. Miscellaneous Electrical Component Inspections - Electrical Wire Interconnection System (EWIS) Item Defect, Damage, Failure or Irregularity Wire/Wire Harness Wire Bundle/wire bundle or wire bundle/structure contact/chafing Wire bundle sagging or improperly secured Wires damaged (obvious damage due to mechanical impact, overheat, localized chafing etc.)
  • Page 639 ICA-D212-725 (96) Page 28 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-4. Miscellaneous Electrical Component Inspections - Electrical Wire Interconnection System (EWIS) Item Defect, Damage, Failure or Irregularity Circuit breakers, contactors, Signs of overheating relays, rheostats or fuses...

  • Page 640: Miscellaneous Electrical Components - Repair

    Use the applicable wiring diagram in Chapter 98 There is one type of circuit breaker used on Eagle and attach the connectors or the wires to the Single helicopters, the fault clearing push-pull proper location or terminals.

  • Page 641: Inspection - Circuit Breakers

    ICA-D212-725 (96) Page 30 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) BEFORE YOU REMOVE A CIRCUIT BREAKER CAUSE ELECTRICAL SHOCK TO PERSONS ON THE HELICOPTER, REMOVE ALL AND/OR DAMAGE TO EQUIPMENT. ELECTRICAL POWER AND DISCONNECT THE BATTERY. IF NOT ACCOMPLISHED, YOU MAY 96.2.6.1...

  • Page 642: Track Mounted Relays

    ICA-D212-725 (96) Page 31 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.2.10 Track Mounted Relays - Removal 96.3 DC POWER SYSTEMS 96.2.10.1 Disconnect battery 96.3.1 DC Power Systems external power from the helicopter. DC power systems include the battery, external 96.2.10.2...
  • Page 643 ICA-D212-725 (96) Page 32 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) in an authorized battery repair station. CAUTION 96.3.5 Inspection – Battery DO NOT USE A WIRE BRUSH. VERIFY VENT PLUGS ARE 96.3.5.1 Loosen connections at disconnects CLOSED BEFORE CLEANING or between cells.
  • Page 644 ICA-D212-725 (96) Page 33 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Perform the following tests using installed 24 VDC battery as power source, or an external 24 VDC 96.3.7.3.8 Open both No.2 ESS BUS FEEDER power supply connected to the battery connector: circuit breakers and verify voltage is still present on the non-essential bus.

  • Page 645: Installation - External Power Receptacle

    ICA-D212-725 (96) Page 34 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.3.11.3.2 Set the BATTERY switch to ON, 96.3.9.3 Protect removed wire ends with close No.1 DC BUS voltmeter and all ESS BUS electrical tape. FEEDER circuit breakers. Verify the dual voltmeter indicates external power source voltage.

  • Page 646: Replacement - Starter/Generator Brushes

    ICA-D212-725 (96) Page 35 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.3.14.4 Remove protective covering from 96.3.16.1 Remove access panel located wires and terminals and connect wires to the underneath the nose of the helicopter, for access starter/generator. to electrical components and circuitry.
  • Page 647 ICA-D212-725 (96) Page 36 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.3.16.2.7 Momentarily energize load Increase engine speed and maintain speed of supplied by No.1 essential DC bus, such as engine so speed of gas producer is 71% N1 or landing light.
  • Page 648 ICA-D212-725 (96) Page 37 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.3.17.2.4 Place TEST switch 96.3.18.2 NON-ESS switch OVERLOAD position verify that NORMAL. Check for 28 VDC on non-essential GENERATOR light illuminates on Master Caution bus in overhead console.

  • Page 649: Power Diode Functional Checkout Procedure

    ICA-D212-725 (96) Page 38 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.3.19 Power Diode Functional Checkout Procedure 96.3.19.1 Refer to Table 96-6 and Figure 96- Perform diode functional checkout procedures perform diode functional checkout when loss of No.1 or No.2 DC essential bus procedures.
  • Page 650 ICA-D212-725 (96) Page 39 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) TEST PURPOSE Initial setting with power on. Ensure no open circuit at CR30 diode. Ensure no open circuit at CR31 diode. Ensure no open circuit at CR32 diode Ensure no open circuit at CR33 diode Figure 96-4.

