BHT-212-CRO-3[1].PDF Repair Manual Main Rotor

BHT-212-CR&O

MODEL

COMPONENT REPAIR ANDOVERHAUL MANUAL

VOLUME 3MAIN ROTOR/

MAIN ROTOR DRIVE SYSTEMNOTICE

The instructions set forth in this manual, as supplemented or modified by Alert Service Bulletinsand other directions issued by Bell Helicopter Textron Inc. and Airworthiness Directives issuedby the Federal Aviation Administration, shall be strictly followed.

Bell HelicopterCOPYRIGHT NOTICE A Subsidiary of Textron Inc.

COPYRIGHT 1997 POST OFFICE BOX 482 * FORT WORTH. TEXAS 76101BELL ® HELICOPTER TEXTRON INC.AND BELL HELICOPTER TEXTRON,A DIVISION OF TEXTRON CANADA LTD.

ALL RIGHTS RESERVED 26 JULY 1993

REVISION 4 - 19 JUNE 1997

BHT-212-CR&O

PROPRIETARY RIGHTS NOTICE

These data are proprietary to Bell Helicopter Textron, Inc. Disclosure,reproduction, or use of these data for any purpose other than helicopteroperation and/or maintenance is forbidden without prior writtenauthorization from Bell Helicopter Textron, Inc.

Additional copies of this publication may be obtained by contacting:Commercial Publication Distribution Center

Bell Helicopter TextronP. O. Box 482

Fort Worth, Texas 76101-0482

PN

BHT-212-CR&0

CHAPTER 62 - MAIN ROTOR

CONTENTS - MAINTENANCE PROCEDURES

Paragraph Chapter/Section PageNumber Title Number Number

62-1 Main Rotor ....................................... 62-00-00 7/8

MAIN ROTOR HUB AND BLADES

62-2 Main rotor hub and blades ....................... 62-00-00 962-8 Overhaul ....................................... 62-00-00 9

MAIN ROTOR BLADES

62-7 Main rotor blades ................................ 62-00-00 1562-8 Overhaul ....................................... 62-00-00 1562-14 Main rotor blade splice cover .................. 62-00-00 30

MAIN ROTOR HUB

62-17 Main rotor hub ................................... 62-00-00 3362-18 Overhaul . ...................................... 62-00-00 3362-22 Repair ......................................... 62-00-00 6262-23 Assembly ...................................... 62-00-00 7162-24 Balancing ...................................... 62-00-00 78

MAIN ROTOR CONTROLS

62-25 Main rotor controls ............................... 62-00-00 87/88

STABILIZER BAR

62-26 Stabilizer bar ..................................... 62-00-00 8962-27 Disassembly ................................... 62-00-00 8962-28 Inspection ...................................... 62-00-00 8962-31 Repair ......................................... 62-00-00 9362-32 Assembly ...................................... 62-00-00 9962-33 Balancing ...................................... 62-00-00 10262-34 Inspection and repair of stabilizer bar

dampers and adapters ......................... 62-00-00 103

SCISSORS AND SLEEVE

62-35 Scissors and sleeve ............................. 62-00-00 10962-36 Disassembly ................................... 62-00-00 10962-37 Inspection...................................... 62-00-00 11062-40 Repair ......................................... 62-00-00 116A62-41 Assembly ...................................... 62-00-00 120

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BHT-212-CR&0

CONTENTS - MAINTENANCE PROCEDURES (Cont)


SWASHPLATE AND SUPPORT

62-42 Swashplate and support overhaul ................ 62-00-00 12362-43 Disassembly ................................... 62-00-00 12362-44 Cleaning ....................................... 62-00-00 12462-45 Inspection ...................................... 62-00-00 12462-48 Repair ......................................... 62-00-00 13062-49 Assembly ...................................... 62-00-00 138

COLLECTIVE LEVER

62-50 Collective lever ................................... 62-00-00 14162-51 Inspection and repair .......................... 62-00-00 141

MAIN ROTOR PITCH CHANGE LINK

62-52 Pitch change link ................................. 62-00-00 14562-53 Inspection ...................................... 62-00-00 14562-54 Repair ......................................... 62-00-00 145

FIGURES

Figure PageNumber Title Number

62-1 Main rotor hub and blade ............................................. 1162-2 Main rotor blade bolt extractor ........................................ 1262-3 Main rotor blade alignment............................................ 1362-4 Main rotor blade ....................................................... 1662-5 Main rotor blade damage and repair units ............................ 2362-6 Main rotor blade trailing edge repair .................................. 2462-7 Troubleshooting detector unit ......................................... 2662-8 Electrical conductive plug-pin location ................................ 2762-9 Crack locator assembly and driver assembly .......................... 2862-10 Electrical conductive paint location .................................... 3062-11 Main rotor hub outboard section ...................................... 3562-12 Main rotor yoke ....................................................... 3762-13 Yoke disassembly tool ................................................ 3962-14 Main rotor hub grip .................................................... 4062-15 Grip disassembly tool ................................................. 4162-16 Main rotor trunnion and pillow block .................................. 4262-17 Trunnion and pillow block disassembly tool ........................... 4562-18 Blade bolt, drag brace, and pitch horn damage limits ................. 5362-19 Main rotor hub wear limits ........................................... 54A/54B62-20 Outboard fitting, inboard fitting, and pillow block damage limits....... 57

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BHT-212-CR&0

FIGURES (Cont)


62-21 Main rotor grip, yoke, yoke nut, and trunnion damage limits .......... 6162-21A Spindle journal wear step limits ....................................... 6162-22 Trunnion limits chart .................................................. 6362-23 Main rotor yoke refinishing areas ..................................... 6762-24 Main rotor hub grip bushing replacement ............................. 6962-25 Pillow block buffer..................................................... 7262-26 Seal installation (new style) ........................................... 7462-27 Drag brace assembly . ............................................. 7762-28 Centering trunnion on hub ............................................ 7962-29 Main rotor hub grip spacing ........................................... 8062-30 Main rotor hub balancing .............................................. 8162-31 Balancing kit .......................................................... 8362-32 Main rotor hub balancing (alternate procedures) ...................... 8462-33 Stabilizer bar ......................................................... 9162-34 Stabilizer bar mixing lever and support damage limits ................ 9562-35 Stabilizer bar tube and frame damage limits .......................... 9662-36 Stabilizer bar control tube damage limits .............................. 9762-37 Shimming procedure for 212-010-302 mixing lever .................... 10162-38 Tube assembly 212-010-311 or 540-011-319 ......................... 10462-39 Stabilizer bar balancing ............................................... 10562-40 Stabilizer bar dampers ................................................ 10662-41 Damper lever damage and repair limits ............................... 10762-42 Damper, damper tube, and adapter damage and repair limits ......... 10862-43 Drive plate wear check ................................................ 11162-44 Scissors and sleeve ................................................... 11262-45 Scissors and drive link damage limits ................................ 11562-46 Hub and sleeve damage limits ........................................ 11662-47 Scissors and sleeve wear limits ....................................... 11962-48 Swashplate and support assembly .................................... 12562-49 Trunnion removal and installation workaid ............................ 12762-50 Swashplate inner and outer ring damage limits ....................... 12962-51 Swashplate support damage limits .................................... 13362-52 Swashplate and support wear limits ................................... 13562-53 Inner ring bushing replacement dimensions ........................... 13662-54 Support bushing replacement dimensions ............................. 13762-55 Collective lever........................................................ 14262-56 Collective lever damage limits ........................................ 14262-57 Collective lever wear limits ........................................... 14362-58 Pitch change link damage and repair limits ........................... 146

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BHT-212-CR&O

CONSUMABLE MATERIAL LIST

The following consumable materials are required to perform the maintenance procedures withinthis chapter.

ITEM CAGE/FSCM/NO. NOMENCLATURE SOURCE

C-005 Lubricant, Solid Film, MIL-L-46010 Commercial

C-006 Use item C-021

C-007 Grease, Oscillation Bearing, MIL-G-25537 Commercial

C-013 Lubricating Oil (10W30), MIL-L-46152 Commercial

C-015 Lubricant (Tube Pack) 204-040-755-5 97499

C-017 Lubricant, Fluorosilicone, Dow Corning No. FS 3452 71984

C-021 Lubricant, Solid Film, Air Cure (Aerosol), MIL-L-23398, 34568

Type II or Tiolube 70

C-100 Chemical Film Material (Alodine 1200 or 1201) MIL-C-81706,Class 1A, Commercial

Form II (Dip Tank) or III (Brush-on).

Apply per MIL-C-5541.

C-101 Corrosion Preventive Compound, MIL-C-16173, Grade 1 Commercial


C-105 Corrosion Preventive; Fingerprint Remover, MIL-C-15074 98308

C-108 LHE Cadmium Plating Solution (For Brush Cadmium 13929

Plating)

C-109 Oaktite Corrosion, Protective Oil or 44389Turco T-543 or 61102Vantrol 4130 30479


C-201 Zinc Chromate Primer, TT-P-1757 Commercial

C-202 Epoxy (Super-Koropon) Primer 22873

C-203 Acrylic Lacquer, MIL-L-81352. Refer to text for color. Commercial

C-204 Epoxy Polyamide Primer, MIL-P-23377, MIL-P-85582, 22873

Type I. Refer to text for color

C-206 Thinner for Acrylic Nitrocellulose Lacquer, MIL-T-19544 Commercial

(Use with Item C-216)

C-207 Epoxy Enamel, 299-947-096 (British Spec. DTD 5555A) 97499

C-208 Epoxy/Zinc Coating, Code 2320-CL-5 06613

C-224 Silver Conductive Paint, SC15 91925

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BHT-212-CR&0

CONSUMABLE MATERIAL LIST (Cont)


C-234 Primer, Urethane Compatible; Base-513X329, Curing 22873

Agent-910X456

C-242 Paint Remover, Epoxy Polyurethane, Dechem 2236A Commercial

C-301 Adhesive, 299-947, Type I 97499

C-304 Solvent, Drycleaning, P-D-680, Type II, pH Insignificant Commercial

C-305 Aliphatic Naphtha, TT-T-548 Commercial

C-306 Toluene, TT-T-548 Commercial

C-308 Adhesive, Sealant, 299-947-107, Type III, Class 7, MIL- 971499

S-8802, Class B2 or 83527Proseal 890 83574

C-309 Methyl-Ethyl-Ketone (MEK), TT-M-261B, pH Insignificant Commercial

(Alternate where MEK use prohibited: RHO SOLV 756) 83527

C-313 Adhesive, 299-947-099 or 97499Metal Set A-4 or 90414EA9340 or 33564RP1258 02684

C-316 Acetone, Q-A-51 Commercial

C-317 Adhesive, Magnabond 6398 (299-947-100, Type II, Class 22121

2) 97499

C-320 Sealant, MIL-S-22473 05972

Grade AV

Grade CV (Blue)

Grade HV (Brown)

Grade AA (Green)

Loctite 222 or Grade E (Purple)

Grade T (Yellow)

C-322 Adhesive, EC2216 04963

C-325 Adhesive, 299-947-107, Type II, Class 5 97499

C-326 Denatured Alcohol Commercial

C-327 Adhesion Promoter, A-934-BXTT 1H543

C-328 Sealing Compound, Pro-Seal 706, Class B-2 or PRC- 83574

1321, Class B-2, or CS3300B, MIL-S-8784 21509

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BHT-212-CR&0



C-331 Adhesive, 299-947-125, Type I 97499EA9309NA 33564

C-334 1.1.1-Trichoroethane, MIL-T-81533 (Vapor) or Commercial

O-T-620 (Cold)

C-335 Use item C-320

C-344 Alcoholic Phosphoric Cleaner (Turco W.O. 1) pH 7 61102

C-363 Adhesive, 299-947-100, Type II, Class 3 (Hysol EA956) 97499

C-368 Tetra-Etch 60622

C-405 Lockwire, MS20995C32 (0.032 Inch Dia.) Commercial

C-406 Aluminum Oxide Cloth, P-C-451 Commercial

C-407 Abrasive Pad, Nylon Web (Scotchbrite) L-P-0050, Type I, 27713 or

Class 1, Size 1 76381

C-409 Use Item C-500

C-411 Steel Wool Commercial

C-423 Abrasive Cloth (P-C-458) or Paper (P-P-101) (All Grits) Commercial

C-463 Cerex 7 oz., No. 3607-21 41335

C-464 India Stone, SS-S-736 Commercial

C-493 Insulation Tubing, Heat Shrinkable - Electrical, MIL-I- 14352

23053/4 BHT Std. 130-054 97499

C-500 Crocus Cloth, Abrasive Coated, A-A-1206 Commercial

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BHT-212-CR&O

MAIN ROTOR

62-1. MAIN ROTOR. scissors and sleeve, and connecting linkageto transmit flight control movements to the

The main rotor incorporates a stabilizer bar main rotor head.and dampers, swashplate and support,

62-00-00Page 7/8

BHT-212-CR&O

MAIN ROTOR HUB AND BLADES

62-2. MAIN ROTOR HUB AND BLADES. FREE BOLTS. IF DIFFICULTY ISENCOUNTERED IN REMOVING

62-3. OVERHAULA. ~BOLTS, USE BOLT EXTRACTINGFIXTURE (FIGURE 62-2).

62-4. Disassembly. NOTE

Do not change adjustment of dragSPECIAL TOOLS REQUIRED brace. Identify blade retaining bolts

for assembly in grips from whichremoved.

NUMBER NOMENCLATURE5. Remove opposite blade using same

T101402 Grip positioning links procedure.

T101414 Wrench62-5. Assembly.

CAUTION

NUMBER NOMENCLATUREENSURE T101402 GRIPPOSITIONING LINKS ARE C-101 Corrosion PreventiveINSTALLED. Compound

1. Support main rotor hub on stand.Support each blade (5, figure 62-1) so leading NOTEedge is straight.

After drag braces are properly2. Remove bolt (7) with shims (6), washers, adjusted, install blades in originaland nut to detach drag brace (8) from blade. position. To avoid disturbing rotorSecure shims to brace or to blade for use in balance, install blade retaining boltsassembly. in grips from which removed.

1. Support main rotor hub on a suitable3. Remove screw (9) with nut and washer to 1 main rotor hub on a suitableunlock nut (10). Remove nut and washer (11) standfrom lower end of blade retaining bolt (4) . -

2. Apply corrosion preventive compound (C-using T101414 wrench. 101) to blade-retaining bolt holes in hub grips

and blade butts, to drag brace and drag brace4. Gently raise tip of blade until blade bolt bolt holes, and faying surfaces of blade andbolt holes, and faying surfaces of blade and(4) can be readily removed. Remove blade blade grips.from grip.

