BELL HELICOPTER 407 Series Maintenance Manual
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BELL HELICOPTER 407 Series Maintenance Manual

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The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or
other directions issued by Bell Helicopter Textron Inc. and Airworthiness Directives (AD) issued by the
applicable regulatory agencies, shall be strictly followed.
COPYRIGHT NOTICE
COPYRIGHT
201
BELL ® HELICOPTER TEXTRON INC.
AND BELL HELICOPTER TEXTRON
CANADA LTD.
ALL RIGHTS RESERVED
Export Classification C, ECCN EAR99
MAINTENANCE MANUAL
VOLUME 1
GENERAL INFORMATION
NOTICE
REVISION 47 — 2 MAY 2019
22 FEBRUARY 1996

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Summary of Contents for BELL HELICOPTER 407 Series

  • Page 1: General Information

    NOTICE The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletins (ASB) or other directions issued by Bell Helicopter Textron Inc. and Airworthiness Directives (AD) issued by the applicable regulatory agencies, shall be strictly followed.
  • Page 2 BHT-407-MM-1 PROPRIETARY RIGHTS NOTICE These data are proprietary to Bell Helicopter Textron Inc. Disclosure, reproduction, or use of these data for any purpose other than helicopter operation or maintenance is forbidden without prior written authorization from Bell Helicopter Textron Inc.
  • Page 3 BHT-407-MM-1 WARNING THIS MANUAL APPLIES ONLY TO HELICOPTERS AND COMPONENTS MAINTAINED IN ACCORDANCE WITH BELL HELICOPTER TEXTRON (BELL) APPROVED PROCEDURES USING BELL APPROVED PARTS. ALL INSPECTION, REPAIR AND OVERHAUL PROCEDURES PUBLISHED BY BELL, INCLUDING PART RETIREMENT LIFE, ARE BASED SOLELY ON THE USE OF BELL PARTS THAT HAVE BEEN MAINTAINED USING BELL APPROVED DATA.
  • Page 4 BHT-407-MM-1 CUSTOMER SUPPORT AND SERVICES Flying smart means that no matter where you are, or what time it is, you can make a call and get additional information, clarification, or advice on a technical or operational issue concerning your helicopter or information contained in our Technical Publications. Product Support Engineering (PSE) is just a phone call away and may be contacted as follows: Model 206, 407, or 505...
  • Page 5 VALUATE OGISTICS UBLICATIONS Have you found something wrong with this manual — an error, an inconsistency, unclear instructions, etc.? Although we strive for accuracy and clarity, we may make errors on occasion. If we do and you discover it, we would appreciate your telling us about it so that we can change whatever is incorrect or unclear.
  • Page 7 CUSTOMER FEEDBACK Return by fax to Product Support Engineering (450) 433-0272, e-mail to publications@b .com, or mail to the address on the next page. Manual Title: Manual Number (if assigned): Date of Issue: Date of Last Revision: Section, Chapter, Paragraph Affected: Your Feedback: Now Reads: Should Read:...
  • Page 8 TAPE HERE POSTAGE NECESSARY Product Support Engineering 12,800 rue de l’Avenir Mirabel, Québec, Canada, J7J 1R4 FOLD ON DOTTED LINES AND TAPE Export Classification C, ECCN EAR99 TAPE HERE...
  • Page 9 Please complete this form and return by mail, e-mail (publications@b .com), or fax (817-280-6466, Attention: CPDC). This will ensure that the new owners/operators receive updates to their Bell Helicopter Textron Technical Manuals and Bulletins. Model of Helicopter Sold or Purchased ___________________________________________ Serial and Registration Number _________________________________________________...
  • Page 10 From NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. 1744 FORT WORTH, TEXAS COMMERCIAL PUBLICATION DISTRIBUTION CENTER P.O. BOX 482 FORT WORTH, TEXAS 76101-0482 FOLD ON DOTTED LINES AND TAPE TAPE HERE Export Classification C, ECCN EAR99...
  • Page 11 BHT-407-MM-1 SPARE PARTS WARRANTY ONE YEAR/1,000 HOURS PRORATED WARRANTY AND REMEDY: Seller warrants each new helicopter part or helicopter part reconditioned by seller to be free from defect in material and workmanship under normal use and service and if installed on Bell model helicopters. Seller’s sole obligation under this warranty is limited to replacement or repair of parts which are determined to Seller’s reasonable satisfaction to have been defective with 1,000 hours of operation or one (1) year after installation, whichever occurs first and reimbursement of reasonable freight charges.
  • Page 13 TC APPROVED BHT-407-MM-1 CHAPTER 4 — AIRWORTHINESS LIMITATIONS SCHEDULE TABLE OF CONTENTS Paragraph Chapter/Section Page Number Title Number Number AIRWORTHINESS LIMITATIONS SCHEDULE Airworthiness Limitations Schedule ..........4-00-00 FIGURES Figure Page Number Title Number Disc Pack Coupling — Inspection............... Main Rotor Yoke — Inspection ................Tail Rotor Hanger Bearing —...
  • Page 14 BHT-407-MM-1 TC APPROVED REVISION NO. DATE OF SIGNATURE APPROVAL SIGNATURE Original 29 March 1996 26 October 1996 18 July 1997 14 April 1998 30 November 1998 8 May 2001 4-00-00 Page 2 Rev. 47 2 MAY 2019 Export Classification C, ECCN EAR99...
  • Page 15 TC APPROVED BHT-407-MM-1 REVISION NO. DATE OF SIGNATURE APPROVAL SIGNATURE 21 September 2001 21 November 2001 29 August 2003 12 November 2004 16 November 2004 28 November 2005 7 November 2006 2 October 2007 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev.
  • Page 16 BHT-407-MM-1 TC APPROVED REVISION NO. DATE OF SIGNATURE APPROVAL SIGNATURE 29 September 2008 23 December 2009 23 February 2010 29 July 2010 8 April 2011 21 February 2014 4-00-00 Page 4 Rev. 47 2 MAY 2019 Export Classification C, ECCN EAR99...
  • Page 17 TC APPROVED BHT-407-MM-1 REVISION NO. DATE OF SIGNATURE APPROVAL SIGNATURE 9 January 2017 2 MAY 2019 4-00-00 2 MAY 2019 Rev. 47 Page 5/6 Export Classification C, ECCN EAR99...
  • Page 19 USE. THE TIME/CALENDAR/RIN LIFE MUST WARNING NOT BE EXCEEDED WITHOUT THE EXPRESS WRITTEN AGREEMENT OF BELL HELICOPTER AND THE LOCAL CERTIFICATION AUTHORITIES. A L L R E PA I R A N D O V E R H A U L...
  • Page 20 The airworthiness lives given to the components and ON COMMERCIAL HELICOPTERS. assemblies are determined by experience, tests and the judgment of Bell Helicopter engineers. The airworthiness lives and inspection intervals cannot be changed without the approval of the Minister of CAUTION Transport Canada.
  • Page 21 TC APPROVED BHT-407-MM-1 Table 4-1. Airworthiness Limitations Schedule (Cont) COMPONENT PART NUMBER AIRWORTHINESS LIFE MAIN ROTOR CONTROLS (CONT) Bearing Universal 406-310-405-101 5000 hours Bearing Universal 406-310-405-103 Unlimited Rod End Assembly 406-310-404-101 5000 hours Rod End Assembly 406-310-404-105 Unlimited Anti-drive Link 406-010-432-101 5000 hours Anti-drive Lever...
  • Page 22 BHT-407-MM-1 TC APPROVED Table 4-1. Airworthiness Limitations Schedule (Cont) COMPONENT PART NUMBER AIRWORTHINESS LIFE TAILBOOM Tailboom Assembly 407-030-801-107 5000 hours Tailboom Assembly 407-030-801-201 Unlimited Tailboom Assembly 407-530-014-101 5000 hours LANDING GEAR Standard Landing Gear Forward 407-050-101-101 5000 RIN Crosstube Standard Landing Gear Forward 407-722-101 5000 RIN Crosstube...
  • Page 23 TC APPROVED BHT-407-MM-1 Table 4-1. Airworthiness Limitations Schedule (Cont) NOTES (CONT): RIN: Retirement Index Number. Components sensitive to operational events, such as torque events or run-on landings, are assigned a maximum RIN number. This number is based on the fatigue damage that results from normal helicopter lifts and takeoffs (torque events) or from run-on landings, whichever applies.
  • Page 24 BHT-407-MM-1 TC APPROVED Table 4-2. Inspection Limitations Schedule INSPECTION INTERVAL COMPONENT PART NUMBER (HOURS OPERATION TIME) Disc Pack Coupling 406-040-340-101 25 hours Tail Rotor Hanger Bearing 406-040-339-101 25 hours Tail Rotor Hanger Bearing 407-340-339-101 Swashplate Bearing 406-310-402-101 50/150 hours Tail Rotor Blade 407-016-001-101 300 hours Yoke Assembly...

  • Page 25: March

    TC APPROVED BHT-407-MM-1 Table 4-2. Inspection Limitations Schedule (Cont) NOTES (CONT): Contact Product Support Engineering for changes or modifications to the structure in area where a mandatory airworthiness inspection is specified. The oil cooler blower and tail rotor segmented driveshaft bearings 407-340-339-101/-103 must be removed from service no later than 31 May 2004 and replaced by bearing 407-340-339-107.
  • Page 26 BHT-407-MM-1 TC APPROVED Figure 4-1. Disc Pack Coupling — Inspection 4-00-00 Page 14 Rev. 47 2 MAY 2019 Export Classification C, ECCN EAR99...
  • Page 27 TC APPROVED BHT-407-MM-1 Figure 4-2. Main Rotor Yoke — Inspection 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev. 47 Page 15...
  • Page 28 BHT-407-MM-1 TC APPROVED Figure 4-3. Tail Rotor Hanger Bearing — Inspection (Sheet 1 of 2) 4-00-00 Page 16 Rev. 47 2 MAY 2019 Export Classification C, ECCN EAR99...
  • Page 29 TC APPROVED BHT-407-MM-1 NOTES It is not necessary to disconnect the forward or aft short shaft or any of the tail rotor driveshaft segment assemblies in order to perform this inspection. Remove the cowlings and covers to get access to the oil cooler blower assembly and the tail rotor driveshaft segment assemblies;...
  • Page 30 BHT-407-MM-1 TC APPROVED 12.0 IN. (304.8 mm) 14.50 NO REPAIR TO SKIN PERMITTED NOTES This inspection applies to the tail rotor blade 407-016-001 only. Do this inspection every 300 hours of component operation. Remove the tail rotor blade. Inspect the blade roots inboard of blade station 14.50 for signs of damage. Examine the inside of the blade root pocket (where the tail rotor yoke is inserted) for signs of crazing on the surface of the blade skins.
  • Page 31 TC APPROVED BHT-407-MM-1 157.00 TAILBOOM IDENTIFICATION PLATE 140.428 AREA 107.397 AREA 72.370 AREA AREA AREA AREA 39.00 300-HOUR VISUAL INSPECTION CRITICAL INSPECTION AREAS (SEE DETAILS) 407_MM_04_0033a Figure 4-5. Tailboom Assembly — 300-Hour Inspection (Sheet 1 of 6) 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev.
  • Page 32 BHT-407-MM-1 TC APPROVED Figure 4-5. Tailboom Assembly — 300 Hour Inspection (Sheet 2 of 6) 4-00-00 Page 20 Rev. 47 2 MAY 2019 Export Classification C, ECCN EAR99...
  • Page 33 TC APPROVED BHT-407-MM-1 Figure 4-5. Tailboom Assembly — 300 Hour Inspection (Sheet 3 of 6) 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev. 47 Page 21...
  • Page 34 BHT-407-MM-1 TC APPROVED 5.5 IN. 4.25 IN. (139.7 mm) (108.0 mm) 2.0 IN. (50.8 mm) AREA AREA 2.0 IN. (50.8 mm) 120.75 98.89 AREA AND AREA (HORIZONTAL STABILIZER NOT SHOWN FOR CLARITY) GENERAL VISUAL INSPECTION (300 HOURS) CRITICAL INSPECTION AREA 407_MM_04_0033d Figure 4-5.
  • Page 35 TC APPROVED BHT-407-MM-1 Figure 4-5. Tailboom Assembly — 300 Hour Inspection (Sheet 5 of 6) 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev. 47 Page 23...
  • Page 36 BHT-407-MM-1 TC APPROVED Upper tailboom skin Horizontal stabilizer Left upper stabilizer attachment support NOTES AT EVERY 300-HOUR INTERVAL: Inspect the complete tailboom assembly for general condition. On the left side of the tailboom only, do a detailed inspection of all areas shown for cracks in the tailboom skin and loose rivets.
  • Page 37 TC APPROVED BHT-407-MM-1 407MM_04_0024 Figure 4-6. Tailboom Assembly — Daily Inspection (Sheet 1 of 2) 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev. 47 Page 25...
  • Page 38 BHT-407-MM-1 TC APPROVED DAILY INSPECTION NOTES 1. Before the first flight of the day, do a check of the left side of the tailboom assembly in the areas where paint was removed for cracks, as follows: a) If required, use a clean cloth moistened with cleaning compound (C-318), prepared in accordance with manufacturer’s recommendations, to remove any exhaust residues or dirt from both areas that require checking, as shown.
  • Page 39 TC APPROVED BHT-407-MM-1 140.428 107.397 AREA AREA 72.370 AREA 90.00 AREA 39.00 100 HOUR VISUAL INSPECTION CRITICAL INSPECTION AREAS (SEE DETAILS) 407_MM_04_0026 Figure 4-7. Tailboom Assembly — 100-Hour Inspection (Sheet 1 of 7) 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev. 47 Page 27...
  • Page 40 BHT-407-MM-1 TC APPROVED 74.370 90.00 31.920 DETAIL 0.00 AREA 7.50 DETAIL DETAIL DETAIL DETAIL DETAIL 39.000 45.515 52.600 58.995 72.475 77.000 85.955 AREA 0.50 IN. 0.50 IN. (12.7 mm) (12.7 mm) 0.00 7.50 9 FASTENERS (LEFT SIDE ONLY) 45.515 DETAIL GENERAL VISUAL INSPECTION (100 HOURS) 100 HOUR INSPECTION (10X MAGNIFYING GLASS) 407_MM_04_0027...
  • Page 41 TC APPROVED BHT-407-MM-1 Figure 4-7. Tailboom Assembly — 100-Hour Inspection (Sheet 3 of 7) 4-00-00 Export Classification C, ECCN EAR99 2 MAY 2019 Rev. 47 Page 29...
  • Page 42 BHT-407-MM-1 TC APPROVED Figure 4-7. Tailboom Assembly — 100-Hour Inspection (Sheet 4 of 7) 4-00-00 Page 30 Rev. 47 2 MAY 2019 Export Classification C, ECCN EAR99...
  • Page 43 TC APPROVED BHT-407-MM-1 8 RIVETS (LEFT SIDE ONLY) 97.89 98.89 107.397 VIEW 120.75 121.75 4.0 IN. (101.6 mm) 4.0 IN. (101.6 mm) HORIZONTAL STABILIZER (REF) 2.0 IN. 2.0 IN. (50.8 mm) (50.8 mm) AREA 107.397 0.00 8 RIVETS (LEFT SIDE ONLY) 7.00 3.00 IN.
  • Page 44 BHT-407-MM-1 TC APPROVED VIEW 140.428 LEFT SIDE ONLY AREA 140.428 0.00 6 RIVETS (LEFT SIDE ONLY) 5.00 6.00 IN. (152.4 mm) VIEW GENERAL VISUAL INSPECTION (100 HOURS) 100 HOUR INSPECTION (10X MAGNIFYING GLASS) 407_MM_04_0031 Figure 4-7. Tailboom Assembly — 100-Hour Inspection (Sheet 6 of 7) 4-00-00 Page 32 Rev.
  • Page 45 TC APPROVED BHT-407-MM-1 100 HOURS OF OPERATION NOTES Inspect the complete tailboom assembly for general condition. On the left side of the tailboom only, do a detailed inspection of all areas shown, for cracks in the tailboom skin and loose rivets. Do not remove the paint or primer. If a loose rivet is found, remove rivet and inspect hole for cracks using a 10X magnifying glass.
  • Page 47 BHT-407-MM-1 CHAPTER 5 — INSPECTIONS AND COMPONENT OVERHAUL SCHEDULE TABLE OF CONTENTS Paragraph Chapter/Section Page Number Title Number Number INSPECTIONS General ..................5-00-00 Items Not Covered in the Inspection..........5-00-00 Crash Damage................5-00-00 Types of Inspections ..............5-00-00 Definitions ..................5-00-00 Inspection and Overhaul Tolerance ..........
  • Page 48 BHT-407-MM-1 TABLE OF CONTENTS (CONT) Paragraph Chapter/Section Page Number Title Number Number 5-30 Main Rotor Overspeed..............5-00-00 5-31 Overtorque ..................5-00-00 5-31A Engine Compressor Stall or Surge ..........5-00-00 5-32 After Lightning Strike..............5-00-00 COMPONENT INTERIM INSPECTION SCHEDULE 5-33 Component Interim Inspection Schedule ........5-00-00 COMPONENT OVERHAUL SCHEDULE 5-34...
  • Page 49 Make sure the Alert Service Bulletins (ASB), the Lead-The-Fleet (LTF), or any other special programs Airworthiness Directives (AD), and the special and the judgement of Bell Helicopter Textron inspections are done when they are required to be engineers. They are subject to change only by Bell done.

  • Page 50: Original

    CRASH DAMAGE component overhaul schedule. Because of the many possible combinations that can For the common Bell Helicopter Textron approved result from crash damage, it is not possible to include optional equipment that is integrated into this the specific repair tasks in this category. The...
  • Page 51 The program is closely • Periodic inspection — An inspection which is repeated at equal time intervals. monitored by Bell Helicopter Textron in an operational environment with selected operators. • Progressive inspection — A scheduled inspection that is divided into smaller segments.
  • Page 52 BHT-407-MM-1 stated, is 10% or up to a maximum of 300 hours authority requires to specifically approve operating time/6 months calendar time, whichever is the inspection and overhaul tolerance. less. The tolerances are established for maintenance If approval of the inspection and overhaul tolerance is scheduling convenience only.

  • Page 53: October

    BHT-407-MM-1 Calendar Example (10% or up to a maximum of 6 months calendar time, whichever is less): 12-MONTH NEXT 12-MONTH MAXIMUM ALLOWED INSPECTION CARRIED INSPECTION INSPECTION TOLERANCE OUT ON: DUE ON: DUE ON: June 10, 2010 10% of 12 months = 1.2 months July 12, 2010 July 31, 2011 (within 10% tolerance)

  • Page 55: Bht-407-Mm

    1200 hour or 24 month inspection (paragraph 5-24) every 1200 hours or 24 calendar 5-8. AIRFRAME INSPECTION PROGRAM months, whichever comes first Bell Helicopter Textron has developed two airframe • 2500 hour inspection (paragraph 5-24A) inspection programs that give you the flexibility to permit maximum helicopter use.
  • Page 56 BHT-407-MM-1 • 300 hour inspection for optional equipment 5-11. CHANGING INSPECTION PROGRAM (paragraph 5-19) You must use either the Airframe Periodic Inspection • 600 hour inspection (paragraph 5-20) program or the Airframe Progressive Inspection program from the start. You can change between the •...
  • Page 57 BHT-407-MM-1 ZONE 2 ZONE 1 ZONE 6 ZONE 5 ZONE 3 ZONE 4 ZONE 9 ZONE 7 ZONE 8 ZONE 10 - Main rotor hub and blade assembly Zone 1 - Tail rotor hub and blade assembly Zone 2 - Forward top deck Zone 3 - Power plant Zone 4...
  • Page 59 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-12. PROGRESSIVE INSPECTION — EVENT #1 INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ ZONE 1 — MAIN ROTOR SYSTEM PLACARDS AND MARKINGS Chapter 11 Examine the placards, decals, and markings.
  • Page 60 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-12. PROGRESSIVE INSPECTION — EVENT #1 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER ZONE 2 — TAIL ROTOR ASSEMBLY PLACARDS AND MARKINGS Chapter 11 Examine the placards, decals, and markings. Make sure you can read them, they are applied correctly, and they are in agreement with the applicable configuration of your helicopter.
  • Page 61 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-12. PROGRESSIVE INSPECTION — EVENT #1 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER b. Inspect tail rotor blades for delamination. c. Inspect pitch links for condition. d. Inspect pitch horns for condition. Chapter 53 e. Inspect tailboom for condition in tail rotor blade tip path area.
  • Page 62 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-13. PROGRESSIVE INSPECTION — EVENT #2 INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ ZONE 3 — FORWARD TOP DECK PLACARDS AND MARKINGS Chapter 11 Examine the placards, decals, and markings.
  • Page 63 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-13. PROGRESSIVE INSPECTION — EVENT #2 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER CONTROLS Chapter 67 Examine all of the control tubes, bellcranks, and the supports for condition, security, and correct operation. Examine the components as follows: a.
  • Page 64 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-13. PROGRESSIVE INSPECTION — EVENT #2 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. Pivot bolts of the pilot valve on the actuators for freedom of rotation. e. Reservoir. f. Pump. g. Remove the pump and inspect the input drive shaft/ adapter as applicable.
  • Page 65 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-13. PROGRESSIVE INSPECTION — EVENT #2 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 63 and Examine the transmission lower and upper (mast bearing) Chapter 96 chip detectors for metal particles. Examine the electrical circuit of the chip detectors for continuity.
  • Page 66 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-14. PROGRESSIVE INSPECTION — EVENT #3 INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ ZONE 4 — POWER PLANT PLACARDS AND MARKINGS Chapter 11 Examine the placards, decals, and markings.
  • Page 67 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-14. PROGRESSIVE INSPECTION — EVENT #3 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 76 Examine the engine controls for condition, correct operation, and security. Examine the components as follows: NOTE Refer to Chapter 76, “Throttle/Fly Detent Rigging Procedure”...
  • Page 68 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-14. PROGRESSIVE INSPECTION — EVENT #3 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Examine the freewheel assembly for condition, leaks, and security. Chapters 63 and 96 Examine the freewheel chip detector for metal particles. Examine the electrical circuit of the chip detectors for continuity. ROTOR BRAKE DISC Chapter 63 Examine the rotor brake disc for condition and security.
  • Page 69 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-15. PROGRESSIVE INSPECTION — EVENT #4 INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ ZONE 5 — AFT TOP DECK PLACARDS AND MARKINGS Chapter 11 Examine the placards, decals, and markings.
  • Page 70 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-15. PROGRESSIVE INSPECTION — EVENT #4 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 65 AFT SHORT SHAFT ASSEMBLY Examine the short shaft for condition and security. a. Loose and working rivets. Examine the disc pack couplings for condition. Do a torque check of the disc pack coupling attachment hardware (150 to 180 inch-pounds (17 to 20 Nm)).
  • Page 71 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-15. PROGRESSIVE INSPECTION — EVENT #4 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. Horizontal stabilizer and the attachment supports for cracks and security. e. Auxiliary fins for condition and security. f. Slat assemblies for condition and security. g.
  • Page 72 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-15. PROGRESSIVE INSPECTION — EVENT #4 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Examine the electrical circuit of the chip detector for continuity. Chapter 67 PITCH CHANGE CONTROL Examine the tail rotor pitch control mechanism for condition and security.
  • Page 73 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-16. PROGRESSIVE INSPECTION — EVENT #5 INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ ZONE 7 — CABIN INTERIOR (CREW AND PASSENGER COMPARTMENTS) PLACARDS AND MARKINGS Chapter 11...
  • Page 74 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-16. PROGRESSIVE INSPECTION — EVENT #5 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Inspect first aid kit contents for condition and for security of installation. Chapter 26 Examine fire extinguisher and quick-release for condition and security. Chapter 96 Examine the heating system of the pitot and static ports for correct operation.
  • Page 75 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-16. PROGRESSIVE INSPECTION — EVENT #5 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 96 ELECTRICAL Perform operational check of airspeed-actuated pedal stop system. ZONE 8 — FORWARD FUSELAGE PLACARDS AND MARKINGS Chapter 11 Examine the placards, decals, and markings. Make sure you can read them, they are applied correctly, and they agree with the applicable configuration of your helicopter.
  • Page 76 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-16. PROGRESSIVE INSPECTION — EVENT #5 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER BHT-407-CR&O-V b. Recondition the battery per BHT-ELEC-SPM and/or Chapter 96 manufacturer’s service manual. c. Inspect the vent lines for obstructions or damage. d.
  • Page 77 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-17. PROGRESSIVE INSPECTION — EVENT #6 INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ ZONE 9 — AFT FUSELAGE PLACARDS AND MARKINGS Chapter 11 Examine the placards, decals, and markings.
  • Page 78 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-17. PROGRESSIVE INSPECTION — EVENT #6 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. Mid fuselage lower longerons. e. Floor of the baggage compartment. f. Walls of the baggage compartment. Chapter 52 g. Baggage compartment door. h.
  • Page 79 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-17. PROGRESSIVE INSPECTION — EVENT #6 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 96 Examine the electrical components, the mounts, and the electrical harness for condition and security. Chapter 63 Examine the transmission oil lines and other drain lines for condition and security.
  • Page 80 BHT-407-MM-1 PROGRESSIVE INSPECTIONS 5-17. PROGRESSIVE INSPECTION — EVENT #6 (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. Retaining strap and rubber cushions. e. Rocking beam. f. Crosstubes. g. Attachment fittings. Chapter 12 LUBRICATION Service and lubricate the helicopter as necessary. ENGINE Rolls-Royce Do the applicable engine inspection.
  • Page 81 BHT-407-MM-1 PERIODIC INSPECTIONS 5-18. AIRFRAME PERIODIC INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 5, Do this inspection every 12 calendar months or every 300 paragraph 5-12 hours of operation.
  • Page 83 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-18A. 150 HOUR INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE This inspection applies only to helicopters S/N 53000 through 55466 and 54568 through 54800.
  • Page 85 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-19. 300 HOUR INSPECTION FOR OPTIONAL EQUIPMENT INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE Complete the following if applicable.
  • Page 86 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-19. 300 HOUR INSPECTION FOR OPTIONAL EQUIPMENT (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER CROSSTUBE FAIRING Chapter 32 Examine the crosstube fairings for condition and security. AUXILIARY FUEL TANK Chapter 99 Examine the auxiliary fuel tank installation for condition and security.
  • Page 87 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-20. 600 HOUR INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ ROTOR BRAKE NOTE BHT-407-CR&O-V Inspection information for the caliper assemblies and disc is contained in Northwest Dynamics Document...
  • Page 88 BHT-407-MM-1 Table 5-2. Rotor Brake Component Versus Inspection Document Table NOMENCLATURE/ RELATED KIT INSPECTION NORTHWEST DYNAMICS EFFECTIVITY PART NUMBER 407-II-8 INTERVAL INSPECTION DOCUMENT CALIPER ASSEMBLY 206-340-301-103 206-706-502-103 S/N 53000 – 53442 600 Hours B0223-OM Pre BHT-407-II-30 407-340-302-101 206-706-502-105 S/N 53443 – 53631 600 Hours B0223-OM 206-706-502-107...
  • Page 89 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-21. 600 HOUR OR 12 MONTH INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ CAUTION FOR HELICOPTERS OPERATED IN CORROSIVE ENVIRONMENT OR EXTREME ENVIRONMENTAL...
  • Page 90 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-21. 600 HOUR OR 12 MONTH INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 12 If installed, lubricate the expandable blade bolts. Install main rotor blades onto the main rotor hub assembly. AUTOMATIC FLIGHT CONTROL SYSTEM (AFCS) 407-706-061 NOTE The following steps are only applicable to the 407GX...
  • Page 91 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-22. 12 MONTH INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ GENERAL Ensure that an airframe periodic inspection (paragraph 5-10) or one complete cycle (all six events) of the progressive inspection...
  • Page 92 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-22. 12 MONTH INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER FORWARD FUSELAGE Chapter 67 Examine the controls for condition, security and correct operation. Examine them in the locations that follow: a. Pedestal. b. Crew seats. c.
  • Page 93 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-22. 12 MONTH INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 76 Examine the throttle control cable for condition and security. Examine it in the locations that follow: a. Crew seats. b. Vertical tunnel. c.
  • Page 94 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-22. 12 MONTH INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 96 Examine the electrical harness for condition and security in the locations that follow: a. Pedestal. b. Crew seats. c. Vertical tunnel. d. Roof beam. e.
  • Page 95 Perform a 12 month inspection on the mast. NOTE The following is applicable to main rotor masts 407-040-038-101, -105, -109, and -111 only. NOTE The mast pole may have been reidentified to one of the following, after repair by Bell Helicopter Textron (BHT): • 407-040-038-111R (replacement tungsten carbide coating by wear sleeve 406-040-026-103) •...
  • Page 96 GARMIN SOFTWARE (S/N 54300 AND SUBSEQUENT) Chapter 95 Verify latest software version configuration available on the Bell Helicopter website (www.bellhelicopter.net). Upgrade the helicopter to the latest software version. 5-00-00 Page 44B Rev. 46 1 MAR 2018...
  • Page 97 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-23. 24 MONTH INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 28 FUEL SYSTEM Remove the fuel transfer/fuel boost pump assemblies.
  • Page 98 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-23A. 1200 HOUR INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 67 CONTROLS Remove and examine the tail rotor pitch change control tube inside the tailboom for condition.
  • Page 99 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-24. 1200 HOUR OR 24 MONTH INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 67 PILOT CYCLIC CONTROL STICK Perform a 1200 hour or 24 month inspection of the pilot...

  • Page 100: July

    BHT-407-MM-1 SCHEDULED INSPECTIONS 5-24A. 2500 HOUR INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 67 CONTROLS NOTE For new and in-service pitch link assemblies, the first 2500-hour inspection occurs at 5000 hours of...
  • Page 101 BHT-407-MM-1 SCHEDULED INSPECTIONS 5-24B. MISCELLANEOUS INSPECTION INITIAL DATA REFERENCE INSPECITON TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE Refer to the requirements from your government authority for the applicable interval(s).
  • Page 103 BHT-407-MM-1 SPECIAL INSPECTIONS 5-25. SPECIAL INSPECTIONS • Torque/Friction Check (Table 5-3) • Freewheel Lubrication System (paragraph A special inspection (Table 5-3) is temporary or of a 5-25A) special time interval that is not consistent with the scheduled inspection. 5-00-00 Export Classification C, ECCN EAR99 9 JAN 2017 Rev.
  • Page 104 BHT-407-MM-1 Table 5-3. Special Inspections DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ INSPECTION SCHEDULE COMPONENT HOURS AFTER INITIAL INSTALLATION SIGNATURE AFTER 1 TO 5 10 TO 25 25 ±5 100 ±10 GROUND...
  • Page 105 BHT-407-MM-1 Table 5-3. Special Inspections (Cont) NOTES: Torque check must be repeated every 1 to 5 hours until torque is stabilized. Torque check must be repeated every 10 to 25 hours until the torque is stabilized. After the torque has stabilized, repeat the torque check every 300 flight hours (specified in progressive inspection).
  • Page 107 BHT-407-MM-1 SPECIAL INSPECTIONS 5-25A. FREEWHEEL LUBRICATION SYSTEM DATA REFERENCE INSPECTION TASK DESCRIPTION DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ This special inspection is required to ensure that there is no debris or blockage of restrictor 406-040-623-101 and restrictor 406-040-624-101 located on the left side of the forward engine firewall.
  • Page 108 BHT-407-MM-1 SPECIAL INSPECTIONS 5-25A. FREEWHEEL LUBRICATION SYSTEM (CONT) DATA REFERENCE INSPECTION TASK DESCRIPTION Figure 63-76 • Transmission oil pressure transmitter (30) • Hose assembly (either end) (8) • Union and fitting (26) • Tube assembly (either end) (25) • Cap (28) 5-00-00 Page 52 Rev.
  • Page 109 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-26. CONDITIONAL INSPECTIONS • Hard landing A conditional inspection does not occur at a specified • Sudden stoppage (main rotor) power ON or time. It is caused by known or suspected unusual events, malfunctions, or defects. Make an analysis of components removed because of •...
  • Page 110 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-26A. DELETED INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER 5-00-00 Page 52B Rev. 45 9 JAN 2017 Export Classification C, ECCN EAR99...
  • Page 111 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-27. HARD LANDING INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ A hard landing is any accident or incident in which the impact of the helicopter with the ground causes severe pitching of the main rotor or results in noticeable yielding or cracking of the fuselage pylon structure or the landing gear.
  • Page 112 Chapter 53 Examine the airframe for damage. If you find any one of the signs that follow, the fuselage must be aligned in a Bell Helicopter approved fixture: TOP DECK a. Deformation or damage to the structure at the pylon beam attachment points.
  • Page 113 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-27. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER e. Cracks and deformation of the pylon supporting structure in the roof beam. f. If the roof beam needs to be replaced. FORWARD FUSELAGE g. Cowling or doors are not aligned. h.
  • Page 114 MECH OTHER If the damage to the fuselage structure is such that you must align the fuselage in a Bell Helicopter approved fixture, remove the components that follow. Put a tag on each component and write. “THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A HARD LANDING.”...
  • Page 115 Disassemble the tail rotor driveshafts and examine them for condition. Chapter 53 Accomplish waviness check of the tailboom skin. If waviness exceeds limits, send tailboom to a Bell Helicopter approved structural repair facility. Chapter 32 Damage or distortion of the tail skid and the mounting points is not cause to send the tailboom for repair on an alignment fixture.
  • Page 116 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-27. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapters 63 and 65 DRIVE TRAIN SYSTEM If any of the conditions described below are noted, then the affected components must be sent to an approved facility for overhaul.
  • Page 117 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-27. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER If no component shows damage that is caused by a hard landing, then all drivetrain components, except for the mast, are serviceable. Examine the mast for distortion. If you see any distortion, discard the mast assembly.
  • Page 118 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-27. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. Remove and discard the engine to transmission driveshaft assembly. Examine all of the air, fluid flexible and rigid lines in the engine compartment for leaks, condition, and security. Chapter 67 MAIN AND TAIL ROTOR FLIGHT CONTROLS Examine all of the main and tail rotor flight controls for...
  • Page 119 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-27. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 28 FUEL SYSTEM Examine the fuel system for condition and leaks. Examine the components as follows: a. Sump retainers and the surrounding structures. b. Area around the fuel sumps for signs of leakage. c.
  • Page 120 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-28. SUDDEN STOPPAGE — MAIN ROTOR — POWER “ON” OR “OFF” INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ SUDDEN STOPPAGE —...
  • Page 121 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-28. SUDDEN STOPPAGE — MAIN ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER If you do not find any damage on a blade, the blade is serviceable. Chapter 62 MAIN ROTOR HUB ASSEMBLY Examine the main rotor hub and Frahm (if installed, TB 407-03-51) for condition.
  • Page 122 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-28. SUDDEN STOPPAGE — MAIN ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER b. Discard all control bolts from hydraulic servo to main rotor pitch horn. If the main rotor hub assembly is not damaged, it is serviceable.
  • Page 123 Examine the mast for torsional yielding by doing a TIR check. If the mast is outside the TIR tolerance, you can send the mast to Bell Helicopter for analysis. If the mast shows signs of torsional yielding, discard the mast assembly, the transmission assembly, and the freewheel (outer race, inner race, and clutch).
  • Page 124 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-28. SUDDEN STOPPAGE — MAIN ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Do a visual inspection. If there is no damage, send the freewheel assembly to an approved facility for overhaul. Put a tag on the freewheel assembly and write, “THIS FREEWHEEL ASSEMBLY WAS REMOVED FROM SERVICE BECAUSE OF A SUDDEN STOPPAGE.”...
  • Page 125 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-28. SUDDEN STOPPAGE — MAIN ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Rolls-Royce Engine Do an engine sudden stoppage inspection. Operation and Maintenance Manual Chapter 64 TAIL ROTOR HUB AND BLADE ASSEMBLY Examine the tail rotor hub and blade assembly for damage.
  • Page 126 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-29. SUDDEN STOPPAGE — TAIL ROTOR — POWER “ON” OR “OFF” INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ SUDDEN STOPPAGE —...
  • Page 127 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-29. SUDDEN STOPPAGE — TAIL ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Do a visual inspection. If you do not find any damage, send the freewheel assembly to an approved facility for overhaul. Follow the special inspection instructions.
  • Page 128 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-29. SUDDEN STOPPAGE — TAIL ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 65 TAIL ROTOR GEARBOX ASSEMBLY Remove and examine the tail rotor gearbox for condition. If you see any of the following, discard the tail rotor gearbox. a.
  • Page 129 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-29. SUDDEN STOPPAGE — TAIL ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER If the sudden stoppage started at the tail rotor hub and blade assembly, discard it. If the sudden stoppage started at the main rotor, the transmission, the tail rotor drive shaft, or at the tail rotor gearbox, look for visible external damage.
  • Page 130 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-29. SUDDEN STOPPAGE — TAIL ROTOR — POWER “ON” OR “OFF” (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Examine the tailboom area of the tail rotor gearbox mounting studs and dowel pins for cracks. Use a 10X power magnifying glass or do a fluorescent penetrant inspection.
  • Page 131 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-30. MAIN ROTOR OVERSPEED INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ MAIN ROTOR OVERSPEED A main rotor overspeed is an incident in which 118% main rotor RPM is exceeded.
  • Page 132 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-30. MAIN ROTOR OVERSPEED (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER If the blade has any other damage, remove the blade. Put a tag on the blade and write, “THIS BLADE WAS REMOVED FROM SERVICE BECAUSE MAIN ROTOR...
  • Page 133 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-30. MAIN ROTOR OVERSPEED (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER If the blade has any other damage, remove the blade. Put a tag on the blade and write, “THIS BLADE WAS REMOVED FROM SERVICE BECAUSE MAIN ROTOR...
  • Page 134 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-30. MAIN ROTOR OVERSPEED (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER BHT-407-FM-X Do a ground run for a minimum of one hour with the helicopter light on its skids. Examine the fuel and the oil systems for leaks.
  • Page 135 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-31. OVERTORQUE INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ OVERTORQUE An overtorque is an incident in which torsional loads greater than those permitted are applied to the helicopter dynamic system.
  • Page 136 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-31. OVERTORQUE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER AFTER OVERTORQUE — 110 TO 120% When a main rotor overtorque has occurred, do the steps that follow: Chapter 62 MAIN ROTOR HUB AND BLADES Examine the blades for condition. If the blade bond is separated at any point on the blade, discard the blade.
  • Page 137 “THIS MAST POLE WAS REMOVED FROM SERVICE BECAUSE OF A MAIN ROTOR OVERTORQUE.” Send the mast pole to Bell Helicopter Textron for analysis to determine if the mast has sustained torsional yielding. If Bell Helicopter Textron finds that the mast has torsional...
  • Page 138 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-31. OVERTORQUE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Examine the boosted main rotor control tubes for damage. Carefully examine the pitch links. Replace all of the damaged parts. Chapter 53 STRUCTURE Examine the cabin roof and the roof beam at the attachment points of the transmission beam for security and condition.
  • Page 139 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-31. OVERTORQUE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 64 e. The tail rotor hub and blades. Chapter 63 Examine the chip detectors of the transmission, the Chapter 65 freewheel and the tail rotor gearbox for unwanted material. AFTER OVERTORQUE —...
  • Page 140 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-31A. ENGINE COMPRESSOR STALL OR SURGE INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE An engine compressor stall or surge can be described as a sharp rumble, a series of loud sharp pops, severe engine vibration, or a rapid rise in...
  • Page 141 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-31A. ENGINE COMPRESSOR STALL OR SURGE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER • If the stall or surge occurred on the ground or in flight at any N speed or torque setting and there was a noticeable yaw of the helicopter, do Part I, Part II, and Part III of this inspection.
  • Page 142 Make an entry on the applicable components Historical Service Record and attach a tag and write, “THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL/SURGE”. Send the component to a Bell Helicopter Textron approved facility for overhaul. Examine the tail rotor driveshafts for condition and security of attachment.
  • Page 143 Historical Service Record and attach a tag on the tail rotor hub assembly and write, "THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL OR SURGE". Send the hub to a Bell Helicopter Textron approved facility for overhaul. Chapter 64 Examine the tail rotor blade(s) for condition.
  • Page 144 Record and attach a tag on the main rotor hub and write, "THIS MAIN ROTOR HUB ASSEMBLY WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL/SURGE." Send the component to a Bell Helicopter Textron approved facility for overhaul. If no defects were detected on main rotor hub, the main rotor hub is serviceable.
  • Page 145 Historical Service Record and attach a tag on the driveshaft and write, “THIS COMPONENT WAS REMOVED FORM SERVICE BECAUSE OF A COMPRESSOR STALL”. Send the driveshaft to Bell Helicopter Textron CPR for evaluation. Refer to IL GEN-04-98. defects...
  • Page 146 Make an entry on the applicable components Historical Service Record and attach a tag and write, “THIS COMPONENT WAS REMOVED FROM SERVICE BECAUSE OF A COMPRESSOR STALL/SURGE”. Send the component to a Bell Helicopter Textron approved facility for overhaul. 5-00-00 Page 82F Rev.
  • Page 147 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-31A. ENGINE COMPRESSOR STALL OR SURGE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER If no metal particles were found, the transmission assembly, freewheel assembly, and/or tail rotor gearbox are serviceable. 5-00-00 ECCN EAR99 29 JUL 2010 Rev. 28 Page 82G...
  • Page 148 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-32. AFTER LIGHTNING STRIKE INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ AFTER LIGHTNING STRIKE Because lightning behavior is difficult to predict, do a full inspection of the helicopter.
  • Page 149 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-32. AFTER LIGHTNING STRIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER a. the main rotor hub blades. b. the transmission and the mast. c. the pylon mount (the corner mounts and the restraints). d. the controls. e.
  • Page 150 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-32. AFTER LIGHTNING STRIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 62 MAIN ROTOR HUB AND BLADE When a lightning strike causes damage to the main rotor hub or blades, do the steps that follow: Main rotor blades.
  • Page 151 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-32. AFTER LIGHTNING STRIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER MAIN ROTOR CONTROLS Chapter 67 Inspect all fixed and rotating control components and bearings for arcing, burning, heat discoloration, welding, or other indications of lightning damage. For components with indications of lightning damage, inspect any bearings for smooth operation and the component for any damage.
  • Page 152 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-32. AFTER LIGHTNING STRIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. If the transmission and mast assembly are serviceable, then after 5 to 10 hours of operation, remove and inspect the chip detectors and filter. If an abnormal amount of unwanted material is found, remove the transmission and mast assembly.
  • Page 153 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-32. AFTER LIGHTNING STRIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Examine all of the components of the driveshafts for signs of arc burns. If you find signs of arc burns on any one component, discard all the drive shafts (except for the oil cooler impeller and housing assembly).
  • Page 154 BHT-407-MM-1 CONDITIONAL INSPECTIONS 5-32. AFTER LIGHTNING STRIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER a. Inspect blades for signs of burns and arcing at tip cap and bushings of blade bolts. Burn marks can be very small. b. Examine tail rotor blade for delamination. Tail rotor hub assembly.
  • Page 155 BHT-407-MM-1 COMPONENT INTERIM INSPECTION SCHEDULE 5-33. COMPONENT INTERIM INSPECTION NOTE SCHEDULE Refer to paragraph 5-6 for information on inspection tolerance. Component Interim Inspection Schedule (Table 5-4) provides the interim inspection time On the Component Interim Inspection Schedule, interval for each applicable helicopter component. examine the components every 60 months of component operation.
  • Page 157 BHT-407-MM-1 COMPONENT OVERHAUL SCHEDULE 5-34. COMPONENT OVERHAUL SCHEDULE The Component Overhaul Schedule (Table 5-5) CAUTION provides the time interval between overhaul for each applicable helicopter component. OVERHAUL SCHEDULE FOR SOME KIT COMPONENTS AND/OR PARTS IS NOT COVERED IN THIS SCHEDULE. REFER WARNING T O A P P L I C A B L E M A I N T E N A N C E M A N U A L S U P P L E M E N T F O R K I T...
  • Page 158 BHT-407-MM-1 Table 5-5. Component Overhaul Schedule OVERHAUL INTERVAL NOMENCLATURE PART NUMBER (HOURS) MAIN ROTOR HUB Hub Assembly 407-010-100-103 2500 hours MAIN ROTOR CONTROLS Swashplate and Support 406-010-401-115 2500 hours DRIVE SYSTEM Input Driveshaft 206-340-300-107 1250 hours Rotor Brake Disc 206-340-301-101 3000 hours Rotor Brake Caliper 206-340-301-103...
  • Page 159 TB 407-03-41, and transmission 407-040-006-111 and subsequent. Input driveshaft 206-340-300-107 must be overhauled every 1250 hours of operation. Overhaul is to be accomplished by Kamatics Corporation only. Return driveshaft to Bell Helicopter Textron (BHT) per Information Letter (IL) GEN-04-98. Refer to Chapter 4 for retirement life.
  • Page 160 BHT-407-MM-1 Table 5-5. Component Overhaul Schedule (Cont) NOTES (CONT): As identified in TB 407-04-60, a 5000-hour overhaul applies to tail rotor gearboxes 406-040-400-117/-117FM that have been modified per TB 407-00-21 and TB 407-01-31, Part I or Part II, and gearboxes 406-040-400-119 and subsequent. As used on S/N 53000 through 53442 Post BHT-407-II-30 and S/N 53443 and subsequent, refer to Northwest Dynamics Document No.
  • Page 161 BHT-407-MM-1 APPENDIX A M407 INSPECTION — CHECKLIST GENERAL Make sure that all of the applicable and the required Scheduled Inspections, Special Inspections, Technical Bulletins, Alert Service Bulletins, and Airworthiness Directives (A.D.) are completed: Make sure that the required inspections and the tests for installed optional equipment are completed: Make sure that the required Special Inspections are completed.
  • Page 163 BHT-407-MM-1 APPENDIX B M407 INSPECTION — DEFECT SHEET Review the logbook for defects and exceedances. Correct the defects on the installed equipment. Correct and make a record of the defect(s) that you identified during this inspection. For any equipment with a defect: if this equipment is not required under the current operating conditions and is not on the Master Minimum Equipment List (MMEL), you can remove it for repair.

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