  • Page 651: Starter And Igniter

    ICA-D212-725 (96) Page 40 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.3.20 Starter and Igniter 96.3.22.1.4 Set START switch on pilot collective One starter/generator is mounted on the engine. to OFF. Verify no voltage is present on If electrical power is supplied to series (or starter) disconnected wire P95A1.

  • Page 652: Ac Power System

    ICA-D212-725 (96) Page 41 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.3.23.9 Set ENGINE FUEL switch to ON. 28VDC – 13.7 Amps at 100% load. Verify battery voltage is present between pin A 28VDC – 17.8 Amps at 150% load.

  • Page 653: Operational Check - Inverter System

    ICA-D212-725 (96) Page 42 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.4.5.1 While supporting the inverter on its mounting pad, install and secure mounting bolts and washers. 96.4.5.2 Remove protective cap or tape from electrical connector and engage and secure connector.

  • Page 654: Torque Indicator

    ICA-D212-725 (96) Page 43 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) NOTE 96.5 AC POWERED INDICATOR S/Ns 30576, 30687, 30931, 30817 SYSTEMS and 30599 use an AC powered torque indicating system. For all 96.5.1 AC Powered Indicator Systems S/Ns except 30576, 30687,...
  • Page 655 ICA-D212-725 (96) Page 44 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) the overlay. Reapply the white slippage mark at 96.5.3.3.3 Reduce pressure remove the top of the instrument. pressure tester from pressure transmitters. 96.5.3.3 After indicator alignment, verify 96.5.3.3.4...
  • Page 656 ICA-D212-725 (96) Page 45 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Table 96-7. Torquemeter Alignment Chart. ENGINE NAMEPLATE ALIGN INDEX ENGINE NAMEPLATE ALIGN INDEX PRESSURE MARK TO PRESSURE MARK TO 50.0 62.5 49.5 62.0 49.0 61.5 10.0 48.5 10.0 61.0...

  • Page 657: Engine Oil Pressure Indicator

    ICA-D212-725 (96) Page 46 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.5.4 Engine Oil Pressure Indicator 96.5.6 Transmission Pressure Indicator NOTE S/Ns 30576, 30687, 30931, NOTE 30817 and 30599 use an AC S/Ns 30576, 30687, 30931, powered Engine Oil Pressure 30817 and 30599 use an AC indicating system.

  • Page 658: Hydraulic Pressure Indicator

    ICA-D212-725 (96) Page 47 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Connect pressure line transmission 30599 refer to Section 96.6 for pressure transmitter. details of the DC powered indicating systems. 96.5.8 Hydraulic Pressure Indicator The fuel pressure indicator system is a remote NOTE type indicating system.

  • Page 659: Insulation Resistance Test - Tank Units And System Wiring Installation

    ICA-D212-725 (96) Page 48 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) quantity test switch has replaced the fuel quantity select switch and allows for a confidence check 96.5.14.4 Adjust EMPTY control on back of of the indicator only. The indicator displays total indicator, if required, until indicator reads exactly fuel quantity at all times.
  • Page 660 ICA-D212-725 (96) Page 49 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Capacitance (uuf) Full Ind System Indicator Empty (1) Added (2) Full (1) Reading Basic 393008-040 121.3 132.0 244.3 1575 393008-082 393008-036 112.3 132.0 244.3 1900 393008-046 393008-037 207.8 237.3...

  • Page 661: Dual Tachometer Indicator

    ICA-D212-725 (96) Page 50 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.5.16 Dual Tachometer Indicator 96.5.17.4 Disconnect connector (P111) from test set and connect to power turbine tachometer generator on engine. NOTE S/Ns 30576, 30687, 30931, 30817 and 30599 use an AC 96.5.18...

  • Page 662: Engine Oil Temperature Indicator

    ICA-D212-725 (96) Page 51 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.6 POWERED INDICATOR indicator reads approximately ambient SYSTEMS temperature with transmission cold. 96.6.3.2 Turn electric power off. NOTE S/Ns 30576, 30687, 30931, 30817 and 30599 use the following AC 96.6.4...

  • Page 663: Turn And Bank Indicator

    ICA-D212-725 (96) Page 52 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) connect connector (P220S) to engine torque pressure switch. 96.6.11A.2 Remove indicator from instrument panel and disconnect the leads from 96.6.7.1.5 Turn electric power off. the back of the indicator.

  • Page 664: Measured Gas Temperature Indicator (-17B Engines)

    ICA-D212-725 (96) Page 53 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) SPECIAL TEST EQUIPMENT NOTE TYPE OR MODEL NOMENCLATURE Tolerances stated do not include Barfield Type Turbine Temperature test equipment tolerances. Test Set 2312G or TT1000A 96.6.11B.1 Supply electrical power helicopter.

  • Page 665: Operational Check - Hydraulic Temperature Indicators

    ICA-D212-725 (96) Page 54 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 2312G or TT1000A 96.6.15.1.1 Apply electrical power to helicopter electrical system. NOTE Tolerances stated do not include 96.6.15.1.2 Verify No.1 HYD OIL temperature test equipment tolerances. indicator reads...

  • Page 666: Gyro Directional Indicator

    ICA-D212-725 (96) Page 55 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) the same manner. The indicator reads in Percent 96.6.18 Gyro Directional Indicator of maximum torque and also has a digital display which displays percent of maximum torque. The...

  • Page 667: Dc Engine Oil Pressure Indicator

    ICA-D212-725 (96) Page 56 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 5 seconds, then will display current torque section for details of the DC pressure for 10 seconds, then display “CA” for Engine Oil Pressure indicating another 5 seconds, then display “CA1”, indicating system.

  • Page 668: Operational Check - Dc Transmission Oil Pressure Indicator

    ICA-D212-725 (96) Page 57 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) except 30576, 30687, 30931, Pressure indicating system. See 30817 and 30599 refer to this section 96.5 for details. For all section for details of the DC S/Ns except 30576, 30687, 30931,...

  • Page 669: Operational Check - Dc Fuel Pressure Indicator

    ICA-D212-725 (96) Page 58 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) S/Ns 30576, 30687, 30931, 30817 S/Ns 30576, 30687, 30931, 30817 and 30599 use an AC Fuel and 30599 use an AC Dual Pressure indicating system. See Tachometer indicating system.

  • Page 670: Dc Gas Producer Tachometer Indicator

    ICA-D212-725 (96) Page 59 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.6.31.1.7 Energize tachometer generator on test set. 96.6.33.1.1 Apply electrical power helicopter electrical system. 96.6.31.1.8 Verify power turbine tachometer pointers on pilot and copilot dual tachometers read 96.6.33.1.2...

  • Page 671: Dome Lights

    ICA-D212-725 (96) Page 60 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.7.3.2 Check that copilot cockpit light is operational in each mode (ON/OFF, DIM/BRIGHT, 96.7.7.2.1 Rotate PILOT INSTR LT control and SPOT/FLOOD on both red and white). slightly clockwise until switch just closes. Verify instrument lights on the pilot instrument panel and 96.7.3.3...

  • Page 672: Operational Check - Engine Instrument Panel Lights

    ICA-D212-725 (96) Page 61 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) transistors located on the nose compartment, and 96.7.11.4 Rotate SEC INSTR LT control in the instrument lights. counter-clockwise direction. Verify instrument secondary lights decrease in brightness. 96.7.9 Operational Check –...

  • Page 673: Operational Check - Overhead Console Lights

    ICA-D212-725 (96) Page 62 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.7.15 Operational Check – Overhead Console Lights The caution and warning system consists of a single caution light annunciator panel, 2 MASTER 96.7.15.1 Apply electrical power to helicopter CAUTION lights, 2 ENGINE RPM warning lights electrical system.
  • Page 674 ICA-D212-725 (96) Page 63 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Light and copilot instrument panels should illuminate each time a caution panel NOTE segment illuminates, and shall be reset During system operational checks, each time in readiness for another MASTER CAUTION light on pilot fault indication.
  • Page 675 ICA-D212-725 (96) Page 64 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) NOTE: #2: Light is in ON condition only when an affected door is open. NOTE: #3: Light may be ON if using external power. NOTE: #4: Light may be ON until sufficient airflow through the engine to activate pressure switch.

  • Page 676: Operational Check - Engine Oil Filter Caution Light

    ICA-D212-725 (96) Page 65 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) TYPE OR MODEL NOMENCLATURE 96.8.7.1 Disconnect wires Q17B18 and Barfield Model Pressure Tester 0- Q17C18 from terminal of forward engine fuel 2311F-S or Equivalent 150 psi. (0-1034 KPa) pump pressure switch (bottom of engine FCU).

  • Page 677: Operational Check - Fuel Filter Caution Light

    ICA-D212-725 (96) Page 66 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.8.9.1 Disconnect wire Q67A22 from 96.8.10.4 Connect connector (P156) terminal #3 of terminal board TB11 (L/H fuel sump airframe fuel filter switch (S94) and turn power plate). Verify FUEL FILTER caution light is extinguished.

  • Page 678: Operational Check - Governor Manual Control Caution Light

    ICA-D212-725 (96) Page 67 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Detector Caution Light NOTE If cells have more than 10% fuel 96.8.13.1 Disconnect connector (P290S) (150 pounds), low fuel level switches from engine chip connector. Connect a temporary short between terminal A and ground.

  • Page 679: Operational Check - Transmission Chip Detector Caution Light System

    ICA-D212-725 (96) Page 68 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.8.16.4 Relieve pressure on transmission illuminates. Verify XMSN CHIP IND SUMP manifold. Verify XMSN OIL PRESS caution light indicator (if installed) on right side of pedestal illuminates at 30  3 psig (206.85  20.69 kPa).

  • Page 680: Operational Check - Intermediate Gearbox Chip Detector Caution Light

    ICA-D212-725 (96) Page 69 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.8.20.3 Remove temporary short. Verify 96.8.23.4 Set BATTERY switch to OFF. XMSN OIL TEMP caution light is extinguished. 96.8.24 Operational Check – Passenger 96.8.20.4 Turn electrical power off.

  • Page 681: Operational Check - Battery Caution Light System

    (with door in closed pressure switch connector (P223). position) for 0.12 inch nominal switch lever travel. (NOTE: This switch should not be installed in a standard EAGLE SINGLE heater installation). NOTE If switch is activated by lever and Pass. 96.8.29.2...

  • Page 682: Rpm Limit Warning (Lights And Audio)

    ICA-D212-725 (96) Page 71 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.8.31.1 Apply electrical power RPM limit warning system is adjusted upon helicopter electrical system. installation. Re-adjustment may be required whenever a tachometer generator or indicator is 96.8.31.2 Select...
  • Page 683 ICA-D212-725 (96) Page 72 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.8.33.4 Decrease engine speed very slowly Limit Warning System (Low RPM Warning) to the point where the amber ROTOR RPM lights illuminate and a swept-frequency audio signal NOTE...

  • Page 684: Adjustment Procedure - Rpm Limit Warning System (Low Rpm Warning)

    ICA-D212-725 (96) Page 73 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) the light again illuminates. If, following step 96.8.35.1 With the rotor in flat pitch and the 96.8.34.8, the warning light is extinguished, turn governor set to MANUAL, slowly increase R3 very slowly clockwise until the light just throttle until the rotor speed is at 102 to 104.5%...

  • Page 685: Operational Check - Engine Fire Detection System

    ICA-D212-725 (96) Page 74 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) three infrared detectors strategically mounted in 96.8.37.1.4 Verify the ENG FIRE handle or the engine compartment, a smoke detector ENG FIRE switch-light illuminates. located in the cargo compartment and a fire handle mounted in the center instrument panel or 96.8.37.1.5...

  • Page 686: Hydraulic Filter Clogged Warning

    ICA-D212-725 (96) Page 75 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.8.39.3 Press CARGO FIRE DETECTOR clogged indication. Reset for these test switch. Verify the CARGO FIRE warning indicators is by turning the outer bezel lights illuminate and flash.

  • Page 687: Utility Lights

    ICA-D212-725 (96) Page 76 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.9.2 Utility Lights When the ANTI COLL light switch is set to The utility light circuit is protected by the UTILITY BOTH, both light assemblies flash at a rate of LT 5 amp circuit breaker and controlled by the approximately 80 flashes per minute.

  • Page 688: Operational Check - Searchlight System

    ICA-D212-725 (96) Page 77 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.9.9 Operational Check – Searchlight relay, and limit switches. The LDG LT ON/OFF System switch controls the ON and OFF functions. The three position LDG LT EXT/OFF/RET switch 96.9.9.1...

  • Page 689: Engine Controls And Accessories Systems

    ICA-D212-725 (96) Page 78 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.10 ENGINE CONTROLS AND ACCESSORIES SYSTEMS 96.10.3.5 Set L/H BOOST PUMP switch to OFF. Verify fuel boost pump in left fuel cell stops 96.10.1 Engine Controls and Accessories...

  • Page 690: Engine Fuel Control Valve

    ICA-D212-725 (96) Page 79 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) system consists of a spring loaded center off, pilot 96.10.5.3 Set ENGINE FUEL VALVE switch to and copilot RPM INCR/DECR switches and the OFF. Verify engine fuel shutoff valve closes and linear actuator (B8).

  • Page 691: Idle Stop Release Solenoid

    ICA-D212-725 (96) Page 80 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.10.11.3 Press L/H SUMP DRAIN switch. 96.10.13.2.2 Release IDLE STOP RELEASE Verify sump drain valve on L/H fuel cell opens. switch on pilot collective stick. Verify engine idle stop solenoid extends.

  • Page 692: Start Fuel Valve

    ICA-D212-725 (96) Page 81 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.10.17.5 Momentarily pull ENGINE START 96.10.15.1 Set ENGINE DE-ICE switch to ON. trigger on copilot collective stick to ON. Verify Verify ENGINE DE-ICE caution light there is voltage at pin A of connector (P89S).

  • Page 693: Operational Check - Force Trim

    ICA-D212-725 (96) Page 82 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) holding forces to be adjusted to any desired stick normally de-energized (open) when the switches or pedal position. Force trim system is de- are in the ON position and energized (closed) energized when the FORCE TRIM switch is when the switches are placed to OFF.

  • Page 694: Heating Systems

    ICA-D212-725 (96) Page 83 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.11.5.2.8 Disconnect connector (P106) from hydraulic No.1 temperature switch (S204) and 96.12.3.3 Set PITOT HTR switch on pilot temporarily place a jumper between pins B and C. overhead console to ON. Verify pilot pitot tube Verify #1 HYDR SYST caution light illuminates.

  • Page 695: Cabin Temperature Control

    ICA-D212-725 (96) Page 84 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.12.5.2.1 Open WARNING circuit CAUTION breaker. Set HEAT AFT OUTLET switch to ON and SYSTEM SELECTOR switch to HEATER. Verify aft outlet valve (if installed) and doorpost AVOID DEPRESSING THE FIRE EXTING valve open and HEATER ON light is illuminated.
  • Page 696 ICA-D212-725 (96) Page 85 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.12.7.1 Disconnect electrical connect from 96.12.8.1 Apply electrical power to helicopter motor. electrical system. 96.12.7.2 Remove flex shaft between air 96.12.8.2 Open WARNING circuit temperature control and motor.

  • Page 697: Bleed Air Priority Switch

    ICA-D212-725 (96) Page 86 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) Figure 96-9. Cabin Temperature Control 96.12.9 Bleed Air Priority Switch 96.12.10.1 Ensure the collective pitch lever is The bleed air priority switch is located adjacent to fully down.

  • Page 698: Operational Check - Bleed Air Priority Switch

    ICA-D212-725 (96) Page 87 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) 96.12.11 Operational Check – Bleed Air Priority Switch 96.12.12 Vent Blower 96.12.11.1 Apply electrical power to helicopter A right and left vent blower is provided. Electrical electrical system.

  • Page 699: Miscellaneous Electrical Systems

    ICA-D212-725 (96) Page 88 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) WIPERS speed control in HIGH, MED, LOW, 96.13 MISCELLANEOUS ELECTRICAL OFF, and PARK positions. SYSTEMS 96.13.2.4 WIPER switch Miscellaneous electrical systems include the COPILOT. Verify only copilot wiper operates in...

  • Page 700: Cargo Release System

    ICA-D212-725 (96) Page 89 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) switch-light and verify FIRE EXTING switch-lights extinguish. WARNING 96.13.4.8 If ENG FIRE and FIRE EXTING switch-lights are installed, repeat steps 96.13.4.2 SQUIBB CARTRIDGES ARE PYROTECHNIC to 96.13.4.7 for copilot’s ENG FIRE and FIRE DEVICES.
  • Page 701 ICA-D212-725 (96) Page 90 of 90 CHAPTER 96 – ELECTRICAL SYSTEM (96-00-00) CHAPTER 96 ELECTRICAL SYSTEM (96-00-00) Appendix A Appendix A contains Dart Drawings D212-725-8 and D212-725-8-G2 Wiring Routing  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 702 ICA-D212-725 (97) Page 1 of 5 CHAPTER 97 – AVIONICS (97-00-00) CHAPTER 97 AVIONICS (97-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 703 ICA-D212-725 (97) Page 2 of 5 CHAPTER 97 – AVIONICS (97-00-00) TABLE OF CONTENTS Table of Contents ............................. 2 List of Figures ..............................2 97.1 Avionics Systems ..........................3 97.2 Troubleshooting – Avionics Systems ....................3 97.3 Configuration ............................. 4 97.4...

  • Page 704: Avionics Systems

    ICA-D212-725 (97) Page 3 of 5 CHAPTER 97 – AVIONICS (97-00-00) and switches are considered to be in 97.1 AVIONICS SYSTEMS their normal position. Perform operational checks after equipment is replaced or airframe wring is Maintenance of avionics circuitry and avionics repaired or replaced.

  • Page 705: Configuration

    The owner/operator should consult the manufacturer for information regarding installation, functional testing, and operation of the above equipment. Avionics wiring diagrams for each aircraft modified per SH07-28 will be provided by Eagle Copters. See Chapter 98 for general and aircraft specific wiring diagrams.
  • Page 706 ICA-D212-725 (97) Page 5 of 5 CHAPTER 97 – AVIONICS (97-00-00) Fig. 97-1. ELT and Remote Switch Panel  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
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  • Page 708 ICA-D212-725 (98) Page 1 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) CHAPTER 98 WIRE DIAGRAMS (98-00-00)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 709 ICA-D212-725 (98) Page 2 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) TABLE OF CONTENTS LIST OF FIGURES ............................2 98.1 WIRING DIAGRAMS ......................... 3 98.2 WIRE IDENTIFICATION ........................3 98.3 SIMPLIFIED ELECTRICAL WIRING SCHEMATICS ................ 3 98.4 EFFECTIVITY ............................ 3 98.5...
  • Page 710 ICA-D212-725 (98) Page 3 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) 98.1 WIRING DIAGRAMS For S/Ns 30687, 30576, 30817, 30931 and 98.3 SIMPLIFIED ELECTRICAL WIRING 30599, updated Wiring Diagrams for the modified SCHEMATICS helicopter can be found on Drawing D212-725-2 located in Appendix A of Chapter 98-00-00.
  • Page 711 ICA-D212-725 (98) Page 4 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) Condition Wire Size Part Number Open harness — AWG 8 through 00 M22759/2-(+)-9 Airframe wiring: AWG 22 through 10 M22759/16-(+)-9 & M22759/41-(+)-9 or M22759/34-(+)-9 AWG 24 M22759/34-(+)-9 Open harness —...
  • Page 712 ICA-D212-725 (98) Page 5 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) 98.5.2 Wire Type Construction 98.5.3 Wire Stripping 98.5.2.1 M22759/2: Nickel-plated soft 98.5.3.1 Before any wire can be assembled to annealed copper with more connectors, terminals, splices, etc., the insulation...
  • Page 713 ICA-D212-725 (98) Page 6 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) Conductor breakage can be virtually eliminated Personnel should refer ARP5369, with care and attention to the area of wire Guidelines for Wire Identification Marking using termination. Stamp Process, guidance minimizing insulation damage.
  • Page 714 ICA-D212-725 (98) Page 7 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) EQUIPMENT IDENTIFICATION 1AUD Forward audio system ATC Transponder (GTX-330) 2AUD Aft audio system Longline/Heli-torch system 1VHF # 1 VHF communication Electric Oil Cooler (if installed) 2VHF # 2 VHF communication...
  • Page 715 ICA-D212-725 (98) Page 8 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) Figure 98-2. Simplified Electrical Schematic  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 716 ICA-D212-725 (98) Page 9 of 21 CHAPTER 98 – WIRE DIAGRAMS (98-00-00) Figure 98-3. Electrical and Electronics Symbols Chart (Sheet 1 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD.  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 717 ICA-D212-725 (98) Page 10 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) Figure 98-3. Electrical and Electronics Symbols Chart (Sheet 2 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 718 ICA-D212-725 (98) Page 11 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) Figure 98-3. Electrical and Electronics Symbols Chart (Sheet 3 of 3)  COPYRIGHT  2007 BY DART AEROSPACE LTD  THIS DOCUMENT IS PRIVATE AND CONFIDENTIAL AND IS SUPPLIED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED FOR ANY PURPOSE OR COPIED OR COMMUNICATED TO ANY OTHER PERSON WITHOUT WRITTEN PERMISSION FROM DART AEROSPACE LTD.
  • Page 719 ICA-D212-725 (98) Page 12 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) AC LOAD ANALYSIS EQUIPMENT NUMBER VA at VA at OF UNITS 115VAC 26 VAC INSTRUMENTS Indicator-Transmission Oil Pressure 2.43 Transmitter- Transmission Oil Press. 2.43 TOTAL 4.86 ENGINE INSTRUMENTS Indicator- Engine Oil Pressure 2.36...
  • Page 720 ICA-D212-725 (98) Page 13 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS NUMBER TOTAL NORMAL EQUIPMENT OF UNITS AMPS/UNIT AMPS LIGHTING Dome Light 1.28 3.84 0.00 Cockpit Light 0.18 0.36 0.36 Instrument Post Lights 0.02 0.18 0.18 Instrument Lighting 0.18...
  • Page 721 ICA-D212-725 (98) Page 14 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS NUMBER TOTAL NORMAL EQUIPMENT OF UNITS AMPS/UNIT AMPS FLIGHT CONTROLS Magnetic Brake-Force Trim 1.20 1.20 Solenoid-Hyd. Bypass Valve 2.20 Solenoid-Idle Stop Release 6.10 Actuator-Governor RPM 1.00 1.00...
  • Page 722 ICA-D212-725 (98) Page 15 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS NUMBER TOTAL NORMAL EQUIPMENT OF UNITS AMPS/UNIT AMPS ENGINE IGNITION SYS. Igniter Unit 1.50 1.50 Solenoid-Valve Igniter 0.75 0.75 0.75 Relay-Starter 4.50 TOTAL 6.75 2.25 MISCELLANEOUS Windshield Wiper 6.20...
  • Page 723 ICA-D212-725 (98) Page 16 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS START & WARM-UP TAKEOFF CRUISE LAND 15 MIN. 15 MIN. 15 MIN. 15 MIN. TOTAL ALL DC BUSSES 50.9 109.7 114.0 110.2 ESSENTIAL DC BUS 50.9 89.4...
  • Page 724 ICA-D212-725 (98) Page 17 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS NUMBER TOTAL NORMAL EQUIPMENT OF UNITS AMPS/UNIT AMPS LIGHTING Dome Light 1.28 3.84 0.00 Cockpit Light 0.18 0.36 0.36 Instrument Post Lights 0.02 0.02 0.02 Instrument Lighting 0.18...
  • Page 725 ICA-D212-725 (98) Page 18 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS NUMBER AMPS/ TOTAL NORMAL EQUIPMENT OF UNITS UNIT AMPS FLIGHT CONTROLS Magnetic Brake-Force Trim 0.40 1.20 1.20 Solenoid-Hyd. Bypass Valve 1.10 2.20 Solenoid-Idle Stop Release 6.10 6.10...
  • Page 726 ICA-D212-725 (98) Page 19 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS NUMBER TOTAL NORMAL EQUIPMENT OF UNITS AMPS/UNIT AMPS ENGINE IGNITION SYS. Igniter Unit 1.50 1.50 1.50 Solenoid-Valve Igniter 0.75 0.75 0.75 Relay-Starter 4.50 4.50 TOTAL 6.75 2.25...
  • Page 727 ICA-D212-725 (98) Page 20 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) DC LOAD ANALYSIS START & WARM-UP TAKEOFF CRUISE LAND 15 MIN. 15 MIN. 15 MIN. 15 MIN. TOTAL ALL DC BUSSES 50.9 109.7 114.0 110.2 ESSENTIAL DC BUS 50.9 89.4...
  • Page 728 ICA-D212-725 (98) Page 21 of 21 CHAPTER 98 –WIRE DIAGRAMS (98-00-00) CHAPTER 98 WIRE DIAGRAMS (98-00-00) Appendix A Appendix A contains Drawings D212-725-2 and D212-725-2-G2 wiring Diagrams as well as aircraft specific avionics wiring diagrams.  COPYRIGHT  2007 BY DART AEROSPACE LTD ...
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