[ CAUTION

BLADES ARE PRECONED ANDELEVATION IS NECESSARY TO

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BHT-212-CR&O

62-6. Blade alignment.CAUTION

SPECIAL TOOLS REQUIREDFOREIGN MATERIAL- ORMISALIGNMENT OF BOLT HOLES NUMBER NOMENCLATURENUMBER NOMENCLATUREWILL RESULT IN DAMAGEDPARTS. T101356 Build-up bench

3. Insert blade (5, figure 62-1) into grip, T101400 Scope supportobserving color coding. Apply a thin coat ofcorrosion preventive compound (C-101) on T1401 Scope assemblybolt (4) shank but not on threads. Align holes T101402 Grip positioning linksand insert bolt through grip and blade fromtop. To find best alignment, gently move tip T101865 Flap stopof blade up and down while inserting bolt.

4. Support end of installed blade. Installwasher (11) (with recess up) and nut (10) on CAUTIONblade bolt (4).

5. Align clevis of drag brace (8) to blade INSTALL T1 01402 GRIPdrag plate hole. Install shims (6) top, bottom, POSITIONING LINKS BEFOREor equally, depending on existing gap location HANDLING HUB AND BLADEbetween clevis and drag plate. Shim for ASSEMBLY.0.000 to 0.005 in. (0.000 to 0.127 mm)clearance. Install bolt (7) with two washers 1. Level T101356 build-up bench assembly.next to nut. Position main rotor with hub trunnion

supported on bench. Place alignment cradles6. Ensure that T101402 grip positioning link or other suitable supports under both bladesis installed between pitch horn and stud on to position blades straight at normal preconedpillow block. angle throughout blade length.

7. Install opposite blade in same manner. 2. Install two T101865 flap stops, attachedwith bolts and washers to each side of hub

8. Torque nuts on drag brace bolts (7) 100 trunnion at lower set of holes.to 120 ft.lbs. (135.58 to 162.696 Nm).

3. Adjust T101402 grip positioning links to9. Torque nut on each blade retaining bolt set hub grips at zero pitch angle, measured(4) 260 to 300 ft.lbs. (352.51 to 406.74 Nm), with a propeller protractor placed acrossusing T101414 wrench. Safety each nut by outboard machined surface on each grip.installing a screw (9) through aligned holes ofnut and blade retaining bolt. Secure with nutand washer. NOTE

10. Torque nuts on drag brace inboard bolts Failure to support blades properly at125 to 150 ft.lbs. (169.48 to 203.37 Nm). preconed angle (2 3/4°) and to set

zero grip angle will result in blademisalignment.

NOTE

If blade alignment is required, refer 4. Position T101400 scope support (4, figure62-3) across hub pillow blocks and securewith two 1/4X28 bolts, 2.25 in. (53.98 mm)long. Place T101401 scope assembly (5) insupport.

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BHT-212-CR&O

1. Pillow block 7. Drag brace bolt2. Hub trunnion 8. Drag brace3. Grip 9. Screw4. Blade retaining bolt 10. Nut5. Main rotor blade 11. Washer6. Shims 12. Pitch horn

SHIM FOR

*0.000 TO 0.127 mm )

3/

9 10212-R-62- 1

Figure 62-1. Main rotor hub and blade

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BHT-212-CR&O

SEE DETAIL B

1- 2

SEE 3r//DETAIL A i 4.050 IN.

14.0 IN. - 3.750IN. 5(355.6 mm) (95.250 mm)

1.0 IN. - -0.125 TO 0.150 IN.(3.175 TO 3.810 mm)

0.750 IN.(19.050 mm)

2

N.F. THREAD 0.875-14

DETAIL B

NOTES

1. Puller rod assembly 4130 (or better), 1.00.D. TO 15.0 inches long (25.4 TO 381.0 mm).

2. 3 hex nuts 0.875 NF (14) thread.

3. Bearing (thrust) inner race 1.0 inch I.D. (25.4 mm).

4. Plate or washer, steel or aluminum, 4.050 to 4.125 inch O.D. (102.84 to 104.775 mm)1.125 inch (28.575 mm) I.D., 0.250 inch (6.35 mm) thick.

5. Plate or washer, steel or aluminum, 3.750 inch O.D. (95.25 mm), 1.125 inch I.D. (28.575mm), 0.250 inch thick (6.35 mm).

6. Tube, steel or aluminum, wall thickness 0.083 TO 0.125 inch (2.108 to 3.175 mm).212-R-62-2

Figure 62-2. Main rotor blade bolt extractor

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BHT-212-CR&O

STA288.00

288.00 5.110

REF ONLY,ALIGNMENT POINTWILL VARY INLOCATION

1. Pitch Change Axis2. Blade Alignment Point (Screw Head)3. Trunnion Axis4. T101400 Support Assembly5. T101401 Scope Assembly

212-R-62-3

Figure 62-3. Main rotor blade alignment

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BHT-212-CR&O

5. Check scope for zero adjustment: 7. To adjust drag brace (37, figure 62-11),loosen nuts (33 and 35) and turn barrel (34)

a. Sight through scope at a surface either forward or aft direction. Torque nutsapproximately 50 ft. (15.24 m) away. Draw a (33 and 35) 275 to 325 ft.lbs. (372.845 tostraight vertical mark on surface aligned with 440.635 Nm).vertical cross hair.

b. Loosen clamp screws on scope mount, NOTErotate scope 180° on tube axis, and tighten Blade alignment point (screwhead)screws. Take another sight to ensure vertical (2) will vary in its location, and is tocross hair aligns on target mark. be used for reference only during

blade alignment.c. If vertical cross hair fails to align ontarget mark, make a second mark at new 8. Reverse scope in support. Repeat stepalignment of vertical hair, then a third mark 6. to align opposite blade Blade-to-blademidway between first and second marks. difference shall not exceed 0.050 in. (1.27Adjust screw marked "L" on side of scope to mm).align vertical cross hair on third mark. Rotatescope 180°s and recheck alignment. Repeat 9. When alignment is correct, remove scopeprocedure until alignment is satisfactory. and support assemblies. Paint a reference

line across drag brace barrel and locknut to6. Sight through scope to alignment screw indicate original alignment position for use in(2), located near leading edge strip and tip, vibration troubleshooting.on upper surface of either blade. Center ofscrewhead should align on vertical cross hairwithin 0.100 in. (2.54 mm) forward and 0.400in. (10.16 mm) aft. Adjust blade drag braceas necessary.

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BHT-212-CR&O

*)^~~ ~~MAIN ROTOR BLADES62-7. MAIN ROTOR BLADES. extension 0.008 in. (0.203 mm) or

less shall be polished out.62-8. OVERHAUL.

b. Any dent in skin, in outboard 4 ft.(1.213 m) of blade which does not tear skin,62-9. Inspection. or produce a void detectable when tapping, oreffect flight characteristics is acceptable.

NOTEc. Dents in skin inboard of a station 4 ft.Return main rotor blades to an (1.219 m) from tip of blade not in excess of

authorized Bell Helicopter Textron 0.06 in. (1.524 mm) deep are acceptable.blade repair shop for bushing Dents in excess of this value shall bereplacement. polished, smoothed, and patched, if within

allowable limitations for patching.1. Check main retention bolt hole and dragplate bolt hole for corrosion, pitting, d. Nicks in extreme trailing edge (10 andelongation, and size (figure 62-4). 16, figure 62-4) not in excess of 0.060 in.

(1.524 mm) deep shall be polished out over a2. Main retention bushing shall be replaced distance of at least 2.0 in. (50.8 mm) eachif I.D. exceeds 2.505 in. (63.627 mm). side of nick.

3. Drag plate bushing shall be replaced if e. Dents in skins of trailing edgeI.D. exceeds 0.877 in. (22.2758 mm). e Dents in skins of trailing edgeD. exceeds 0.877 in. (222758 mm). extension are permissible provided dent is not4. Any corrosion or pitting of either bushing visible on opposite side of blade.in excess of replacement dimension afterpolishing is cause for removal. Polishing in dent a skin or scratch exists in sha

small local areas exceeding replacement det in skin, total depth of both shall notdiameter shall not exceed 20% of inside exceed 0.06 in. (1.524 mm). If a nick ordiameter surface area. 20% of scratch cannot be polished out, it shall be cut

out and patched if within allowable limits for5. Inspect for nicks, scratches, and dents. patching.

a. Nicks and scratches anywhere on g. Nicks or scratches in abrasive strips,surface of skins or trailing edge strip not in doublers, grip plates not in excess of 0.012excess of 0.008 in. (0.2032 mm) in depth are in. (0.3048 mm) in depth are acceptable ifacceptable if polished out. polished out. Sanding to be accomplished in a

spanwise direction.

NOTE 6. Voids in spar assembly, outboard ofIf a nick or scratch in skin in excess station 100.of 0.008 in. (0.203 mm) deep can bepolished smooth without leaving skin NOTEin polished area so thin it can bedented with fingernail pressure, then A void is defined as an unbondeda patch may be applied over area area which is normally bonded.without cutting a hole. (Refer to Many subdefinitions of voids areparagraph 62-8 and figure 62-4 for given such as lack of adhesive, gasmain rotor blade patching pocket, misfit, etc. This manualprocedures and patching limitation.) makes no distinction, but groups allNicks and scratches in skin trailing such defects in the one general termedge strip or skin of trailing 'void'.

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15

1. Butt cover 11. Main spar2. Balance weights 12. Leading edge, abrasive strip

6. Grip plates 16. Trailing edge extension7. Nose block 17. Detector8. Honeycomb core 18. Conductive paint9. Skin 19. Splice cover

10. Trailing edge extrusion

212-R-62-4

Figure 62-4. Main rotor blade

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BHT-212-CR&O

NOTE c. Voids within 0.38 in.(9.652 mm) of edgeof abrasive strip, except at butt end as per

There is no center abrasive strip on above, are not acceptable.main rotor blade 212-015-501.

d. Voids between reinforcement doublera. A 1.0 in. (25.4 mm) wide (maximum) and spar, not larger than 0.5 by 1 in. (12.7 by

void between abrasive strip and nose block at 25.4 mm), are acceptable. If voids comeextreme leading edge is acceptable to within closer than 1.0 in. (25.4 mm) to each other,1.0 in. (25.4 mm) of tip of blade. If void runs consider as a single void. Maximum totalthrough splice joint between center and area of voids not to exceed 10.0 sq.in. (6452outboard abrasive strips, it shall be sq. mm).completely sealed.

b. Other voids not exceeding 30 sq.in. NOTE(193.55 cm sq.) with a maximum to 10 sq.in. Any acceptable void described in(64.5 cm sq.) in any single void are this step which is apparent at buttacceptable. If voids come closer than 1.0 in. is to be sealed with adhesive.(25.4 mm) to each other, consider as a singlevoid. 8. Voids at butt end of blade.

c. Voids within 0.38 in. (9.652 mm) of a. Voids not deeper than 3.0 in. (76.2 mm)edge of abrasive strip are not acceptable. between nose block and box beam areHowever, edge voids 0.08 in. (2.032 mm) acceptable.maximum deep by any length or 0.25 in. (6.35mm) maximum deep by 3.0 in. (76.2 mm) b. Voids between trailing edge extrusionmaximum length may be sealed with and skin not deeper than 1.0 in. (25.4 mm) or

wider than 1.0 in. (25.4 mm), are acceptable.

d. Voids between reinforcement doubler c. Any other void not longer than 1.0 in.and spar not larger than 1.0 by 3.0 in. (25.4 (25.4 mm) or deeper than 0.35 in. (8.89 mm)by 76.2 mm) are acceptable. Minimum is acceptable.spacing between centers is 5.0 in. (127 mm).Maximum total area of voids to be 30 sq.in. d. Voids are not acceptable within 0.5 in.(193.56 sq. cm). (12.7 mm) of front or rear edge of either grip

plate, (viewing the section of butt end).

NOTE

NOTEAny acceptable void described inthis step which is apparent at tip end Any acceptable voids described inis to be sealed with adhesive. this step which are apparent at butt

end are to be sealed with adhesive.7. Voids in spar assembly, inboard of station100. 9. Voids in retention area, inboard of station

100.a. A 1.0 in. (25.4 mm) wide (maximum)

void between abrasive strip and nose block is a. Inspect main rotor blade grip pads foracceptable. edge voids, corrosion, and condition of

adhesive squeeze-out. Hair line cracks inb. Voids between abrasive strip and paint finish should be suspect for possible

reinforcement doubler not exceeding 10.0 voids. Single edge voids on any one sidesq.in. (6452 sq. mm) with a maximum of 2.0 which are 0.060 in. (1.524 mm) in depth andsq.in. (1290.4 sq mm) in any single void are 2.0 in. (50.8 mm) in length are acceptable butacceptable. Minimum spacing between void shall be sealed. Edge voids in excess ofcenters shall exceed 3.0 in. (76.2 mm). these limits are not reparable and is cause for

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blade replacement. Seal acceptable edge a. Voids between skin and skins of trailingvoids with adhesive. edge extension shall not exceed 1/3 width of

mating surfaces.b. Voids between doublers or innermost

doubler and skin 2.0 in. (50.8 mm) wide, b. Voids between skin and core shall notmaximum, (chordwise) by 4.0 in. (101.6 mm) exceed 1.0 in. (25.4 mm) in width by 25.0 in.long maximum, (spanwise) are allowable, (635 mm) long. Voids within 1.0 in. (25.4providing they are not closer than 1.0 in. mm) of each other are to be considered as(25.4 mm) to edge of doubler or to another one void. Outboard of Sta. 228, voidsvoid. Total allowable area of voids between between skin and core shall not exceed 1.0all doublers shall not exceed 10.0 sq.in. (6452 in. (25.4 mm) chordwise by 20.0 in. (508 mm)sq. mm). spanwise.

c. Voids between skin and core in 5 in. c. Voids of any length between skin andbox beam reinforcement doubler not(127 mm) wide region running adjacent to box beam reinforcement doubler nottrailing edge extrusion, not wider than 1.0 in. exceeding 0.25 in. (635 mm) width are(25.4 mm) or longer than 10.0 in., (254 mm) acceptable. Voids not larger than 0.38 in.with a minimum width of 1.0 in. (25.4 mm) of (9.7 mm) by 2.0 in. (50.8 mm) are acceptablegood bond between them, are permissible. In provided spacing between void centersremaining area, width of void may not exceed exceeds 6.0 in. (162.4 mm). Edge voids are0.5 in. (12.7 mm). The total area of all voids not acceptable.is not to exceed 30 sq.in. (19.356 sq. mm). Edge voids

d. Edge voids between edge of skin andskins of trailing edge extension less than 0.06

d. Edge voids between edge of skin and in. (1.5 mm) wide by any length aretrailing edge extrusion, less than 0.06 in. acceptable if sealed with adhesive.(1.524 mm) wide by any length or less than0.25 in. (6.35 mm) wide by 7.0 in. (177.8 mm) e. Edge voids between trailing edge skinslong are acceptable if sealed with adhesive. and 0.050 in. (1.27 mm) thick spacer at

extreme trailing edge of blade are acceptable,e. Voids within 1.0 in. (25.4 mm) of main up to 0.060 in. (1.5 mm) maximum depth, are

retention bolt hole, in any bond line, are not acceptable if sealed with adhesive.permissible.

11. Any crack in any location in mainf. Other voids between skin and trailing bonded part of blade is cause for

edge extrusion which do not exceed 1/3 width replacement. remove blade and notify Bellof mating surfaces by 10.0 in. (254 mm) long Helicopter Textron Product Supportare acceptable. Department if crack was not caused by an

accident.g. Voids between skin and box beam

reinforcement doubler wider than 0.25 in. 12. The condition of paint on any stainless(6.35 mm) are not acceptable. steel abrasive strip or leading edge, is

unimportant.

NOTE 13. If paint is worn through, over the

void between skin and spar next to a as practical (BHT-212-MM).void between skin and core, arecloser than 1.0 in. (25.4 mm) apart,consider as one void, and thestricter limitation shall apply.

10. Voids under the skin, outboard of station100.

62-00-00Page 18

BHT-212-CR&O

62-10. 12 months or 1000 hour (3) To inspect for corrosion under looseinspection. adhesive squeeze-out, trim loose squeeze-out

by cutting or scraping. Take care not todamage adjacent surfaces. Sand trimmedMATERIALS REQUIRED area smooth using 280 grit or finer abrasivecloth or paper (C-423).

NUMBER NOMENCLATURE(4) Determine depth and length of any

C-100 Chemical Film Material edge void by using a 0.0015 in. (0.0381 mm)feeler gage. (Refer to paragraph 62-8 forlimits of edge void.)

C-234 Primer(5) Remove pin holes in squeeze-out by

C-305 Aliphatic Naphtha cutting or scraping, taking care not to damageadjacent surfaces. Sand trimmed area

C-317 Adhesive smooth using 280 grit or finer abrasive cloth

C-322 Adhesive or paper (C-423).

C-407 Abrasive Pad (6) A crack in paint finish which followsdoubler tip outline may indicate a possible

C-423 Abrasive Cloth or void. Carefully tap outboard several inches ofPaper doubler with a heavy coin or a small tapping

hammer. A void can be detected by a changein sound from that of surrounding area. If

1. Perform following inspection and repair on voids are found, a maximum of 2.00 in. (50.8main rotor blades each 12 months or each be removed from outboard tips of1000 hours, whichever occurs first. doublers to eliminate void. When one of

these doublers is trimmed more than 1.0 in.a. Inspect main rotor blades as follows: (25.4 mm), an equal amount of that over 1.0

in. (25.4 mm) shall be trimmed from adjacent(1) Clean blade from an area starting at shorter doubler tip. The pattern of cut, when

butt end of blade to several inches outboard removing material, should be approximatelyof doublers on both upper and lower blade the same radius as the original tip with nosurfaces using aliphatic naphtha (C-305) or Use extreme care

sharp edges or corners. Use extreme careany good degreasing solvent. during cutting to avoid damage to adjacentsurfaces.

(2) Inspect main rotor blade grip pads, surfaces.grip plates, doublers, drag plates, and (7) The grip plate and drag plate trimadjacent surfaces for voids, edge voids, limit is 1.0 in. (25.4 mm) and will only becorrosion, cracks, and condition of adhesive trimmed due to damage or delamination. Forsqueeze-out along bond lines. (Refer to example, if the shortest doubler is trimmedparagraph 62-8 for inspection criteria andparagraph 62-8 for inspection criteria and 2.0 in. (50.8 mm), the grip plate or drag platerepair limits unless otherwise stated herein.) will not be trimmed unless it is damaged or

delaminated.

CAUTION b. Refinish main rotor blade as follows:

DURING TRIMMING AND SANDING NOTEOPERATIONS, DO NOT NICK,OPERATIONA, If rework performed has removed a

SURFACES OR EDGES DO NOT large amount of original paint finish,SURFACES EDGES. DO NOT it is recommended that the top two

coats of acrylic lacquer be removedfrom an area starting at butt end of

62-00-00Page 19

BHT-212-CR&O

blade to several inches outboard of 2. Any blade which has reached maximumdoublers on both upper and lower service life.blade surfaces and a completerefinish be accomplished. 3. If one or more cracks develop and extend

from a previously repaired area and the crack(1) All edges around grip pads, grip exceeds allowable repair limits.

plates, doublers, and drag plates should havea smooth fillet of adhesive squeeze-out. A 4. Holes in skin larger in area than allowedbulge or lump of adhesive could be mistaken for patching.for a bulge caused by corrosion. Sand downall spots of protruding adhesive squeeze-out 5. Any corrosion which penetrates entirelyusing 280 grit abrasive cloth or paper (C- through skin and is beyond patch limitations.423).

6. Voids between skin and honeycomb core(2) After all sanding has been of basic blade larger than 25 sq.in. (161.30

completed, scrub exposed metal surfaces sq. cm)using abrasive pad (C-407) and mild soap toremove traces of sanding residue and other Any penetration through spar trailingcontamination. Rinse with distilled orcontamination. Rinse with distilled or edge extrusion, doublers, grip plates, or dragdemineralized water and wipe dry. plates.plates.

(3) Apply brush chemical film material 8. Edge voids deeper than 0.50 in. (12.7(C-100) to bare metal surfaces. The solution 8. Edge voids deeper than 0.50 in. (12.7mm) at tip end of any of root end doublers orshould remain on blade until a goldenirridescent to brown color developes (usually grip plates30 seconds to 2 minutes). Rinse by wipingwith cloth saturated with distilled or 9. Edge voids in leading edge of doublersdemineralized water. which exceed 0.060 in. (1.5 mm) in depth and

at trailing edge of doublers which exceed 0.10in. (0.254 mm) in depth.(4) Fill any remaining pin holes,

grooves, seams or trimmed edges, which maytrap moisture, around grip plates, grip pads, NOTEdrag plates and doubler edges with adhesive(C-317) or adhesive (C-322). A tongue Major damage to trailing edgedepressor should be used to produce a extension which does not damagesmooth application, free of lumps and bulges. basic blade (trailing edge extrusionAllow adhesive to harden overnight. and skins) should be sent to an

authorized blade repair station.(5) Spray one light coat of primer (C-

234) to all surfaces which have been sanded 10. Obvious deformation of blade.to bare metal. Allow to air dry 30 minutes to4 hours. 62-12. Repair.

(6) Spray two top finish coats of lacquer(C-203) to match original finish. Allow to air MATERIALS REQUIREDdry 1 to 24 hours between coats. Followingfinal top coat, allow acrylic lacquer finish to NUMBER NOMENCLATUREair dry 48 hours or one hour at roomtemperature plus one hour at 105°F (41°C). C-309 Methyl-Ethyl-Ketone

(MEK)

62-11. Nonreparable damage. C-313 Adhesive

1. Water or corrosion in honeycomb core. C-317 Adhesive

62-00-00Page 20

BHT-212-CR&O

MATERIALS REQUIRED (CONT) $* _____________ JCAUTION

NUMBER NOMENCLATURE

C-322 Adhesive REPAIRS DESCRIBED IN THISPARAGRAPH INBOARD OF

C-423 Abrasive Cloth or STATION 234.0, SHALL BEPaper INSPECTED DAILY FOR CRACKS.

1. Polish out all acceptable nicks and 3. Cut out skin around damaged area. Thisscratches using 180 grit abrasive cloth or may be accomplished by using a hole saw orpaper (C-423) followed by 400 grit. Final scribing through skin with a sharp instrument.polish with 600 grit abrasive cloth or paper(C-423). Remove only enough material to NOTEcompletely remove the nick or scratch. Steelwool may be used on abrasive strip to polish If a circular hole is cut out to removeout defects. Accomplish sanding in a damaged area, it shall not exceedspanwise direction. 2.0 in. (50.8 mm) in diameter.

However, it is permissible to cut out2. All acceptable edge voids should be an oblong hole if the generalmechanically cleaned out, where possible, direction of hole falls within 15° of aand "swabbed out" with filler before trying to line parallel to the leading edge orfill the cavity. All edge voids shall be filled as trailing edge of blade. Maximumdeeply as possible by placing extra filler size of oblong hole shall not exceedmaterial over the cavity, and quickly pressing 1.0 in. (25.4 mm) wide by 4.0 in.filler into cavity with flat side of blade. Repeat (101.6 mm) long. Ends of hole shallthis operation several times. Fill and seal all have a minimum radius of 0.25 in.edge voids with adhesive (C-313), adhesive (6.35 mm).(C-317), or adhesive (C-322). Smooth andallow to cure according to manufacturersrecommendation. It is not necessary to cut a hole if

defect can be polished smoothwithout leaving skin in area so thin it

NOTE can be dented with fingernailpressure. In these cases, the area

Scratches, nicks, gouges, tears, still shall have a patch applied in theholes, etc. in skins which exceed same manner as though a holelimits specified in paragraph 62-8, existed. Maximum diameter of ado not touch or damage in any way patch of this type is to be 4.0 in.the trailing edge extrusion or the (101.4 mm) with at least 0.75 in.spar (box beam), or do not come (19.05 mm) of bonded area aroundwithin 1.0 in. (25.4 mm) of doublers, perimeter of dent (except adjacent tomay be repaired locally by patching trailing edge skins as shown inas described in this paragraph and figure 62-6).returned to service. These limitsshall be met after hole is cleaned upfor shall be met after he is For patch 4. Remove skin in cutout area disturbingforlimits to trailching (fiedge extrusion, refeFor patch core as little as possible. It is desirable tolimits to trailing edge extrusion, refer heat cutout disc to 200F (93C) maximumto figure 62-6. heat cutout disc to 200°F (93°C) maximumto figure 62-6. and lift out disc of skin while heated.

Surrounding area should be protected fromheat application.

5. Deburr edges of hole ensuring skin is freeof scratches and nicks.

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BHT-212-CR&O

6. Remove all paint from around hole in area 62-13. Repair-- main rotor blades withpatch will cover using clean rags dampened blade inspection system (BIS).with MEK (C-309). Do not allow any MEK toenter blade. Remove primer by sanding in a MATERIALS REQUIREDspanwise direction using 300 grit or finerabrasive cloth or paper (C-423).

NUMBER NOMENCLATURE7. Prepare a patch of 2024-T3 aluminumalloy 0.020 in. (0.508 mm) thick. The patch C-100 Chemical Film Materialshall be large enough to overlap the hole atleast 0.75 in. (19.05 mm) around perimeter, C-202 Primerexcept as shown on figure 62-5. Deburr C-203 Lacqueredges of patch.

C-204 Primer8. Sand mating surfaces of blade and patchusing 400 grit abrasive cloth or paper (C- C-224 Paint423). Wipe both surfaces clean with a ragdampened with MEK (C-309) and dry with a C-309 Methyl-Ethyl-Ketoneclean cloth. (MEK)

C-322 Adhesive

CAUTIONSPECIAL TOOLS REQUIRED

THE AREA TO BE BONDED SHALLBE CLEAN, DRY, AND FREE OF NUMBER NOMENCLATUREGREASE, OIL, WAX, ETC.

212-091-014-001 Crack Locator

9. Apply adhesive (C-317), to bond areas of 212-091-015-001 Driver Assemblypatch and blade. Fill area where skin wasremoved. or

10. Apply patch to blade moving patch 212-091-016-001 Test Setslightly back and forth under pressure to seatit properly and to expell air pockets in the oradhesive. Blend out excess adhesive around Simpson Model 260 MultimeterSimpson Model 260 Multimeterthe edges. (or equivalent)

11. The patch may be held in place whilecuring with rubber bands made from an innertube or other mechanical means with NOTEcellophane sheet inserted between holding Since one of the dual functions ofdevice and blade. Cure at 140 to 160°F (60 the 212-091-014-001 crack locatorto 71°C) for two hours. assembly is to functionally test

detector unit assembly, it is not12. If patch was in area of BIS, repair in necessary to obtain the 212-091-accordance with paragraph 62-13. necessary to obtain the 212-091-016-001 test set if crack locator and

driver assemblies are available.13. Refinish repaired area (BHT-212-MM).

If crack locator and the 212-091-015-001 driver assembly are notavailable, blade inspection systemmay be checked by a multimeter(step 2.)

62-00-00Page 22

STA 1 x 4 IN. (25.4 x 101.6 mm) OBLONG STA28.00 2.0IN. IN N WITHIN 15° OF LEADING EDGE OR 28800

ONE INCH OF THE DOUBLERS TRAILING EDGE(50.8 mm) TRAILING EDGE OF BLADE

{~ ? PATCH REPAIR 212-R-62-5

BHT-212-CR&O

HOLE AFTER CLEAN-UP

PATCH SKIN

A Patch repair is permitted in this area provided the trailing edge extrusion has not sustainedany damage.

A Patch repair, inboard portion of main rotor blade where trailing edge extrusion is forward oftrailing edge skins.

A If edge distance is 0.750 inch (19.05 mm) or more a round patch may be used instead of thetriangular patch.

A Patch repair, outboard portion of main rotor blade where trailing edge skins are forward oftrailing edge extrusion.

A Patches are allowed in this area provided no damage has occurred to trailing edge extrusionand spacer. 212-R-62-6

Figure 62-6. Main rotor blade trailing edge repair

62-00-00Page 24

BHT-212-CR&O

1. If crack locator and driver assembly are connectors. At least 8.5 volts shall beavailable, perform the following: present.

a. A steady light on detector unit (c) Locator driver or crack locatorassembly indicates a possible blade crack, or faulty.that a circuit malfunction exists. Usediagnostic procedures to determine cause (d) Connections from detector to(figure 62-7). blade surface conductors broken.

b. If a broken conductor appears to be (e) A break of both paintedcause of steady indication, after diagnostic conductors exists between location beingprocedures are performed, then perform a checked and butt end of blade.close visual inspection. If visual inspectiondoes not reveal any cause, and circuit is still (4) Holding crack locator atopen, or can be maintained open by flexing approximately 45° while scanning chordwise,blade, perform the following: briefly check opposite side of blade for

presence of signal. Absence of signal(1) Plug driver assembly into fitting indicates a break in both conductors.

assembly on butt of blade (ensure batteryvoltage of 8.5 volts minimum). Position ON/ (5) Once presence of signal isOFF switch to ON (figure 62-8 for pin established, determine chordwise location oflocations). conductors and strike lines between points to

serve as guidelines along blade.(2) Position crack locator ON/OFF

switch to ON and lay crack locator on blade (6) Orient probe chordwise (90° tosurface near butt end, but outboard of conductors) and slowly scan full length ofdoublers. Orient it roughly 45° to blade and blade surface. Keep dimple on probe withinmove it chordwise over the surface. As the 1/4 in. (6.35 mm) of guideline.probe passes over location of paintedconductors, a meter should moveapproximately full scale. As crack locator is NOTEmoved slowly, meter should rise, fall back tozero, then rise again. The point where it is As ends of conductors are reached,zero between the two peaks locates the it s normal for a meter reading toconductors chordwise on blade within 3/8 inch appear, unless both paint(9.525 mm). The dimple in top of probe is conductors are broken.location mark. Make a mark on blade forreference. (figure 62-9). If blade must be held under stress,

to maintain an open circuit, scan(3) If no indication on crack locator is surface which is in tension. If blade

obtainable, there are several possible causes: circuit checks open under no stress,scan both surfaces.

(a) Circuit has reclosed.(7) Watch for meter indications and

(b) Battery dead in blade or locator. mark any points where meter readingsThe battery in locator can be checked by appear. When a reading does appear, moveplugging a detector into locator test socket crack locators chordwise and spanwise toand activating detector TEST function. Its obtain maximum, keeping crack locatorindicator light shall be visible in a lighted approximately 90° to conductors. Noteroom. The battery in blade can be checked readings at each point.the same way, by plugging detector into it.Alternately, a voltmeter can be used to c. Interpretation of results.measure battery voltages. Check betweenpins 1 (+) and 5 (-) on crack locator and blade (1) Relatively high reading at one

location.

62-00-00Page 25

BHT-212-CR&O

STEADY LGHT

REMOVE DETECTOR

PERFORM BATTERYCHECK

REPLACEWTH DEPRESS RESET REINSTALL

DETECTOR

FLASHING LIGHT

GROUND RUN ANDHOVER AT HIGHGROSS WEIGHT

* THE TEST BUTTON MUST BECONSTANTLY DEPRESSED DURINGBLADE FLEXING. THIS ALLOWS

REMOVE DETECTOR DETECTOR TO BYPASS CENTRIFUGAL FLASHING LIGHTSWITCH AND CHECK CONTINUITY OFTHE SYSTEM.

VISUAL INSPECTIF CRACKS ARE UPPER & LOWERFOUND, REMOVE _ BLADE SURFACE FOR

SERVICE & EVIDENCE OFCRACKS

IF INTERMITTENT

Figure 62-7. Troubleshooting detector unit

62-00-00Page 26

BHT-212-CR&O

SEE DETAIL A

WIRE 9-22(UPPER BLADESURFACE) FWD BLACK WIRE

BATTERY (-)

WIRE 8-22(GROUND)

WIRE 2-22 (LOWERDETAIL A BLADE SURFACE)

RED WIRE BATTERY (+) 212-R-62-8

Figure 62-8. Electrical conductive plug-pin location

NOTE and above are strong indications of failures incrack detector conductors or the blade itself.

Ignore readings obtained at knownend locations of paint circuits. (3) After locating open circuit inIgnore readings where conductors conductive paint, clean blade to bare metal inbend around corners, such as near area where conductor is broken and inspectend of longest doubler, unless a using a 10X glass and dye check.high reading is obtained.

(4) If crack is found, remove blade from(a) At least one painted conductor is service and contact Product Support

broken, the crack locator again at 45° . On Manager, Bell Helicopter Textron.either side of this location, scan chordwise forpresence of a signal. If no signal is present (5) If no crack is found in blade, repairoutboard of this location, circuit is broken all conductive circuits on blade and refinishacross both conductors. A strong possibility surface in accordance with step 3.of a blade crack exists.

2. If crack locator and driver assembly are(b) If signal is present both outboard not available blade inspection system may be

checked by a multimeter as follows:and inboard of this location, at least one paintconductor is broken. There is still a A steady light on detector unitpossibility of a blade crack. assembly indicates a possible blade crack or

that a circuit malfunction exists. Use the(2) In general, any reading 0.2 or diagnostic procedures to determine the cause

above, should be viewed with suspicion, (figure 62-7).especially if it occurs sharply at one location.Readings due to conductor ends or curvaturetend to show up less sharply. Readings 0.4

62-00-00Page 27

BHT-212-CR&O

SEE VIEW A

3 CRACK LOCATOR ASSY212-091-014-1

5900 4

8 0° 37 00 2 ON

212-R-62-9

Figure 62-9. Crack locator assembly and driver assembly

62-00-00Page 28

BHT-212-CR&O

b. If a broken conductor appears to be the 3. Refinish conductive circuits on blade andcause of steady indication, after diagnostic refinish surface as follows:procedures are performed, perform a closevisual inspection. If visual inspection does a. Touch up bare skin spot with chemicalnot reveal any cause, and circuit is still open, film material (C-100). Allow to dry.or can be maintained open by flexing blade,perform the following: b. Apply primer (C-204) to bare spot only.

Allow to dry 1 to 8 hours.(1) Remove detector unit and check

operation using 212-091-016-001 test set. If c Mix adhesive (C-322) perunit checks good, proceed to step (2). manufacturers instructions. Then mix 13% to

15% (by weight) of primer (C-202) into the(2) Using extreme care, sand small adhesive. Mix thoroughly. Thin to a

area of finish and mist coat down to sprayable consistency by adding MEK (C-conductive paint on forward stripe, upper 309) not to exceed 50% by volume of mixedsurface, just outboard of glass layup (area 1, adhesive (approximately 35% by volume willfigure 62-10). produce a sprayable consistency). Pot life of

thinned adhesive is approximately 3 hours.(3) Remove detector unit assembly.

With ohmmeter, check continuity from d. Apply adhesive mix spray coating overconnector pin 9, figure 62-8, to exposed reworked area only. Do not overlap intoconductor. If an open condition is not conductive paint. After application of finalindicated, check continuity from connector pin coat of adhesive mix, allow to air dry at room2 to the exposed conductor. This will isolate temperature for 16 to 24 hours.open circuit to either upper (pin 9) or lowerblade surface (pin 2). e. Mask off each side of bare conductive

paint continuing across touched up spot.(4) After determining blade surface,

carefully sand small area of finish to f. Apply paint (C-224) using a small brushconductive paint at halfway point (most across the repaired area overlapping ontooutboard area) (figure 62-10, area 2). bare conductive paint on each side.

(5) Check continuity from exposed g. Remove 212-074-200-001 detector unitconductor in step (1) to exposed conductor in assembly at butt of blade by removing fourstep (3) and applicable connector pin 2 or 9, screws. Check for system continuity using an(figure 62-8). ohmmeter between pins 2 and 9 of connector

inside 212-074-207 fitting. The reading shall(6) To further isolate open, expose be less than 1200 ohms. Check system for

conductive area halfway between area just leakage between pins 8 and 9. Reading shallprobed (area 3, figure 62-10). be greater than 50,000 ohms.

(7) After locating open circuit inconductive paint, clean blade to bare metal in NOTEarea where conductor is broken and inspect If reading between pins 2 and 9 is(10X glass and dye check). more than 1200 ohms, additional

conductive paint needs to be(8) If crack is found, remove blade from applied. A reading of less than

service and contact Product Support 50,000 ohms between pins 8 and 9Manager, Bell Helicopter Textron. indicates a short between blade

body and conductive paint in repairc. If no crack is found in blade, repair all area, if indicated, or rework area to

conductive circuits on blade, and refinish eliminate short by making sure layersurface in accordance with step 3. of primer (C-204) is sufficiently thick

62-00-00Page 29

BHT-212-CR&O

1.00 IN. (25.4 mm)MYLAR TAPE

WARNING

DO NOT USE KNIFE TO TRIM TAPEON BLADE.

15±1 IN.5.03 ± 0.10 IN. (381 ± 25.4 mm)(127.762±2.54mm)

AREA 3 (MID SPANWISEAREA 1 OF CONDUCTIVE PAINT)

-- AREA 2

GROUND0.25 IN. (6.35 mm) 1.00 IN. (25.4 mm)MYLAR TAPE MYLAR TAPE

212-R-62-10

Figure 62-10. Electrical conductive paint location

to prevent a short between blade 1. Position cover (19, figure 62-4) on bladeskin and conductive paint. so inboard end of cover is 2.0 in. (50.8 mm)

from scarf joint at extreme leading edge.h. After system passes continuity and Pencil mark around cover outline.

leakage checks, apply two more coats ofadhesive (C-322), a mist coat of primer (C- 2. Remove all paint and prime to bare metal204) and two coats of lacquer (C-203). in area receiving cover. Extend removal area

0.50 in. (12.7 mm) over the cover outline.62-14. MAIN ROTOR BLADE SPLICE Use 180 grit or finer abrasive cloth or paperCOVER. (C-423).

3. Prior to installation of cover, inspect scarf62-15. Installation. joint for filler erosion and evidence of

corrosion. If corrosion is present, contact BellMATERIALS REQUIRED Helicopter Textron, Product Support

Department or an authorized blade repairstation for shipping instructions.

NUMBER NOMENCLATURE

C-309 Methyl-Ethyl-Ketone 4. Wipe area with a clean cloth dampened(MEK) with MEK (C-309). Repeat with successive

clean cloths and MEK until cloth remainsC-317 Adhesive clean after wiping. Wipe dry with a final clean

cloth.C-423 Abrasive Cloth or

Paper 5. Remove peel ply from inside of coverassembly. Lightly sand composite bondedadhesive on inside of cover with 320 grit or

62-00-00Page 30

BHT-212-CR&O

finer abrasive cloth or paper (C-423). Wipe 1. New blades with final paint finish fullyarea with a clean cloth dampened with MEK cured shall be wiped with a clean cloth or rag(C-309). Wipe dry with a clean cloth. dampened with aliphatic naphtha (C-305) and

wiped dry prior to full evaporation of naphtha.6. Apply adhesive (C-317) to inside of coverand to blade surface. Rub adhesive around 2. Blades which have been in service shallon blade and cover to ensure complete have all contamination cleaned off usingwetting of contact surfaces. abrasive pad (C-407) or equivalent followed

by wiping with clean cloth dampened with7. Position cover on blade and move slightly aliphatic naphtha (C-305) and wiped dry priorback and forth to expel air pockets. Wipe off to full evaporation of naphtha.excessive adhesive. Fair in edges of coverwith adhesive.

NOTE8. Hold cover in place with heavy rubber Blades having tape replaced are tobands or bungee cords. be treated same as blades which

have been in service.9. Cure at 140 to 160°F (60 to 71°C) for twohours. Apply heat locally only and do not 3. Cut a piece of tape 112 in. (2844.8 mm)exceed the maximum temperature. long and 5.0 in. (127 mm) wide. Tape shall

be same width and length (within reasonable10. Refinish blade as required. limits) for each blade of a set to prevent anout of balance condition.

11. Perform steps 1. through 10. on otherblade. 4. Tape shall be applied to blade by

minimum of two personnel. Place one end of62-16. Polyurethane tape application. tape flush with tip end of blade so equal

coverage will be applied to bottom and topsurfaces. Using a plastic spatula or

MATERIALS REQUIRED equivalent, firmly affix tape to extreme leadingedge of blade for full length of tape.

NUMBER NOMENCLATURE5. Using spatula or equivalent, affix tape

C-305 Aliphatic Naphtha firmly to each side of leading edge. In theevent an air bubble is entrapped, raise that

C-407 Abrasive Pad area of tape, releasing air and reaffix tapefirmly. Properly applied tape should show noevidence of air bubbles.Use of polyurethane tape is optional with of air bubbles.

individual operator. Its use is recommended 66. Inspect tape daily for proper adhesionfor protection against abrasion of leadingedge of blade in areas of high sand and dust and tape condition. Repacement is to beconditions. The tape affords medium based on daily inspection findings.protection against rain. It may be removedand replaced with new tape as often asnecessary.

62-00-00Page 31/32

BHT-212-CR&O

MAIN ROTOR HUB

62-17. MAIN ROTOR HUB . paragraph 62-20 for inspectionrequirements before disassembly.Yoke, 204-011-102-(ALL dash

62-18. OVERHAUL. numbers) with 2100 hours or moretotal time in service shall be

SPECIAL TOOLS REQUIRED replaced with stainless steel mainrotor yoke assembly, 212-011-102-105 within the next 300 flight hours,

NUMBER NOMENCLATURE but not later than December 31,1993. Yokes with more than 3300

T101356 Buildup bench hours shall not exceed 3600 hour

2100 hours shall be changed atT101402 Grip positioning link 2400 hours or not later than

December 31, 1993, whicheverT101405 Plate comes first. Helicopters with T.B.

212-91-138 incorporated will useT101406 Plate stainless steel main rotor yokeT101421 Adapter plate assembly, 212-011-102-109.

T101450 Arbor 1. Position T101421 adapter plate onT101356 buildup bench assembly, with flat

T101454 Puller jaw surface of adapter plate down.

T101458 Main rotor balance set 2. Place main rotor hub on buildup bench,T101559 Grip spacing tool cut lockwire, remove drain plug (17, figure 62-T101559 Grip spacing tool 11), packing (18), and drain oil from gripsT101865 Flap stop (11).

2769 Tube assembly 3. Remove relief fitting (12) on inboard sideof plate (13) to relieve vacuum while draining

7A050 Balancing kit oil. Install fitting after draining.

4. Remove grip as follows:62-19. Disassembly.

NOTENOTE

Procedure for removal of one grip isReview Mandatory Retirement outlined. Opposite grip removal isSchedule (BHT-212-MM). Retire all identical and should be removed atitems scheduled for retirement. If same time.main rotor hub is beingdisassembled for replacement of a. Remove nut (20) and washer (19).part(s) instead of overhaul, Remove bolt (9), and washer (10), and dragdisassemble only to extent brace (37) from grip (11).necessary.

b. Remove nut (22), washer (21), and boltIf main rotor hub has been subjected (1).to an accident or incident outside therealm of normal usage, refer to

62-00-00Page 33

BHT-212-CR&O

c. Remove bolts (15) and washers (16). yoke from buildup bench. Tap outboard endTap pitch horn (14) with a nonmetallic of strap (9) inboard with nonmetallic hammerhammer to disengage bushings from grip. until inboard fitting (15) is centered in yoke

opening. Slide back up ring (17) outboard tod. Remove bolt (26), washer (25), clamp clear pin (16). Push pin out of fitting. Identify

(24), and lock (23). Remove nut (28) and key pin (16) and strap (9) to retain as mating(29). parts. Remove fitting, packing (14), and

backup ring from center of yoke. Pull strape. Push pin (30) out of outboard fitting (9) through outboard end of spindle.

(27) and remove fitting. Identify pin (30) andstrap (2) to retain as mating parts. Separate b. Pull seal sleeve (3) with packings (1packings (31) from outboard fitting (27). and 8) and channel seal (2) from yokePress grip (11) inboard and rotate spindle. Separate seal sleeve, packings, andapproximately 90 ° counterclockwise to seal. Place yoke on build-up bench.disengage from radius ring (3). Support gripand pull outboard to remove. c. Remove screws (5) and lockplate (6)

from yoke spindle. Use nut (28, figure 62-11)5. Disassemble drag brace (37) as follows: as a wrench and remove nut (7, figure 62-12).

Using T101406 plate and standard puller,a. Loosen nuts (33 and 35). remove bearing inner race (10), spacer (11),

bearing inner race (12) and radius ring (23) orb. Remove fitting (32) and clevis (36). shield assembly (23A) from yoke. (Refer to

Remove nuts (33 and 35) from barrel (34). figure 62-13 for tool usage.) Remove packing(22, figure 62-12) from radius ring.

NOTE 8. Disassemble grip as follows:Clevis end of drag brace has coarsethreads and fitting end has fine a. Remove bolts (20, figure 62-14),threads. washers (21), and plate assembly (22) from

end of grip (1). Remove packing (26), shims6. Remove pillow blocks and trunnion as (25), and seal (19) from plate (22). Removefollows: bolt (13), spring washers (14), washers (15

and 16), and packing (17) from center ofa. Remove and discard four nuts (8), cover (10). Remove cover, packings (9 and

washers (7), and bolts (6) from pillow blocks 7), and sight glass (8). Remove plug (12) and(4). packing (11) from cover (10). Remove relief

fitting (18) and drain plug (24) from plate (22).b. Use a nonmetallic drift and tap

bushings (5) from yoke and pillow blocks (4). b. Position T101405 bearing removalplate in outboard end of grip (1) and press

c. Lift pillow blocks and trunnion assembly bearing (2), spacer (4), and bearing (6) fromfrom yoke. Release relief fitting and separate grip. (Refer to figure 62-15 for tool usage.)pillow blocks from trunnion. Remove packings (3 and 5, figure 62-14) from

spacer (4).

NOTE 9. Disassemble trunnion and pillow blocks

Be prepared for oil drainage from as follows:each pillow block.

NOTE7. Disassemble yoke as follows:

Procedure is given for one spindlea. Remove bolts (19, figure 62-12) and only. Opposite spindle is identical

washer (18) from static stop (20). Remove and should be disassembled atstatic stop from bottom of yoke (13). Remove same time.

62-00-00Page 34

BHT-212-CR&O

NOTES

Apply corrosion preventive compounds(C-104) on all internal faying surfacesmarked with *.

Apply primer (C-204) to faying surfacesmarked with 0 and install while primeris still wet.

Apply corrosion preventive compound(C-101) to external surfaces of bolts,nuts, washers marked with *.

Seal around pillow block bushings (5),

12

140

212-R-62-11-1

Figure 62-11. Main rotor hub outboard section (Sheet 1 of 2)

62-00-00Page 35

BHT-212-CR&O

**1. Blade bolt *19. Washer2. Strap *20. Nut3. Radius ring *21. Washer

04. Pillow block *22. Nut05. Bushing 023. Lock06. Bolt 024. Clamp

7. Washer *25. Washer8. Nut *26. Bolt

*·9. Bolt 027. Outboard fitting*10. Washer *28. Nut

11. Grip 029. Key12. Relief fitting 030. Pin

013. Plate 31. Packing014. Pitch horn * 32. Fitting

*015. Bolt 033. Nut*16. Washer 034. Barrel

17. Drain plug *035. Nut18. Packing **36. Clevis

37. Drag brace

212-R-62-11-2

Figure 62-11. Main rotor hub outboard section (Sheet 2)

a. Remove nut (1, figure 62-16) and for tool usage.) Remove thrust washer (10,washer (2). Pull lock (9) and packing (8) from figure 62-16).spindle (4). Separate packing from lock.

b. Use standard puller and remove 62-20. Conditional Inspection.bearing inner race (7), packing (6), and radiusring (5) from trunnion spindle (4). (Refer to MATERIALS REQUIREDfigure 62-17 for tool usage.)

c. Remove bolts (16, figure 62-16), spring NUMBER NOMENCLATUREwashers (15), washers (13 and 14), cover C-309 Methyl-Ethyl-Ketone(20), packing (21), reservoir (22), and packing (MEK)(23) from pillow block (24). Remove fillerplug (18) and relief fitting (17).

d. Remove bolt (31), washers (30), NOTEbalance washers (29), and balance weight i

(28) from liner (27). If records or physical appearance of

e. Remove nuts (32), washers (33), bolts subjected to an accident or incident(11), and washers (12) from liner (27) and outside the realm of normal usagepillow block (24). Remove liner (27), shims perform the following Conditional(26), and packings (36) from pillow block. Inspection. If hub does not requireRemove seal (35) and retainer ring (34) from Conditional Inspection, accomplishliner. Use T101454 puller jaws and pull Normal Inspection, paragraph 62-21.bearing (25) from liner. (Refer to figure 62-17 If the following evaluation

necessitates replacement of any

62-00-00Page 36

BHT-212-CR&O

12

(204-011-102-021)SHOWN)

13A(212-011-102-105)

23A 18

SOLID FILM LUBETHIS AREA

NOTES

Apply a bead of sealant (C-328) to yoke spindle and radius ring faying surfaces.

2. Apply corrosion preventive compound (C-104) on all internal faying surfaces marked with .

3. Apply primer (C-204) to faying surfaces marked with and install while primer is still wet.

Do not remove any yoke material or teflon coating on bearings to ease installation. It ispermissible to heat bearings 150 - 200°F (83-93°C). Bearing bore and yoke spindles may becoated with hub lubricating oil (C-013) during installation.

Apply corrosion preventive compound (C-127) to thinly coat surface of mast clearance hole inyoke.

6. Apply corrosion preventive compound (C-101) to external surfaces of bolts, nuts, andwashers, marked with *. Do not apply to working threads. 212-R-62-12-1

Figure 62-12. Main rotor yoke (Sheet 1 of 2)

62-00-00Page 37

BHT-212-CR&O

1. Packing 13A. Yoke2. Seal 14. Packing3. Seal sleeve 15. Inboard fitting4. Seal sleeve assembly 16. Pin5. Screw 17. Backup ring6. Lockplate 18. Washer7. Nut 19. Bolt8. Packing 20. Static stop9. Strap 21. Shield

10. Bearing inner race 22. Packing11. Spacer 23. Radius ring12. Bearing inner race 23A. Shield assembly13. Yoke 24. End cap

212-R-62-12-2

Figure 62-12. Main rotor yoke (Sheet 2)

part, also replace both retention along with both retention straps and four strapstraps and four strap pins. pins.

1. Carefully inspect all detail parts visually 3. Dimensionally check for indications offor any apparent damage or abnormal permanent deformation or damage to partsappearance. Visual defects which are cause specified below. A dimensional discrepancyto replace entire hub are: of any part will cause only that part to be

replaced along with parts defined in NOTEa. Yoke obviously bent outside limits above unless stated otherwise in that

established in this manual. particular evaluation procedure.

b. Pitch horn pulled from grip. a. Grip.

c. A segment of sheared mast attached totrunnion.

CAUTIONd. Obvious deformation of any other detail

part within the hub assembly would causeonly the part deformed to be replaced along WHEN MEASURING DISTANCEMEASURING DISTANCEwith parts defined in NOTE above. BETWEEN INNER FACES OF

TANGS, DO NOT FORCE TANGS2. Any detail part within hub assembly which APART MORE THAN 4.506 IN.has sustained surface damage shall also be (114.4524 mm).subject to surface damage inspection andrepair as outlined in paragraph 62-21. (1) A new bolt should fit throughSurface damage in excess of overhaul bushings such that it can be turned with therequires replacing only the damaged part fingers. Set tangs to 4.502 to 4.506 in.

(114.3508 to 114.4524 mm) dimension using

62-00-00Page 38

BHT-212-CR&O

938 PUSH PULLERLESS 1106 LEGS

T101406 PLATE

1124 PULLING' ATTACHMENT

Removal of radius ring,bearing inner races andinner spacer from yoke.

212-R-62-13

Figure 62-13. Yoke disassembly tool

suitable clamping tool or small screw jack. Do b. Yoke.not pinch tangs together more than 4.502 in.(114.3508 mm) or forced apart greater than (1) The precone angle and the4.506 in. (114.4524 mm). If bolt will not fit spanwise straightness must be checked withthrough both bushings simultaneously, a propeller protractor or clinometer.replace entire hub assembly. Measurement must be taken from the

outboard bearing surfaces. Precone angles(1A) Check blade bolt bushing for must be equal within 0°6' . The following chart

indications of looseness or wear. lists the disposition of the yoke for themeasured precone and spanwise

(2) A new bolt should fit freely through straightness.drag brace hole. If bolt will not fit through bothbushings simultaneously, or if bushing isloose in grip, replace entire hub assembly.

PRECONE

REUSE SCRAP YOKE SCRAP HUB

2°30'/300 ' Within 215'/2°30 ' If less than 2°15 '

or

Within 3°00'/3°15' If greater than 3°15'

62-00-00Rev. 3 Page 39

BHT-212-CR&O

NOTES

/A\ Apply primer (C-204) to faying surfaces of shim (25), plate (22) and grip (1). Install whileprimer is still wet.

2A Apply a film of sealant (C-328) to faying surface at seal (19) and plate (22). 212-R-62-14

Figure 62-14. Main rotor hub grip

62-00-00Page 40

BHT-212-CR&O

SPANWISE STRAIGHTNESS

REUSE SCRAP YOKE SCRAP HUB

0°0'/0°06 ' 0°06'/0°18' Greater than 0°18'

c. Main bolt.(2) The flat center section of the yoke

must be checked for flatness. Even if the (1) Measure the diameter of bolt in sixprecone is within limits, should the flat center or eight different locations. The dry filmsections show curvature in excess of 0.0015 lubricant must be removed beforeinch (0.0381 mm), the yoke must be replaced. measurement. Lubricant can be removed byIf the yoke exceeds precone limits and the scrubbing with MEK (C-309). Diameterscenter section is not flat within above limit, should not vary over 0.0005 inch (0.0127then entire hub assembly must be scrapped. mm).

(3) The pillow block bushing bores must (2) Check the bolt on a surface plate forbe round within 0.001 inch (0.0254 mm) out- indications of bending. The centerline of theof-round is exceeded, cadmium plate should bolt must be in line throughout the length ofbe removed and the bore remeasured. the shank within 0.0015 inch (0.0381 mm). IfElongation in excess of 0.002 inch (0.0508 this dimension is exceeded on either bolt,mm) is cause to scrap the entire hub both bolts must be replaced.assembly.

d. Drag brace bolt.

Removal of bearingouter races and outerspacer from grip

212-R-62-15

Figure 62-15. Grip disassembly tool

62-00-00Page 41

BHT-212-CR&O

1. Apply corrosion preventive compound (C-104) on all internal faying surfaces marked with *.

2. Apply primer (C-204) to faying surfaces marked with 0 and install while primer is still wet.

3. Apply corrosion preventive compound (C-101) to external surfaces of bolts, washers, and nutsmarked with *. Do not apply to working threads.

Apply a bead of sealant (C-308) around pillow block bushings, bolt heads, nuts, and washers.

Apply a bead of sealant (C-308) around inboard end of radius ring prior to installation of pillowblock bolts.

212-R-62-16-1

Figure 62-16. Main rotor trunnion and pillow block (Sheet 1 of 2)

62-00-00Page 42

BHT-212-CR&0

*1. Nut 19. Packing*2. Washer 20. Cover

3. Trunnion 21. Packing4. Spindle 22. Reservoir5. Radius Ring 23. Packing6. Packing 024. Pillow block7. Bearing Inner Race 25. Bearing8. Packing 026. Shim9. Lock *027. Liner

10. Thrust washer 28. Balance weight*11. Bolt 29. Balance washer

12. Washer 30. Washer*13. Washer 31. Bolt*14. Washer 32. Nut*15. Spring washer 33. Washer*16. Bolt 34. Retaining ring

17. Relief fitting 35. Seal18. Filler plug 36. Packing

212-R-62-16-2

Figure 62-16. Main rotor trunnion and pillow block (Sheet 2)

(1) Roll drag brace bolt on a flat table to of the trunnion, neither indicator should readcheck for bending. in excess of 0.0005 inch (0.0127 mm) T.I.R.

(2) Any indication of bending is reason (2) The base surface of the trunnionto scrap the bolt. should be checked for flatness on a surface

plate. A deviation from flat in excess of 0.001inch (0.0254 mm) will require replacing the

e. Strap fittings. trunnion.

(1) Strap pin hole should be round g. Drag brace.within 0.001 inch (0.0254 mm).

(1) An unworn bolt must be free fitting(2) Elongation in excess of 0.0015 inch through the clevis bushings.

(0.0381 mm) with the larger diameter in thespanwise direction is cause for replacing (2) With the aid of a straight edge,entire hub assembly. check the inner surfaces of clevis tangs and

surface surrounding holes for indications off. Trunnion. bending. Any distinct deviation from flat is

cause to replace the drag brace.

(1) Trunnion bearing surfaces must be h. Pitch horn.concentric within 0.002 inch (0.0508 mm)T.I.R. Concentricity should be checked by (1) An unworn bolt must be free fittingmounting the trunnion in V-blocks with the V- through the pitch link bushings. Any binding isblock touching only the outer 0.100 inch (2.54 reason to scrap the pitch horn.mm) of the bearing surfaces. A dial indicatorshould be mounted at the inboard edge ofeach trunnion bearing surface. With rotation

62-00-00Page 43

BHT-212-CR&O

(2) With a straight edge, check the flat NOTEmachine surfaces surrounding the pitch linkjoint for deformation. Deviations from flat in The following general formula shall 0excess of 0.001 inch (0.0254 mm) per inch be used for determining amperage(mm) are cause to scrap the pitch horn. (meter). Ampere turns = number of

coil turns (on coil name plate) XAmperage (meter).

(3) The pitch horn to grip surface must ( )be checked on a surface plate. This surface EXAMPLE:should be flat within 0.001 inch (0.0254 mm)per inch (mm). If necessary, removeper inch (mm). If necessary, remove For a 5 turn coil, 11,000 ampere turns - 5interfering bushings. coil turns = 2,200 amperes.

4. Accomplish Normal Inspection Figure and Index Nomenclature Code(paragraph 62-20). No.

62-11, 1 Bolt M (See62-21. Normal Inspection. step 6)

MATERIALS REQUIRED 62-11, 5 Bushing M

Refer to BHT-ALL-SPM for specification and 62-11, 6 Bolt Msource.

62-11, 14 Pitch horn FNUMBER NOMENCLATURE

62-11, 22 Nut FC-206 Thinner

C-308 Adhesive 62-11, 27 Outboard fitting M (Seestep 5)

C-309 Methyl-Ethyl-Ketone(MEK) 62-11, 28 Nut M

C-327 Promoter 62-11, 30 Pin M (See

C-344 Cleaner step 41)

C-407 Abrasive Pad 62-11, 32 Fitting M (Seestep 8)

C-411 Steel Wool |62-11, 33 Nut M (See

step 12)1. Inspect component parts of hub asfollows. If any part shows indications of 62-11, 34 Barrel M (Seeexcessive wear, or is not within tolerance, step 10)check mating part for abnormal wear.

62-11, 35 Nut M (See

2. Inspect the following parts by magnetic step 12)particle (Code M) or fluorescent penetrant(Code F) as applicable. Demagnetize parts 62-11, 36 Clevis M (Seeafter magnetic particle inspection. step 1)

62-12, 13 Yoke M (SeeNOTE step 3)

For approved fluorescent penetrant 62-12,13A Yoke M (Seematerial, refer to BHT-ALL-SPM. step 3)

62-00-00Page 44 Rev. 4

BHT-212-CR&O

(Cont) a. Remove grey lacquer finish usingthinner (C-206).

EXAMPLE:

62-12, 15 Inboard fitting M (See CAUTION I

I62-12, 16 Pin M (See USE OF GLASS BEAD OR SAND

IS NOT AUTHORIZED.

62-16, 3 Trunnion M (Seestep 4) NOTE

62-16, 24 Pillow block F Removal of solid film lubricant,cadmium plating, super koroponepoxy primer, or polyamide epoxy

3. Magnetic particle inspection of yoke (13, primer is not required for magneticfigure 62-12). The yoke must be inspected by particle inspection.all of the following steps using wet continuous

residual method of magnetization. NOTE

3A. Inspect yoke (13A, figure 62-12) by Shot peened area will have anfluorescent penetrant method (BHT-ALL- excess amount of magneticSPM). particles.

938 PUSH PULLERLESS 1106 LEGS 938 PUSH PULLER

LESS 1106 LEGS

Removal of pillowblock bearing outer

8063 STEP PLATE

7 / .. o1107 LEGS T101454- T101454

.x.~ .....- -' .- 1151 PULLING..-.......-.-...-.v.... .......-.. . ' ATTACHMENT

| 1124 PULLING ATTACHMENT . ATTACHMENT

Removal of ring and :::: ::: 1124 PULLING

212-R-62-17

Figure 62-17. Trunnion and pillow block disassembly tool

62-00-00Rev. 4 Page 45

BHT-212-CR&O

If ac magnetic particle inspection NOTEequipment is used, use 60 percentof dc amperes specified. If ac magnetic particle inspection

equipment is used, use 60 percentc. Place yoke longitudinally between of dc amperes specified.

contact heads of inspection equipment. Pass3,000 amperes of dc current through the a. Thoroughly degrease trunnion.yoke.

b. Magnetize trunnion by placing it so thatd. Inspect yoke completely for indications. trunnion arms contact gauze heads of

inspection equipment. Pass 2500 amperes ofe. Place yoke in a coil with longitudinal dc current through trunnion.

axis of coil perpendicular to the plane of thecoil. The yoke shall be placed so that seven ± c. Inspect trunnion completely forone inch (177.8 ± 25.4 mm) of one spindle indications.protrudes from coil. Magnetize yoke using15,000 ampere-turns. d. Place trunnion in a coil with long axis

(trunnion spindles) approximately 90 degreesf. Inspect yoke completely for indications. to direction of current flow in coil. Magnetize

trunnion using 15,000 ampere-turns.g. Repeat step e. with the opposite

spindle protruding seven ± one inch (177.8 ± e. Inspect trunnion completely for25.4 mm) from coil. indications.

h. Inspect yoke completely for indications. f. Acceptance criteria:

i. Repeat step e. with approximately equal (1) Indications interpreted as cracks arelengths of yoke protruding from each end of cause for rejection regardless of length orcoil. location.

j. Inspect yoke completely for indications. () Indication of stringers or non-metallic inclusions will be acceptable provided

k. Thoroughly demagnetize yoke. they do not exceed the following limits:

l. Acceptance criteria.l . Acceptance criteria. (a) Indications of defects parallel tothe long axis of the trunnion arms within 15(1) Indications interpreted as cracks are

cause for rejection regardless of size or degrees are acceptable provided they do notcause for rejection regardless of size or exceed 0.5 inch (12.7 mm) in length and do

. not extend into the radius. The total length ofall inclusions shall not exceed 1.5 inchesm. After completion of inspection,

demagnetize yoke, and check with pocketfield indicator or compass to assuredemagnetization. (b) Indication of defects parallel to

the long axis of the trunnion arms with 15

4. Magnetic particle inspection of trunnion degrees which extend into the radius are(3, figure 62-16). The trunnion must be cause for rejection.inspected by all of the following steps usingwet continuous method. Use of fluorescent (c) Indications of defects in thecoated particles with ultra violet light is trunnion arms, that are more than 15 degreesmandatory. The length of any indication shall off the long axis, transverse, orbe determined by the residual method of circumferential are cause for rejection.magnetization.

(d) Indications of defects on the outersection of the trunnion (excluding the trunnion

62-00-00Page 46

BHT-212-CR&O

spindles) are acceptable provided residual d. Rotate the outboard fitting 180 degreesparticle buildup does not indicate cracks. on the central conductor and repeat steps b.

and c.(e) Indications which are caused by a

sharp change in section are acceptable. e. Place a one inch (25.4 mm) diametercentral conductor through the in-line holes in

(f) Strong magnetic indications where outboard fitting. Place central conductorconsiderable build-up of particles are present, between the contact heads of inspectionindicating the defect has considerable depth equipment. Pass 2,000 amperes of dc currentand/or cross section shall be cause for through the central conductor.rejection regardless of length, size ordirection. f. Inspect outboard fitting completely for

indications.(g) Indications of defects extending

into or in slots, internal splines, or the g. Place outboard fitting in the coil suchthreaded holes (1/4 inch or 3/8 inch (6.3500 that the longitudinal axis of outboard fitting isor 9.5250 mm) diameter) are cause for perpendicular to plane of coil. Magnetizerejection. outboard fitting using 15,000 ampere-turns.

g. After completion of inspection h. Inspect outboard fitting completely fordemagnetize trunnion and check with pocket indications.field indicator or compass to assuredemagnetization. i. Rotate outboard fitting 180 degrees

about its axis and repeat step g.5. Magnetic particle inspection of outboardfitting (27, figure 62-11) and inboard fitting j. Inspect outboard fitting thoroughly for(15, figure 62-12). The outboard and inboard indications.fittings must be inspected by all of thefollowing steps using wet continuous method. k. Acceptance criteria:Use of fluorescent coated particles with ultraviolet light is mandatory. The length of any (1) Magnetic indications interpreted asindication shall be determined by the residual cracks, seams, laps or shuts are cause formethod of magnetization. rejection.

(2) Magnetic indications of stringers orNOTE non-metallic inclusions will be acceptable if

they are within all the following limits.If ac magnetic particle inspection Indications below 1/64 inch (0.39688 mm) inequipment is used, use 60 percent length are not rateable. On rejected parts, allof dc amperes specified. rateable inclusions will be noted.

a. Remove end cap (24) from inboard (a) Indications of defects parallel tofitting. Thoroughly degrease outboard and the axial direction of the part (± 15°) areinboard fittings. acceptable provided they do not exceed 5/8

inch (15.875 mm) in length. There shall notb. Place a 1-3/4 inches (44.45 mm) be more than eight inclusions 1/32 inch

diameter central conductor (copper or (0.79375 mm) or greater in length nor shallaluminum bar) through rectangular hole in the total aggregate length of all inclusionsoutboard fitting. Place central conductor exceed 1-1/4 inches (31.75 mm).between the contact heads of inspectionequipment. Pass 3,000 amperes of dc current (b) Indications that are more than +through central conductor. 150 off the axial direction of the part are not

acceptable regardless of size or location.c. Inspect outboard fitting completely for

indications.

62-00-00Page 47

BHT-212-CR&O

(c) Indication that break over corners, d. Place blade bolt inside coil such thatrun into fillets or threads are not acceptable. long axis of the blade bolt is approximately 90

degrees to direction of current flow in the coil.(d) Indications that terminate at slots, Magnetize blade bolt using approximately

holes or fillet are not acceptable. 9,400 ampere-turns magnetizing force with dccurrent.

(3) Indications which are caused by achange in section such as a sharp edge or e. Inspect blade bolt completely forslot are acceptable. indications.

(4) Strong magnetic indications where f. Acceptance criteria:considerable build-up is present indicating thedefect has definite depth and/or cross section, (1) Magnetic indications interpreted asshall be cause for rejection regardless of size, cracks, seams, laps, shuts or bursts arelength, direction or location. cause for rejection regardless of size or

location.I. After completion of inspection,

demagnetize the fitting and check with a field (2) Magnetic indications of stringers orindicator or compass to assure non-metallic inclusions will be acceptable ifdemagnetization. they are in the following limits. Indications

below 1/64 inch (0.39688 mm) are notm. Perform steps 5.b. through 5.1. on considered rateable.

inboard fitting (15, figure 62-12).

(a) Indications parallel to the longn. Bond end cap (24) to inboard fitting axis (±15°) are acceptable provided they do

withadhesive (C-308). not exceed 1/2 inch (12.7 mm) in length. Notmore than two such indications allowed in any

6. Magnetic particle inspection of blade bolt 1.0 square inch (645.2 sq. mm) of surface(1, figure 62-11). The blade bolt must be area. The total aggregate length of multipleinspected by all of the following steps using small indications shall not exceed 1-1/2wet continuous method. Use of fluorescent inches (38.1 mm) in any 1.0 square inchcoated particles with ultra violet light is (645.2 sq. mm) of surface area.mandatory. The length of any indication shallbe determined by the residual method of (b) Indications that are more thanmagnetization. ±150 off the long axis are rejectable

regardless of size or location.NOTE

(c) Indications that terminate atIf ac magnetic particle inspection edges, slots, threads, and fillets are notequipment is used, use 60 percent acceptable.of dc amperes specified.

(d) Indications of surfacea. Thoroughly degrease blade bolt. discontinuities which break over corners or

run into fillets are not acceptable.b. Magnetize blade bolt by placing blade

bolt between contact heads of inspection (e) Indication of subsurfaceequipment. Pass approximately 1,500 discontinuities which break a transverse face,amperes of dc current through blade bolt are cause for rejection.longitudinally, thus developing a circularmagnetic field. (3) Indication caused by a change in

section thickness are acceptable.c. Inspect blade bolt completely forindications. (4) Indications in internal or external

threads are not acceptable.

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BHT-212-CR&O

(5) Strong magnetic indications where f. Place drag brace fitting in coil such thatconsiderable build-up is present, indicating the longitudinal axis of drag brace fitting isthe defect has considerable depth and/or perpendicular to plane of the coil. Magnetizecross section shall be cause for rejection drag brace fitting using 15,000 ampere-turns.regardless of length, direction, or location.

g. Inspect drag brace fitting completely forg. After completion of inspection, indications.

demagnetize blade bolt and check with pocketfield indicator, or compass, to assure h. Acceptance Criteria.demagnetization.

(1) Magnetic particle indications7. Inspect blade bolt (1, figure 62-11) for interpreted as cracks are rejectable.mechanical and corrosion damage (figure 62-18). If visual indications of wear are present, i. After completion of inspectiondimensionally inspect bolt (figure 62-19). demagnetize drag brace fitting and check withInspect bolt for damage and scratches in dry pocket field indicator or compass to assurelubricant film. demagnetization.

8. Magnetic particle inspection of drag brace j. Inspect internally for corrosion. Anyfitting (32, figure 62-11). The drag brace internal superficial corrosion which cannot befitting must be inspected by all of the removed with cleaner (C-344), abrasive padfollowing steps using wet continuous method. (C-407) or steel wool (C-411) is cause forUse of fluorescent coated particles with ultra rejection.violet light is mandatory. The length of anyindication shall be determined by the residual 9. Inspect drag brace (37, figure 62-11) formethod of magnetization. cracks, nicks, scratches, corrosion and

damaged threads (figure 62-18). InspectNOTE fitting and clevis for wear of protective paint

on mating surfaces.If ac magnetic particle inspectionequipment is used, use 60 percent 10. Magnetic particle inspection of dragof dc amperes specified. brace barrel (34, figure 62-11). The drag

brace barrel must be inspected by all of thea. Thoroughly degrease drag brace fitting. following steps using wet continuous method.

Use of fluorescent coated particles with ultrab. Place drag brace fitting longitudinally violet light is mandatory. The length of any

between contact heads of the inspection indication shall be determined by the residualequipment. Pass 2500 amperes of dc current method of magnetization.through drag brace fitting.

c. Inspect drag brace fitting completely for NOTEindications. If ac magnetic particle inspection

equipment is used, use 60 percentd. Place a 3/4 inch (19.05 mm) diameter of dc amperes specified.

central conductor (copper or aluminum bar)through clevis holes of the drag brace fitting. a. Thoroughly degrease drag brace barrel.Place central conductor between contactheads of inspection machine. Pass 1000 b. Place drag brace barrel longitudinallyamperes dc current through central between contact heads of inspectionconductor. equipment. Pass 1000 amperes of dc current

through drag brace barrel.e. Inspect drag brace fitting completely for

indications. c. Inspect drag brace barrel completely forindications.

62-00-00Page 49

BHT-212-CR&0

d. Place drag brace barrel in coil such f. Place drag brace clevis in the coil suchthat the longitudinal axis of drag brace barrel that the longitudinal axis of drag brace clevisis perpendicular to plane of the coil and equal is perpendicular to plane of the coil.lengths of drag brace barrel protrude from Magnetize drag brace clevis using 15,000each end of coil. Magnetize drag brace barrel ampere-turns.using 11,000 ampere-turns.

g. Inspect drag brace clevis completelye. Inspect drag brace barrel completely for indications.

for indications.h. Acceptance Criteria:

f. Acceptance Criteria.(1) Magnetic particle indications

(1) Magnetic particle indications interpreted as cracks are rejectable.interpreted as cracks are rejectable.

i. After completion of inspectiong. After completion of inspection demagnetize drag brace clevis and check with

demagnetize drag brace barrel and check pocket field indicator or compass to assurewith pocket field indicator or compass to demagnetization.assure demagnetization.

12. Magnetic particle inspection of drag11. Magnetic particle inspection of drag brace nuts (33 and 35). The drag brace nuts Ibrace clevis (36). The drag brace clevis must must be inspected by all of the following stepsbe inspected by all of the following steps using wet continuous method. Use ofusing wet continuous method. Use of fluorescent coated particles with ultra violetfluorescent coated particles with ultra violet light is mandatory. The length of anylight is mandatory. The length of any indication shall be determined by residualindication shall be determined by residual method of magnetization.method of magnetization.

NOTENOTE

If ac magnetic particle inspectionIf ac magnetic particle inspection equipment is used, use 60 percentequipment is used, use 60 percent of dc amperes specified.of dc amperes specified.

a. Thoroughly degrease drag brace nut.a. Thoroughly degrease drag brace

clevis. b. Place a 1-1/4 inch (31.75 mm)diameter central conductor (copper or

b. Place drag brace clevis longitudinally aluminum bar) through the drag brace nut andbetween contact heads of inspection central conductor between contact heads ofequipment and pass 2000 amperes of dc inspection equipment. Pass 1500 amperes ofcurrent through the drag brace clevis. dc current through central conductor.

c. Inspect drag brace clevis completely c. Inspect drag brace nut completely forfor indications. indications.

d. Place a 3/4 inch (19.05 mm) diameter d. Place drag brace nut in coil such thatcentral conductor (copper or aluminum bar) the diameter of drag brace nut is concentricthrough clevis holes. Place central conductor with the coil diameter.between contact heads of inspectionequipment. Pass 1000 amperes of dc current e. Magnetize drag brace nut using 15,000through central conductor. ampere-turns.

e. Inspect drag brace clevis completelyfor indications.

62-00-00Page 50 Rev. 4

BHT-212-CR&O

f. Inspect drag brace nut completely for for rejection. A total of 400 loose ends foundindications. over the entire strap surface is cause for

rejection.g. Rotate drag brace nut 180° around its

diameter and repeat steps d. thru f. b. Strap bulge in excess of 0.06 inch(1.524 mm) outside the normal straight

h. Acceptance Criteria: contour is cause for rejection. Bulging of strapcross-section in any area from the ends of the

(1) Magnetic particle indications strap to 4.0 inches (101.6 mm) inboard isinterpreted as cracks are rejectable. normal and not cause for rejection.

c. Cracks in urethane coating are noti. After completion of inspection demagnetize c. Cracks in urethane coating are not. After completion of inspection demagnetize permitted. Delamination between urethanedrag brace nut and check with pocket field wedges and spools is acceptable.indicator or compass to ensure demagnetization.

d. Delamination of urethane coating from

13. Inspect pitch horn (14, figure 62-11) for the bushings is acceptable. Delamination incracks, dents, nicks and corrosion to limits of any other area is cause for rejection.figure 62-18. Inspect bushings for loosenessand elongation of bolt holes. e. A permanent set in twist may occur and

is not cause for rejection.

14. Inspect nut (28, figure 62-11) for cracks,nicks, damage and corrosion. Inspect threads f. Strap stiffness can vary when flexed inon nut (28) for galling and damage. Inspect an loaded condition and is not cause foroutboard fitting (27) for damage. (Figure 62- rejection.20.) g. Oil contamination resulting in swelling15. Inspect attaching hardware for damage of the urethane coating is cause for rejection.15. Inspect attaching hardware for damage,deformation and crossed or damaged threads. If oil has come in contact with strap butInspect strap pins (30 figure 62-11) and (16, swelling has not occurred, strap assemblynspect strap pins (30, figure 62-11) and (16, shall be cleaned with denatured alcohol tofigure 62-12) for damage and corrosion.Inspect bonded washers for security. remove al traces of ol.

h. Displacement of urethane wedges16. Inspect static stop (20, figure 62-12) for n bushings and inner surface of wirebetween bushings and inner surface of wireelongation of bolt holes and excessive wear bundle is cause for rejection.at point of contact with mast.

i. Cracks in strap bushings are cause for17. Inspect yoke (13 or 13A) for scratches and rejection. Inspect using a 10 power glass.corrosion. Pay particular attention to pillow blockbushing bores and spindle radius. (Figure 62-21.) j. Inspect bushings for fretting corrosion.Inspect bearing seats to limits of figure 62-19 and A maximum of 0.005 inch (0.127 mm) in62-21A if visual inspection indicates wear. Inspect depth for 25 percent total area is allowed onthreads for galling and damage. (Figure 62-21.) bushing flange surfaces. A maximum of 0.002

inch (0.0508 mm) in depth is allowed for 1/4of total bushing bore surfaces.

18. Inspect strap (9, figure 62-12) for wirestrand failures and for abnormalities, such as 19. Inspect inboard strap fitting (15, figuredisplacement of urethane wedges between 62-12) for nicks, damage and corrosion.bushing and inner surface of wire bundle as (Figure 62-20.)follows:

20. Inspect backup ring (17, figure 62-12) fora. A total of 25 broken wires (50 loose cracks, nicks, damage and distortion.

ends) protruding through urethane coating ofany one of the eight outside corners is cause

62-00-00Rev. 2 Page 51

BHT-212-CR&O

21. Inspect inner spacer (11) for corrosion. 32. Inspect bearings (2 and 6) for brokenroller and for spalling of outer race inside

22. Inspect nut (7) for cracks, corrosion and surface. Check for smoothness in operationdamaged threads. (Refer to figure 62-21 for and discoloration due to overheating.limits).

33. Inspect trunnion (3, figure 62-16) for23. Inspect bearing inner races (10 and 12) nicks, damage, and corrosion. (Refer to figurefor evidence of spalling of outer diameter and 62-21 for limits.) Inspect dry-lube film ondiscoloration due to overheat. Inspect for spindles for scratches and wear limits. (Figuresigns of races turning on yoke. 62-22.)

24. Inspect bearing inner races (10 and 12) 34. Inspect bearing inner race (7, figure 62-for integrity of (green) teflon coating. If teflon 16)for evidence of spalling and forcoating is peeling, flaking, or worn through discoloration due to overheating. Check foruntil metal is showing, replacement of bearing signs of race turning on trunnion 3)is necessary. 35. Inspect radius ring (5) for worn outer

surface, corrosion, cracks, and damage.25. Inspect radius ring (23) in seal contactarea for signs of grooving. Grooving depth not 36. Inspect reservoir (22) and cover (20) forto exceed 0.020 inch (0.508 mm). Inspect cracks and damage.rings for cracks and corrosion damage (noneallowed). Inspect shield (21) for tears, 37. Inspect pillow block (24, figure 62-16)bonding or other damage. for nicks, damage, and corrosion (refer to

figure 62-20 for limits).26. Inspect shield assembly (23A) fordamage to elastomer element, broken bond 38. Inspect liner (27, figure 62-16) forbetween elastomer element and metal cracks, warpage, and damage. Inspecthousing, and damaged packing groove. Any helicoil insert for looseness and damageddefects require replacement of shield threads.assembly.

39. Inspect bearing (25) for spalling and27. Inspect plate (22, figure 62-14) for discoloration due to overheating. Check forcracks, elongated bolt holes and distortion. broken rollers and for smoothness in

operation.28. Inspect shims (25) for curled or

28 inspect damaged laminations. (25) Inspect lock (23, figure 62-11), clamp(24), and key (29) for cracks and damage.

29. Inspect reservoir cover (10) and sight Inspect lock (9, figure 62-16) and thrustglass (8) for cracks and damage. washers (10) for damage.

41. Magnetic particle inspection of pin (30,30. Remove grip tang buffer pads (1A, figure 62-11) and pin (16, figure 62-12). Thefigure 62-14) (if installed). Inspect grip (1) pins must be inspected by all of the followingsurfaces for mechanical and corrosion steps using wet continuous method. Use ofdamage. (Figure 62-21 for limits.) Replace fluorescent coated particles with ultravioletgrip if corrosion pitting on tang surface under light is mandatory. The length of anybuffer pads exceeds limits. Inspect rosan indication shall be determined by residualinserts for security and damaged threads. method of magnetization.Inspect diameters, bushing loose in the grip,gap between bushing flange and grip, widthbetween grip tangs and bearing liner inside NOTEdiameter to limits of figure 62-19. Fluorescentpenetrant grip, refer to BHT-ALL-SPM. If ac magnetic particle inspection

equipment is used, use 60 percent31. Inspect outer spacer (4, figure 62-14) of dc amperes specified.for cracks, corrosion, and damage. a. Remove washers from each end of pin.

62-00-00Page 52 Rev. 4

BHT-212-CR&O

204-011-140DRAG BRACE

204-011-151 ABLADE BOLT DAMAGE AREA REPAIR SYMBOLS

TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED

MECHANICAL AND ( 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm)CORROSION Before and After Repair Before and After Repair

O© 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.030 IN. (0.762 mm)Before and After Repair Before and After Repair Before and After Repair

MECHANICAL 0.010 IN. (0.254 mm) 0.030 IN. (0.762 mm)Before and After Repair Before and After Repair

CORROSION 0.005 IN. (0.127 mm) 0.015 IN. (0.381 mm)Before and 0.010 IN. Before and 0.030 IN.

(0.254 mm) After Repair (0.762 mm) After Repair

MAXIMUM AREA PER 0.25 SQ. IN. Not CriticalFULL DEPTH REPAIR (161.3 SQ. mm)

0.25 SQ. IN. 0.35 SQ. IN. Not Critical(161.3 SQ. mm) (225.8 SQ. mm)

0.10 SQ. IN. 0.50 SQ. IN.(64.52 SQ. mm) (322.6 SQ. mm)

NUMBER OF REPAIRS Two Not Critical

212-R-62-18-1BOLT HOLE DAMAGE: · 0.001 IN. (0.0254 mm) for 1/4 Circumference.

Figure 62-18. Blade bolt, drag brace, and pitch horn damage limits (Sheet 1 of 2)

62-00-00Page 53

BHT-212-CR&O

THREADS

A

CREST

1/3 THREAD HEIGHT ZONE 1 - CRESTTHREAD HEIGHT ZONE 2 - FLANK

2/3 THREAD HEIGHT ZONE -ROOT

ROOT

C-cTHREAD PROFILE (ENLARGED)

TYPE/LOCATION OF DAMAGE THREAD REPAIR

MECHANICAL DAMAGE:

Zone 1 1/5 Thread height, A=45°, 2 occurences per thread, 1/3 total no. thread

Zone 2 0.005 IN. (0.127 mm), A=45 °, 1 occurence per thread, 1/4 total no. thread

Zone 3 None allowed

CORROSION DAMAGE:

Zone 1/5 Thread height, A=45°, 2 occurences per thread, 1/3 total no. thread

Zone 2 0.005 IN. (0.127 mm), A=45 ° , 1 occurence per thread, 1/4 total no. thread

Zone 3 0.002 IN. (0.0508 mm), A=45 ° , 2 occurence per thread, 1/2 total no. threads(maintain original root radius, blend to flank)

CRACKS: None allowed 212-R-62-18-2

Figure 62-18. Blade bolt, drag brace, and pitch horn damage limits (Sheet 2)

62-00-00Page 54 Rev. 3

BHT-212-CR&0

- SEE DETAIL A

ITEM NOMENCLATURE inches mm inches mm

1 Liner ID 5.624 142.850 5.631 Avg. 143.0272 Liner A ID 5.374 136.500 5.381 Avg. 136.677

212-R-62-19-1

Figure 62-19. Main rotor hub wear limits (Sheet 1 of 2)

62-00-00Rev. 4 Page 54A/54B

BHT-212-CR&O

NOTES

A Measured at centerline of blade bolt hole.

A Maximum gap of 0.0025 in. (0.0635 mm) allowed between bushing flange and grip surface.

A Maximum gap of 0.0025 in. (0.0635 mm) allowed between bushing flange and tang surface.

A Refer to figure 62-21A for maximum allowable wear step.

Wear step limits in figure 62-21A apply only to 212-011-102-105/-109 yokes configured withinner races 212-311-009-101 and 212-311-010-101.

212-R-62-19-2

Figure 62-19. Main rotor hub wear limits (Sheet 2)

GENUINE BELL PARTS ARE YOUR BEST VALUE 62-00-00Rev. 2 Page 55

BHT-212-CR&O

FIT TING FITTING PILLOW BLOCK204-012-103 212-010-103 204-011-108

DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

CORROSION(Before and after repair) 0.005 IN. (0.127 mm)

MECHANICAL 0.005 IN. (0.127 mm)

(Before and after repair) 0.020 IN. (0.508 mm) 0.040 IN. (1.016 mm)

CORRISION(Before repair) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

(After repair) 0.020 IN. (0.508 mm) 0.040 IN. (1.016 mm)

MAXIMUM AREA PER 0.50 SQ. IN.FULL DEPTH REPAIR (322.6 SQ. mm)


NUMBER OF REPAIR One insideAREA One outside

One per segment Not Critical

EDGE CHAMFER 0.020 IN. (0.508 mm)

0.060 IN. (1.524 mm) 0.100 IN. (2.54 mm)

THREAD DAMAGE:DEPTH: One-quarter of threadLENGTH: One-half inch (one-half mm)NUMBER: One

STRAP PIN HOLE: 0.0005 IN. (0.0127 mm) for 1/4 circumference

BOLT HOLE DAMAGE: 0.001 IN. (0.0254 mm) for 1/4 circumference. 212-R-62-20

Figure 62-20. Outboard fitting, inboard fitting, and pillow block damage limits

62-00-00Page 56

BHT-212-CR&O

^3^^''*''^ YOKE ASSEMBLY (^\l^----^/204-011-102

YOKE ASSEMBLY204-011-102 GRIP

n^---~^,^>-t1 204-011-121 \-

DAMAGE AREA REPAIR SYMBOLS


MECHANICAL AND ( 0.002 IN. (0.0508 mm) 0.005 IN. (0.127 mm) 0.020 IN. (0.508 mm)

CORROSION After Repair Before and After Before and After Repair

(Restore to RHR 125)

MECHANICAL ) 0.020 IN. (0.508 mm) 0.060 IN. (1.524 mm)Before and After Repair Before and After Repair

CORROSION 0.010 IN. (0.254 mm) 0.030 IN. (0.762 mm)Before and Before Repair and

0.020 IN. (0.508 mm) 0.060 IN. (1.524 mm)After Repair After Repair

MECHANICAL AND () 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.002 IN. (0.0508 mm)

CORROSION Before and After Repair Before and After Repair Before and After Repair

MAXIMUM AREA PER 0.50 SQ. IN. 0.50 SQ. IN. Not Critical

FULL DEPTH REPAIR (322.6 SQ. mm) (322.6 SQ. mm)

ot Critical

.0.10 SQ. IN. 0.50 SQ. IN. 0.10 SQ. IN.

(64.52 SQ. mm) (322.6 SQ. mm) (64.52 SQ. mm)

BORE DAMAGE: 0.002 IN. (0.0508 mm) for 1/4 circumference.

212-R-62-21 -1

Figure 62-21. Main rotor grip, yoke, yoke nut, and trunnion damage limits (Sheet 1 of 5)

62-00-00Rev. 3 Page 57

BHT-212-CR&O

TRUNNION ASSEMBLY204-011-105


NUMBER OF REPAIRS (I) Two Per Side Not Critical Not CriticalDiametrically Opposed

Not Critical

One Per Segment Not Critical Not Critical

EDGE CHAMFER ( ) 0.030 IN. (0.762 mm) 0.040 IN. (1.016 mm)

0.060 IN. (1.524 mm) 0.100 IN. (2.54 mm)

0.040 IN. (1.016 mm) 0.040 IN. (1.016 mm) 0.040 IN. (1.016 mm)

SPLINE DAMAGE: Depth: One-Third of Spline

3 Length: One-Half of Spline

Number: Three Splines

THREAD DAMAGE: ( Depth: One-Third of Thread

Length: One-Half Inch (One-Half mm)

(3 ) One-Quarter Inch (One-Quarter mm)

Number: Two Per Segment (One-Half mm)

02) One Per Segment

Depth:

Length:

BOLT HOLE DAMAGE: · 0.002 IN. (0.0508 mm) for 1/4 circumference.212-R-62-21-2

Figure 62-21. Main rotor grip, yoke, yoke nut, and trunnion damage limits (Sheet 2)

62-00-00Page 58 Rev. 3

BHT-212-CR&O

YOKE ASSEMBLY



MECHANICAL 0.002 In. (0.0508 mm) 0.005 In. 0.005 In.BEFORE AND AFTER REPAIR (Restore to RHR 16) (0.127 mm) (0.127 mm)

CORROSION 0.002 In. (0.0508 mm) 0.005 In. 0.005 In.BEFORE AND AFTER REPAIR (Restore to RHR 16) (0.127 mm) (0.127 mm)

MAXIMUM AREA PER 0.20 Sq. In. 0.20 Sq. In. 0.50 Sq. In.NONOVERLAPPING FULL (129.032 Sq. mm) (129.03 Sq. mm) (322.6 Sq. mm)DEPTH REPAIR

NUMBER OF Two per side Four FourNONOVERLAPPING diametrically opposedREPAIRS

EDGE CHAMFER 2 Not applicable

THREAD DAMAGEDEPTH: One-third of threadLENGTH: One-half inchNUMBER: Two per segment

BORE DAMAGE: 0.002 IN. (0.0508 mm) for 1/4 circumference.212-R-62-21-3


62-00-00Rev.2 Page 59

BHT-212-CR&O

BUSHING - PILLOW BLOCK204-011-135-105

TYPE OF DAMAGE DAMAGE AREA REPAIR SYMBOLS

MECHANICAL AND 0.002 In. (0.051 mm) 0.010 In. (0.051 mm)CORROSION

MAXIMUM AREA PER ( 0.01 Sq. In. (6.4 mm2) 0.10 Sq. In. (64.5 mm2 )

FULL DEPTH REPAIR

NUMBER OF REPAIRS ( 1 per segment 1 per segment

EDGE CHAMFER ) 0.02 In. (0.50 mm) 0.03 In. (0.76 mm)

BORE DAMAGE: ( 0.001 Inch (0.025 mm) for 1/4 circumference212-R-62-21-4


62-00-00Page 60

BHT-212-CR&O

YOKE NUT204-012-106-101

DAMAGE AREA REPAIR SYMBOL

TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR SYMBOLS ALLOWED

MECHANICAL AND 0.010 IN. (0.254 mm) Before and AfterCORROSION

MAXIMUM AREA PER 0.10 SQ. IN. (64.52 SQ. mm)FULL DEPTH REPAIR

NUMBER OF REPAIRS Two

EDGE CHAMFER 0.030 IN. (0.762 mm)

SPLINE DAMAGE Depth: One-Third of Spline

Length: One-Half of Spline

6 Number: Two Splines

THREAD DAMAGE Depth: One-Third of Thread

Length: One-Fourth Inch

Number: Two. Not Within 90 Degrees

NOTES

Area of repair on surfaces with blade or drag brace shall not exceed one-half of any quadrant.

Material removal not to exceed mechanical damage repair limit.

Overlapping repairs are not permitted.

A Cross hatch damage area repair symbols is only if buffer pad is not installed.

5A No delamination of buffer pad to grip is allowed.

Maximum depth repair to journals is limited by maximum wear step allowance (figure 62-21 A) andby minimum diameter limitations (figure 62-19). (Repair depth is not additive to maximum wearstep.)

7. No cracks allowed. 212-R-62-21-5


62-00-00Rev. 2 Page 60A/60B

BHT-212-CR&O

TOP

AFT I FORWARD

BOTTOM \ )VIEW1B-B13

LOOKING INBOARD

FORWARD SIDE OF WEAR AREAS ON BEARINGSPINDLE JOURNALS

SHOT PEENED AREA WEAR AREAWEAR STEP

SECTION A-A

ITEM NOMENCLATURE A MAXIMUM WEAR STEP1 Outboard Journal 0.008 (0.203 mm)2 Inboard Journal 0.003 (0.076 mm) FWD side

0.0045 (0.114 mm) Top or bottom0.006 (0.152 mm) Aft side

NOTE

A Minimum diameter in figure 62-19 applies to wear step. (Maximum wear step shall not exceedminimum diameter).

A Wear step limits apply only to 212-011-102-105/-109 yokes configured with inner races212-311-009-101 and 212-311-010-101.

212-R-62-21A

Figure 62-21A. Spindle journal wear step limits

62-00-00Rev.2 Page 61

BHT-212-CR&O

b. Thoroughly degrease pin. C-005 Solid Film Lubricant

c. Place pin longitudinally between C-021 Lubricantcontact heads of machine. Pass 1000 C-100 Chemical Film Materialamperes of dc current through pin.

C-101 Corrosion Preventived. Completely inspect pin for indications. Compound

e. Place pin in coil such that longitudinal C-108 Brush Cad m i u maxis is perpendicular to plane of coil. Plating SolutionMagnetize pin using 15,000 ampere-turns.201

C-201 Primerf. Completely inspect pin for indications. C-203 Primer

g. Acceptance criteria. C-204 Lacquer

(1) Magnetic particle indications C-207 Enamelinterpreted as cracks are not acceptable andthe pin must be scrapped. C-301 Adhesive

C-304 Solvent(2) If any strap pins are found cracked, C-304the mating strap fitting shall also be scrapped. C-305 Aliphatic Naphtha

h. After completion of inspection C-309 Methyl-Ethyl-Ketonedemagnetize pin and check with pocket field (MEK)indicator or compass to assuredemagnetization. C-317 Adhesive

C-328 Sealing Compoundi. Clean ends of pin and two C-328 Sealing CompoundAN960JD816L washers using a abrasive pad C-334 1.1.1-Trichloroethane(C-407) and MEK (C-309). Wipe dry with aclean cloth. C-344 Cleaning

j. Bond one AN960JD816L washer to C-363 Adhesiveeach end of pin. Use adhesive (C-317) to Abrasivebond washers. Allow adhesive to cure for 24hours at room temperature or for 30 minutes C-411 Steel Woolat a temperature of 145 to 180°F (63 to82°C). C-423 Abrasive Cloth or

Paper

62-22. REPAIR C-463 Cerex

C-464 India StoneMATERIALS REQUIRED C-464 India Stone

Refer to BHT-ALL-SPM for specification and C-500 Crocus Clothsource.

NUMBER NOMENCLATURE

62-00-00Page 62 Rev. 4

BHT-212-CR&O

1. Replace all packings and seals. Replace b. Mix adhesive in accordance withO^ self-locking nuts and unserviceable attaching following note. Apply adhesive to fayinghardware. surface of pin and washer. Locate washer on

pin centerline within 0.010 inch (0.254 mm).

2. Replace parts that fail magnetic particle Apply firm pressure to bond and cure bond inor fluorescent penetrant inspection, accordance with following note.

3. Replace parts having mechanical or NOTEcorrosion damage that exceed repair limits offigures 62-18, 62-20, and 62-21. For EA934 (C-317) mix 33 parts B to

100 parts A. Ensure firm contact4. Replace parts that exceed wear limits of between parts and allow to cure atfigures 62-19 and 62-22. room temperature 70 to 95°F (21 to

35°C) for 24 hours. (Maximumstrength in 6 to 7 days at room

5. Replace shims if laminations are curled or strengt in 6 to 7 a at rmdamaged. temperature.) Alternate curing may

be accomplished by heating area175 to 190°F (79 to 88°C) for 60

6. If bonding between washer and ends of minutes.strap retaining pins is broken, bond washer inplace with adhesive (C-317). 7. Replace radius ring (shield assembly) (23,

figure 62-12) if damage penetrates harda. Lightly abrade surfaces to be bonded anodized finish or if groove in seal area

with 400 grit abrasive cloth or paper (C-423). exceeds 0.020 inch (0.508 mm) in depth. IfDo not remove cadmium plating from sides radius ring shield is torn or damaged, replace. and chamfer of pin. as follows:

4

2

ITEM NOMENCLATURE MIN. MAX.inches mm inches mm

1 Bushing OD 0.9980 25.3492 0.9990 25.37461A Bushing (204-011-135) OD 0.9980 25.3492 0.9994 25.3848

2 Pillow Block ID 3.7500 95.25 3.7520 95.30083 Liner ID 3.4992 88.87968 3.5010 88.72544 Spindle (After Coating) OD 2.2490 57.1246 2.2505 57.1627

Figure 62-22. Trunnion limits chart 212-R-6222

62-00-00Page 63

BHT-212-CR&O

a. Remove damaged shield and clean off fitting and barrel with primer (C-204). Do notaged adhesive. allow primer on threads of barrel or fitting.

b. Vapor degrease shield and ring. c. Polish damaged areas of drag bracebolts (9) blending edges of damage into

c. Apply adhesive (C-301) to mating surrounding surface to a smooth contour,surfaces of both the shield and ring and to using crocus cloth (C-500). Damage areainside diameter of shield. Mix and cure shall not exceed one-fourth of boltadhesive to specifications listed on container. circumference after cleanup. Replace bolts if

outside diameter is less than the followingd. Position shield on radius ring and apply limits.

sealing compound (C-328) to bridge gapbetween shield and machined breakout of ring (1) Inboard drag brace bolt 0.8721 inch(two places). Apply light pressure to the (22.15134 mm).assembly and cure for 24 hours at 160°F(71°C), or five days at room temperature. (2) Outboard drag brace bolt 0.8721

inch (22.15134 mm).8. Repair drag brace (37, figure 62-11) asfollows: 9. Blade bolt (1, figure 62-11).

a. Externally. a. Polish out minor scratches, scoremarks and damage with crocus cloth (C-500)

(1) Polish out minor nicks, scratches (figure 62-18).and dents with crocus cloth (C-500) . (Figure62-18.) Coat repaired areas with brush brush b. Replace blade bolts if scored, corrodedcadmium plating solution (C-108) (BHT-ALL- or worn (figure 62-18 or 62-19).SPM). Replace components if damage orcorrosion exceed limits of figure 62-18. c. Coat repaired areas with brush

cadmium plating solution (C-108). (Refer to(2) Repaint, two coats as required, BHT-ALL-SPM for prescribed cadmium plating

inside tang surfaces of clevis (36, figure 62- method.) Replace solid film lubricant (C-005)11) and outboard flat surfaces of fitting (32) by spray or dip method if damaged orwith enamel (C-207) . Allow enamel to cure at removed for inspection. Apply 0.0002 to65 to 85°F (18 to 29°C) for 48 hours or 0.0005 inch (0.00508 to 0.0127 mm) thick onelevated temperature of 180°F (82°C) two all exterior surfaces (BHT-ALL-SPM).hours.

10. Pitch horn (14, figure 62-11).

NOTE a. Polish out minor nicks, dents andAllow enamel to a i r dry scratches with crocus cloth (C-500).approximately 30 minutes prior toelevated temperature curing. b. Coat repaired areas with chemical film

material (C-100).b. Internally.

c. Replace pitch horn if cracked, or if(1) Remove internal corrosion from damaged or corrosion exceeds limits of figure

fitting (32, figure 62-11) with cleaner (C-344), 62-18.abrasive pad (C-407) or steel wool (C-411). Ifcorrosion cannot be removed by either d. Replace bushings that are loose or out-method, replace fitting. of-round as follows:

(2) Treat area of corrosion removal by (1) Press out bushing in horn baseassembling fitting to barrel (34). Fill and drain (surface mating with grip). Replace pitch horn

62-00-00Page 64

BHT-212-CR&O

if diameter of hole in horn base exceeds d. Refinish yoke as follows:0.688 inch (17.4752 mm).

(1) First overhaul interval for yokes not(2) Bushings in control end of pitch previously painted.

horn:

(a) Press out single bushing first then CAUTIONuse a drift to remove one of the dualbushings.

APPLICATION OF ALCOHOLIC(b) Press out remaining bushing. PHOSPHERIC CLEANER SHALL

Replace pitch horn if diameter of hole in BE ACCOMPLISHED TO ENSUREcontrol end of pitch horn exceeds 0.5005 inch REMOVAL OF ANY CORROSION.(12.7127 mm).

(a) Apply cleaner (C-344) to areas A,(3) Thoroughly clean pitch horn with B, and C, figure 62-23, using a clean cloth.

solvent (C-304), apply wet primer (C-201) to Rub briskly for approximately 30 to 60hole in pitch horn and outside diameter of seconds.bushing spindle. Apply heat lamp to pitchhorn and press in bushing. (b) Rinse thoroughly with clean

flowing distilled water and wipe dry with a(4) Line ream bushings in control end of clean cloth.

pitch horn 0.3743 to 0.3748 inches (9.50772to 9.51992 mm) after installation. Bushings in (c) Touchup any cadmium plating asbase do not require line reaming. required in areas B and C using brush brush

cadmium plating solution (C-108).11. Nut (28, figure 62-11) and pin (30).

(d) Apply minimum thickness ofa. Polish out minor nicks and scratches. 0.0004 inch (0.01016 mm) aliphatic naphtha

(C-305)solid film lubricant (C-005) to area Ab. Replace part if cracked, damaged or (spindles) (BHT-ALL-SPM). Do not apply solid

corroded. film lubricant to area B (spindle radius).

12. Static stop (20, figure 62-12). Replace NOTEstatic stop if bolt holes are elongated orcracked or if part is distorted. If oven equipment necessary to bake

solid film lubricant (C-005) is not13. Yoke (13 and 13A, figure 62-12). available, lubricant, solid film (C-

021)may be used which can bea. Polish out minor scratches and damage cured 150°F (66°C) by heat lamps or

on noncritical areas of yoke with crocus cloth, heat gun.

b. Figure 62-21 for repair limits. (e) Apply one spray coat of primerLongitudinal scratches on spindle not in (C-202) to all surfaces of area C, except theexcess of 0.002 inch (0.0508 mm) deep need seating bore area for the inboard strap fitting.not be completely removed. Surface burrs Apply one spray coat of primer to area Bshould be removed using crocus cloth (C- (spindle radius). Allow to air dry at least one500). Clean up minor damage to threads. hour but no more than four hours.

c. Replace yoke if cracked, bearing seats areworn beyond limits of figure 62-19 or if damaged NOTEbeyond repair. Check yoke journals for evidence Acrylic lacquer will not adhere toof a wear step. If wear step is greater than the primer (C-202) that has dried morelimits shown in figure 62-21A replace yoke. than four hours.

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BHT-212-CR&O

primer (C-202) to areas where primer wasCAUTION removed and one mist coat to areas where

***************** primer is intact. Allow to air dry at least onehour but no more than four hours.

ACRYLIC LACQUER THICKNESSMUST BE UNIFORM WITH 0.001 (f) