BELL HELICOPTER 205A-1 Maintenance Manual
  1. Manuals
  2. Brands
  3. BELL HELICOPTER Manuals
  4. Toy
  5. 205A-1
  6. Maintenance manual

BELL HELICOPTER 205A-1 Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

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
REISSUE — 7 AUGUST 1990
REVISION 9 — 5 JULY 2016
BHT-205A1-MM-1

Advertisement

Table of Contents
loading

Related Manuals for BELL HELICOPTER 205A-1

Summary of Contents for BELL HELICOPTER 205A-1

  • Page 1 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-205A1-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-205A1-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-205A1-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 or 407...
  • 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@bh.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 IMPORTANT HELICOPTER SALES NOTICE Please complete this form and return by mail, e-mail (publications@bh.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 _________________________________________________ Name of New Owner (company or individual) ______________________________________ Name of New Operator _______________________________________________________...
  • 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-205A1-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 23: Table Of Contents

    BHT-205A1-MM-1 CHAPTER 5 — INSPECTIONS TABLE OF CONTENTS Paragraph Chapter/Section Page Number Title Number Number INSPECTIONS General ..................5-00-00 Inspection Requirements ............... 5-00-00 Crash Damage................5-00-00 Types of Inspections ..............5-00-00 Definitions ..................5-00-00 Inspection and Overhaul Tolerance ..........5-00-00 SCHEDULED INSPECTIONS Scheduled Inspections..............

  • Page 24: Table Of Contents

    BHT-205A1-MM-1 TABLE OF CONTENTS (CONT) Paragraph Chapter/Section Page Number Title Number Number 5-32 Each 3000 Hours of Component Operation........5-00-00 5-33 Each 3100 Hours of Component Operation........5-00-00 CONDITIONAL INSPECTIONS 5-34 Conditional Inspections..............5-00-00 5-35 Hard Landing ................. 5-00-00 5-36 After Blade Strike or Other Rotating System Torque Spike ...
  • Page 25 5-1. GENERAL Lead The Fleet (LTF), or any other special programs and the judgement of Bell Helicopter Textron engineers. They are subject to change only by Bell This chapter contains the requirements for the Helicopter Textron or an approved Airworthiness Scheduled, Special, and Conditional Inspections and a Authority.
  • Page 26 BHT-205A1-MM-1 Make sure the scheduled inspections, the special accordance with the degree of damage to the specific inspections, and the required tests for all of the part and the applicable repair procedures in this installed kits are complied with. manual. Call Product Support Engineering with your analysis of the crash damage.
  • Page 27 BHT-205A1-MM-1 For the common Bell Helicopter Textron approved • Maintenance — Inspection, overhaul, repair, optional equipment that is integrated into this preservation, and the replacement of parts, but maintenance manual, refer to this chapter for the excludes preventive maintenance. scheduled...

  • Page 28: Scheduled Inspections

    AIRWORTHINESS LIFE (CHAPTER 4). If approval of the inspection and overhaul tolerance is required by the applicable governing aviation authority, The Bell Helicopter Textron approved tolerance for this is the responsibility of the owner/operator. scheduled inspections, special inspections, interim inspections, and overhaul intervals, unless otherwise...
  • Page 29 BHT-205A1-MM-1 Calendar Example (10% or up to a maximum of 30 days calendar time, whichever is less): (Cont) 12-MONTH NEXT 12-MONTH MAXIMUM ALLOWED INSPECTION CARRIED INSPECTION INSPECTION TOLERANCE OUT ON: DUE ON: DUE ON: June 30, 2012 10% of 12 months = 1.2 months June 30, 2012 June 30, 2013 (maximum allowed is 30 days)
  • Page 31 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-7. SCHEDULED INSPECTIONS Inspect helicopter daily, each 100 hours, and each 1000 hours of flight operation. 5-00-00 5 JUL 2016 Rev. 9 Page 9/10 Export Classification C, ECCN EAR99...
  • Page 33 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ GENERAL All areas checked shall include a visual inspection for evidence of corrosion, particularly when helicopter is flown near or over salt water or in areas of high industrial emissions.
  • Page 34 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER External power receptacle for arcing and condition. 10. External power caution light switch for security and operation. 11. Navigation lights for damage and security. 12. Landing light for damage. 13.
  • Page 35 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Upper and lower main rotor blade surfaces for damage, evidence of corrosion, and cracks. Particular attention shall be given to the doubler area and all bond lines. Hairline cracks in the paint finish should be inspected closely for possible voids.
  • Page 36 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER 15. Stabilizer bar dampers for full fluid level and security of attachment. 16. Scissors and sleeve assembly for worn bearings and foreign object damage, condition, and security. 17.
  • Page 37 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER 28. Examine all transmission and gearbox inspection windows and sight glasses for cracking, crazing, and discoloration. If any of these conditions are present, the part must be removed and replaced prior to returning helicopter to service.
  • Page 38 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER 41. Hydraulic reservoirs for proper oil level. Chapter 29 42. Hydraulic reservoir temperature indicator TEMP-PLATES ASB 205-06-73-1 for discoloration and overheat condition. A change in color of temperature indicator indicates...
  • Page 39 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Tail rotor gearbox for security and obvious damage and oil leakage. Input quill coupling and surrounding area for grease leakage. Oil for proper level. Chapter 66 Inspect coupling temperature indicator TEMP-PLATES for overheat condition.
  • Page 40 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Cabin doors for corrosion, damage, distortion, security, and freedom of operation. Cabin doorpost and forward crew door for cracks and cabin door seals for security and condition. Emergency escape panel mechanism locking pin for proper engagement and security.
  • Page 41 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-8. DAILY INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER 17. Cyclic, collective, and anti-torque controls for visible damage, security, and for proper feel and response. 18. Check for indications of "pop-up" red buttons on the integrated valve and filter assembly.

  • Page 42: Inspection Of Main Rotor Hub Grip Tangs And Barrel

    BHT-205A1-MM-1 Figure 5-1. Inspection of Main Rotor Hub Grip Tangs and Barrel 5-00-00 Page 20 Rev. 7 8 JUL 2013 Export Classification C, ECCN EAR99...
  • Page 43 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Accomplish complete daily inspection in conjunction with the following: MAIN ROTOR Main rotor blades for evidence of bond failure and leading...
  • Page 44 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Clean tail rotor blades to maintain improved visibility. TRANSMISSION Visually inspect main case for cracks in web above input quill. NOTE When three-micron filter element 204-040-760-105 is installed, oil need not be drained and element need not be replaced until 1/2 of the transmission Time Between Overhaul period or 12 months is reached.
  • Page 45 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER TRANSMISSION DEBRIS MONITOR Remove full flow monitor from transmission sump case. Remove cup and screen tube from monitor. Visually inspect screen tube for contamination and non-magnetic debris. Inspect external surface of monitor and chip detectors for magnetic chips and particles.
  • Page 46 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Service intermediate and tail rotor gearboxes to proper oil level. Check condition of clamps for tail rotor shaft coupling to gearbox couplings. Inspect clamps for evidence of cracks in or near the bolt hole lugs.
  • Page 47 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. Open access door on right side of fuselage and inspect the four tailboom attachment fittings on fuselage aft bulkhead for cracks, giving special attention to the area around tailboom attachment bolt and most aft fasteners.
  • Page 48 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Check all heating and cooling ducts and controls for cracks, security, and operation. Check cabin structure for cracks, loose rivets, and other damage. FUSELAGE Inspect friction dampers.
  • Page 49 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Remove battery and perform reconditioning cycle in accordance with battery instruction manual. Install serviceable battery. FLIGHT CONTROLS Inspect all control rods for clearances, security, and general condition.
  • Page 50 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Elevator rigging for proper setting and travel. Check elevator horn for security, mechanical damage, and corrosion. Trailing edge tabs and tip caps for condition and security. Every sixth 100 hour inspection (600 hours) or 12 months: Remove left and right elevators.
  • Page 51 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-9. 100 HOUR INSPECTION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 29 Check cyclic hydraulic cylinders piston rods for evidence of excessive wear or scoring. Wear of the piston rod indicates cylinder assembly is incorrectly aligned to lower supports and should be readjusted.
  • Page 53 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-10. 1000 HOUR INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Accomplish complete Daily and 100 Hour Inspections in conjunction with the following: Remove and replace components as scheduled in component overhaul schedule...
  • Page 54 BHT-205A1-MM-1 SCHEDULED INSPECTIONS 5-10. 1000 HOUR INSPECTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 65 Inspect swashplate and support assembly 204-011-400-17 subsequent, scissors sleeve assembly 204-011-401-019 and subsequent. Disconnect bottom of each drive link from swashplate trunnion and each mixing lever control tube from scissors.
  • Page 55 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-11. SPECIAL INSPECTIONS 12. Each 500 hours of component operation. Perform applicable special inspection of helicopter: 13. Each 600 hours/12 months of tail rotor driveshaft coupling operation. Daily inspection. 14. Each 600 hours or 12 months of component Daily or each 10 hours of flight, whichever occurs operation, whichever occurs first.
  • Page 57 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-12. DAILY OR EACH 10 HOURS OF FLIGHT OPERATION, WHICHEVER OCCURS FIRST UNTIL 250 HOURS INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE...
  • Page 58 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-12. DAILY OR EACH 10 HOURS OF FLIGHT OPERATION, WHICHEVER OCCURS FIRST UNTIL 250 HOURS (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER b. Utilizing port opening in main gear case and a bright light and mirror, inspect all 62 teeth in spiral bevel gear 204-040-701-103.

  • Page 59: Spiral Bevel Gear Serial Numbers

    BHT-205A1-MM-1 212_MM_05_0010+ Figure 5-2. Spiral Bevel Gear Serial Numbers 5-00-00 Export Classification C, ECCN EAR99 8 JUL 2013 Rev. 7 Page 37...

  • Page 60: Inspection Of Spiral Bevel Gear

    BHT-205A1-MM-1 ROTOR BRAKE QUILL PORT LOOKING UP THROUGH ROTOR BRAKE QUILL PORT MANUFACTURING FLATS INPUT PINION COAST SIDE PATTERN (VERY LIGHT) LOCATED AT ONE OR TWO POSITIONS NOT ACCEPTABLE DETACHED STRIKE MARKS USUALLY ONE PER TOOTH USUALLY ON ONE OR MORE GROUPS OF 2, 3 OR 4 TEETH SCORED PATCH NOT CONCAVE SIDE...
  • Page 61 BHT-205A1-MM-1 REGISTRATION NO.__________________________ SPIRAL BEVEL GEAR (204-040-701) UNACCEPTABLE PATTERN SPIRAL BEVEL GEAR (204-040-701) UNACCEPTABLE PATTERN 212_MM_05_0005+ Figure 5-3. Inspection of Spiral Bevel Gear (Sheet 2 of 3) 5-00-00 Export Classification C, ECCN EAR99 8 JUL 2013 Rev. 7 Page 39...
  • Page 62 BHT-205A1-MM-1 REGISTRATION NO.__________________________ SPIRAL BEVEL GEAR (204-040-701) UNACCEPTABLE PATTERN SPIRAL BEVEL GEAR (204-040-701) UNACCEPTABLE PATTERN 212_MM_05_0006+ Figure 5-3. Inspection of Spiral Bevel Gear (Sheet 3 of 3) 5-00-00 Page 40 Rev. 7 8 JUL 2013 Export Classification C, ECCN EAR99...
  • Page 63 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-13. BETWEEN 5 AND 10 HOURS OF FLIGHT AFTER EACH INSTALLATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE Accomplish between 5 and 10 hours of flight after...
  • Page 64 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-13. BETWEEN 5 AND 10 HOURS OF FLIGHT AFTER EACH INSTALLATION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 66 INTERMEDIATE GEARBOX Torque check intermediate gearbox retaining bolts 50 to 70 inch-pounds (5.7 to 7.9 Nm). 5-00-00 Page 42 Rev.
  • Page 65 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-14. EACH 8 HOURS OF COMPONENT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Accomplish inspection of fin spar caps 212-030-447-001 and 212-030-447-101 every 8 flight hours.
  • Page 67 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-15. EACH 25 HOURS OF COMPONENT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ SWASHPLATE GIMBAL RING BOLTS NOTE Do not attempt to turn bolts.
  • Page 68 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-15. EACH 25 HOURS OF COMPONENT OPERATION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER MAIN ROTOR HUB GRIP 204-011-121 — Detailed Visual Inspection Prepare both main rotor grip tangs for inspection by cleaning exposed surfaces with. denatured alcohol (C-326) and wipe dry.
  • Page 69 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-15. EACH 25 HOURS OF COMPONENT OPERATION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER TAIL ROTOR STATIC STOP ASB 205-96-68 Inspect trunnion assembly 212-010-738 or 212-011-713 ASB 205-96-69 flapping stop for yielding as noted in Chapter 65 to determine if tail rotor yoke assembly may have been exposed to bending.
  • Page 70 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-15. EACH 25 HOURS OF COMPONENT OPERATION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Only superficial corrosion that can be removed with aluminum wool or very fine grade abrasive pad (C-407) is permissible. Corrosion on the spar 0.003 inch deep or less is acceptable when polished out.

  • Page 71: Tail Rotor Blade - Special Inspection

    BHT-205A1-MM-1 5.00 20.00 35.00 51.00 MAGNIFICATION MAGNIFICATION MAGNIFICATION 412_MM_05_0003+ Figure 5-4. Tail Rotor Blade — Special Inspection 5-00-00 8 JUL 2013 Rev. 7 Page 49/50 Export Classification C, ECCN EAR99...
  • Page 73 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-16. EACH 25 HOURS FOR THE NEXT FOUR INSPECTIONS INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ TAIL ROTOR HANGER BEARINGS WITNESS MARKS NOTE Accomplish visual inspection of witness (only...
  • Page 74 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-16. EACH 25 HOURS FOR THE NEXT FOUR INSPECTIONS (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Remove any hanger bearing from service where the witness marks indicate that the grease shield has moved. 5-00-00 Page 52 Rev.
  • Page 75 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-17. EACH 25 HOURS OF COMPONENT OPERATION OR 15 DAYS, OR EACH 5 DAYS FOR BLADES OPERATING IN SALT LADEN ATMOSPHERE, WHICHEVER OCCURS FIRST INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________...
  • Page 77 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-18. 100 HOURS AFTER EACH INSTALLATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 53 Torque check tailboom attachment bolts.
  • Page 79 II or III ultrasonic capability for further investigation. All grips that have a crack indication and have been inspected by a level II or III are to be sent to Bell Helicopter Textron. Refer to Information Letter IL GEN-04-98 for shipping instructions.
  • Page 81 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-20. EACH 300 HOURS OF COMPONENT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ STARTER-GENERATOR Chapter 96 Check starter-generator for allowable brush wear.
  • Page 83 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-21. EACH 300 HOURS OR 3 MONTHS OF COMPONENT OPERATION, WHICHEVER OCCURS FIRST INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ MAIN DRIVESHAFT 205-040-004-017...
  • Page 85 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-22. EACH 500 HOURS OF COMPONENT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ FIRE DETECTOR SYSTEM BHT-205A1-MM-2 Test fire detector system with Pyrotector 30-502 tester or...
  • Page 87 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-23. EACH 600 HOURS/12 MONTHS OF TAIL ROTOR DRIVESHAFT COUPLING OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE Accomplish each 600 hours of component operation...
  • Page 89 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-24. EACH 600 HOURS OR 12 MONTHS OF COMPONENT OPERATION, WHICHEVER OCCURS FIRST INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ MAIN DRIVESHAFT 205-040-004-003, 011, AND -103...
  • Page 90 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-24. EACH 600 HOURS OR 12 MONTHS OF COMPONENT OPERATION, WHICHEVER OCCURS FIRST (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Visually inspect driveshaft for obvious mechanical damage, flexplate looseness, corrosion, and/or fretting at flexplate bolted joints.
  • Page 91 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-25. EACH 6 MONTHS INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 52 Perform operational check of crew doors emergency ejection system.
  • Page 93 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-26. EACH 12 MONTHS INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ GENERAL Inspect all fuel system, oil system, and hydraulic system filler caps for proper functioning and sealing.
  • Page 95 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-27. EACH 1000 HOURS OR 12 MONTHS OF COMPONENT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Chapter 65 Inspect main rotor blades 204-011-250-ALL.
  • Page 97 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-28. FIRST 1000 HOURS OF COMPONENT TIME AND EACH 3000 HOURS THEREAFTER OF COMPONENT TIME INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE...
  • Page 98 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-28. FIRST 1000 HOURS OF COMPONENT TIME AND EACH 3000 HOURS THEREAFTER OF COMPONENT TIME (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Inspect flight control tube assemblies 205-076-176-001, 205-076-164-005, and 212-076-151-001/-007 as follows: a. Measure and record overall length of control tube, and then remove adjustable clevis.
  • Page 99 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-29. EACH 1200 HOURS OF COMPONENT OPERATION — DELETED INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER NOTE The Each 1200 Hours of Component Operation special inspection been moved 1200 Hours or 24 Months, Whichever Occurs First, special inspection (paragraph 5-30).
  • Page 101 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-30. EACH 1200 HOURS OR 24 MONTHS, WHICHEVER COMES FIRST INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE Accomplish each 1200 hours/24 months (whichever...
  • Page 102 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-30. EACH 1200 HOURS OR 24 MONTHS, WHICHEVER COMES FIRST (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER MAIN ROTOR YOKE 212-011-102 — Detailed Visual Inspection BHT-205A1-CR&O-1 Remove bearing races and spacers. Inspect yoke spindle for cracks and corrosion pits. Inspect yoke spindle bearing journals for wear.
  • Page 103 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-30. EACH 1200 HOURS OR 24 MONTHS, WHICHEVER COMES FIRST (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Inspect buffer pads tang inner surfaces delamination. Any delamination will require buffer pad replacement (Figure 5-5). 5-00-00 Export Classification C, ECCN EAR99 8 JUL 2013 Rev.

  • Page 104: Inspection Of Main Rotor Hub Grip Tangs And Barrel (1200 Hours/24 Months)

    BHT-205A1-MM-1 Figure 5-5. Inspection of Main Rotor Hub Grip Tangs and Barrel (1200 Hours/24 Months) 5-00-00 Page 82 Rev. 7 8 JUL 2013 Export Classification C, ECCN EAR99...
  • Page 105 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-31. EACH 24 MONTHS OF FLIGHT CONTROL SYSTEM BOLT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE Accomplish each 24 months of flight control system...
  • Page 106 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-31. EACH 24 MONTHS OF FLIGHT CONTROL SYSTEM BOLT OPERATION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER e. Two mixing lever to scissors tubes bolts 20-057-5-27D. f. Two scissors tube to scissors bolts 20-057-5-27D. g. Two pitch link to universal tube bolts 20-057-6-27D. h.
  • Page 107 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-31. EACH 24 MONTHS OF FLIGHT CONTROL SYSTEM BOLT OPERATION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER v. Deleted. Clean bolts with cloth dampened with MEK (C-309). Inspect bolts for thread damage, shank wear, and corrosion.

  • Page 109: Each 3000 Hours Of Component Operation

    BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-32. EACH 3000 HOURS OF COMPONENT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ MAIN ROTOR MAST BHT-205A1-CR&O-1 Inspect inside and outside diameters of mast for corrosion...

  • Page 111: Each 3100 Hours Of Component Operation

    BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-33. EACH 3100 HOURS OF COMPONENT OPERATION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ TRANSMISSION 212-040-001-135 Chapter 66 Remove main input driven gear quill.
  • Page 112 Perform complete inspection clutch Chapter 66 205-040-350-101/-103 (FORMSPRAG). BHT-205A-1-CR&O-1 Visually inspect bevel gear teeth and main input pinion teeth for general condition and wear pattern. BHT-205A1-CR&O-1, Inspect planetary ring gear, sun gears, and planetary Chapter 66 pinions for general condition and wear pattern. Inspect all parts of upper and lower planetary visually for wear and damage.
  • Page 113 BHT-205A1-MM-1 SPECIAL INSPECTIONS 5-33. EACH 3100 HOURS OF COMPONENT OPERATION (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER CAUTION DURING ASSEMBLY OF SPIRAL BEVEL GEAR TO SHAFT, ENSURE MATING SURFACES ARE DRY. ANY FORM OF LUBRICANT ON SHAFT WILL RESULT IN TORQUE LOSS OF ATTACHMENT BOLTS AND SUBSEQUENT FRETTING DAMAGE.

  • Page 115: Conditional Inspections

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-34. CONDITIONAL INSPECTIONS If overhaul evaluation is specified, complete both the conditional inspection and normal inspection procedures (as applicable) for that component listed in Perform applicable conditional inspection of BHT-205-CR&O-1 manual. helicopter after hard landing, after blade strike or other rotating system torque spike, sudden stoppage/ If applicable conditional inspection does not acceleration...

  • Page 117: Hard Landing

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-35. HARD LANDING INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Hard landing is defined as any accident or incident in which ground impact of the helicopter causes severe pitching of main rotor, allowing hard contact of hub with mast, or results in yielding or cracking the mounting lugs of the transmission...
  • Page 118 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-35. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER (1) If crosstubes have yielded, remove landing gear and inspect support and structure to which they are attached for signs of yielding or other damage. (2) If supports and attaching structure are not damaged, replace damaged landing gear components.
  • Page 119 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-35. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER (1) Main rotor blades. (2) Main rotor hub. (3) Tail rotor blades. (4) Tail rotor hub. NOTE Inspect tail rotor flapping stop for yielding to determine if tail rotor yoke assembly may have been exposed to bending (Chapter 65).
  • Page 120 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-35. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER NOTE If significant damage has been found in any area of the airframe, inspection shall be expanded in those areas until it extends beyond the zone of damage. d.
  • Page 121 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-35. HARD LANDING (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER l. Pressurize hydraulic system and check for leaks, interference, binding, and for satisfactory operation. m. Inspect fuel, oil and pneumatic system for damage. Make engine ground run and visually check fuel, oil and pneumatic lines for leaks Inspect power...

  • Page 123: After Blade Strike Or Other Rotating System Torque Spike

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-36. AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE To be accomplished after a main blade or tail rotor...
  • Page 124 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-36. AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Tail rotor blades — Any impact damage to the leading edge or lower skin that exceeds the limits specified in Chapter 65.
  • Page 125 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-36. AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER NOTE Components removed from helicopter evaluation following a sudden stoppage shall be evaluated as an interrelated group. Removal records accompanying each component...
  • Page 126 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-36. AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER c. Pylon control components: BHT-205A1-CR&O-1 (1) If one or more of the following discrepancies in step (a) through step (d) are found, swashplate assembly and hub and sleeve assembly shall be removed and an overhaul evaluation shall be performed.
  • Page 127 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-36. AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER NOTE If transmission and mast assembly are removed for overhaul evaluation, both components shall be evaluated for serviceability as a set. BHT-205A1-CR&O-1 (2) If blade strike incident was confirmed but the main rotor mast is not visibly bent or twisted, an overhaul evaluation...
  • Page 128 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-36. AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 66 (2) If no damage that would render the tail rotor driveshaft unserviceable is noted, further inspect the tail rotor driveshafts in accordance with the requirements specified in Chapter 66.
  • Page 129 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-36. AFTER BLADE STRIKE OR OTHER ROTATING SYSTEM TORQUE SPIKE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER l. Transmission sump assembly: NOTE If transmission assembly has already been removed for overhaul omit, step l. If no evidence of damage was found in step g through step k, omit step (1) through step (3).

  • Page 131: Deleted

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-37. DELETED INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER 5-00-00 5 JUL 2016 Rev. 9 Page 109/110 Export Classification C, ECCN EAR99...

  • Page 133: Deleted

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-38. DELETED INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER 5-00-00 5 JUL 2016 Rev. 9 Page 111/112 Export Classification C, ECCN EAR99...

  • Page 135: Overspeed

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-39. OVERSPEED INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Overspeed is defined as any incident in which 110% main rotor RPM is exceeded and/or engine overspeed limits in engine manufacturer's manual are exceeded.
  • Page 136 (4) If discrepancies are found in step (1) and step (2) above, return both blades to a Bell Helicopter Textron authorized blade repair facility. Make an entry in component record to show that reason for removal was Overspeed. Indicate percent and duration if known.
  • Page 137 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-39. OVERSPEED (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER g. Perform a close inspection of the following components. If no visual damage is found, the components may be retained in service. (1) Main transmission. (2) Intermediate gearbox. (3) Tail rotor gearbox.

  • Page 139: Overtorque

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-40. OVERTORQUE INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Overtorque is defined as any incident in which torsional loads are introduced into the helicopter dynamic system in excess of established limits.
  • Page 140 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-40. OVERTORQUE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER e. Intermediate gearbox. f. Tail rotor gearbox. g. Tail rotor driveshafts. h. Tail rotor driveshaft hangers. i. Stabilizer bar assembly. j. Swashplate. k. Scissors and sleeve assembly. l.
  • Page 141 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-40. OVERTORQUE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER e. If chip detector, internal filter, and pump inlet screen appear normal and there is no evidence of internal failure, operate the transmission for 5 hours, then check chip detector, internal filter, and pump inlet screen.
  • Page 142 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-40. OVERTORQUE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER c. Remove fifth mount bolts, and remove fifth mount. Perform a thorough inspection of bolts and fifth mount support. Check for bent bolts and bent fifth mount support. Check for proper bolt hole alignment between transmission and fifth mount support.

  • Page 143: Compressor Stall Or Surge

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-41. COMPRESSOR STALL OR SURGE INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Engine compressor stall or surge is characterized by a sharp rumble or a series of load sharp reports, severe engine vibration and a rapid rise in exhaust gas temperature (EGT), depending on severity of surge.
  • Page 144 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-41. COMPRESSOR STALL OR SURGE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Power train. a. If compressor stall occurs below 85% N1 speed, comply with the following step (1) and step (2). (1) Remove magnetic chip detectors from...
  • Page 145 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-41. COMPRESSOR STALL OR SURGE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER (4) Remove the tail rotor drive quill from the transmission and inspect the gear teeth for damage with a 10X magnifying glass. If there is no indication of scoring or scuffing and there is no other damage that would render the transmission unserviceable, it is suitable for continued use.
  • Page 146 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-41. COMPRESSOR STALL OR SURGE (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Airframe. a. Check tailboom vertical fin for evidence of damaged skin panels and/or structure and rivets for looseness and/or sheared heads. If inspection does not indicate evidence of damage, return helicopter to service.

  • Page 147: Lightning Strikes

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-42. LIGHTNING STRIKES INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ NOTE In all instances below, if significant damage has been found in any area, inspection shall be expanded in those areas until it extends beyond zone of damage.
  • Page 148 Any evidence of arc burning or pitting is cause for rejection. (3) Remove flex-frame coupling driveshaft and return it to Bell Helicopter Textron for evaluation (IL GEN-04-98). Do not disassemble the couplings. d. Remove the tail rotor output coupling from the main transmission assembly and all other crown-tooth couplings from the tail rotor drive system for inspection.
  • Page 149 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-42. LIGHTNING STRIKES (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER Chapter 66 (1) Remove inspect transmission chip detectors and debris monitor. (2) If any evidence of arc burning or pitting is noted or excessive debris is found, remove transmission and mast assembly for overhaul.
  • Page 150 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-42. LIGHTNING STRIKES (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER (1) If excessive debris is found on chip detectors, remove transmission and mast assembly for overhaul. (2) If little or no debris is found, operate helicopter light on skids for 1 hour.
  • Page 151 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-42. LIGHTNING STRIKES (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER When established lightning struck helicopter, inspections of electrical and instrument systems which follow are mandatory to ensure safety of flight: a. Inspect all electrical wiring, bundles, and connectors for burning or electrical arcing.
  • Page 152 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-42. LIGHTNING STRIKES (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER g. Perform operational check on all instruments. Remove and repair/replace instruments and sensor found to be defective. h. Perform operational check on all caution messages for proper operation.
  • Page 153 BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-42. LIGHTNING STRIKES (CONT) INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER d. Any airframe metal parts not specifically identified above, but are suspect, shall be noted in maintenance log and shall be reinspected prior to next 100 hours of flight. Inspect avionics systems: a.

  • Page 155: Magnetic Compass Malfunction

    BHT-205A1-MM-1 CONDITIONAL INSPECTIONS 5-43. MAGNETIC COMPASS MALFUNCTION INITIAL DATA REFERENCE INSPECTION TASK DESCRIPTION MECH OTHER DATE: __________________W.O. _____________________ FACILITY: _________________ _ ________________________ HELICOPTER S/N: __________ _ ________________________ REGISTRY NO.: ____________ _ ________________________ TOTAL TIME:_______________________________________ SIGNATURE:_______________ _ ________________________ Check magnetic compass for accuracy. If excessive error is indicated, the compass must be calibrated using standard compensating methods.

  • Page 157: Component Overhaul Schedule

    BHT-205A1-MM-1 COMPONENT OVERHAUL SCHEDULE 5-44. COMPONENT OVERHAUL SCHEDULE CAUTION The Component Overhaul Schedule (Table 5-1) 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 A P P L I C A B L E S E R V I C E...
  • Page 158 BHT-205A1-MM-1 Table 5-1. Component Overhaul Schedule (Cont) OVERHAUL INTERVAL NOMENCLATURE PART NUMBER (HOURS) ROTORS (CONT) Scissors and Sleeve 204-011-401-009/-011 1000 hours Scissors and Sleeve 204-011-401-019/-021 Conditional Main Rotor Hub 204-012-101-005 2400 hours Stabilizer Bar Assembly 212-010-300-001 Conditional Tail Rotor Hub Assembly 212-010-701-ALL 1000 hours Tail Rotor Hub Assembly...
  • Page 159 BHT-205A1-MM-1 Table 5-1. Component Overhaul Schedule (Cont) OVERHAUL INTERVAL NOMENCLATURE PART NUMBER (HOURS) POWER TRAIN (CONT) Tail Rotor Driveshaft 212-040-600 3000 hours Hangers HYDRAULIC Collective Servo Actuator 205-076-030-001 2400 hours Anti-torque Servo Actuator 205-076-031-001/-003 Conditional Cyclic Servo Actuator 205-076-036-007/-009/-011/-013/-101/-103/ 1000 hours -105/-107 Hydraulic Accumulator 205-076-041-001...
  • Page 160 BHT-205A1-MM-1 Table 5-1. Component Overhaul Schedule (Cont) NOTES (CONT): The following items are to be overhauled every 2500 hours of operation: a. Idler assembly 209-011-711-ALL b. Lever assembly 209-011-712-ALL c. Nut, tail rotor retention 212-010-706-ALL d. Crosshead 212-010-775-ALL e. Link assembly 209-011-713-ALL Special inspection required at 3000 hours (paragraph 5-32).

Table of Contents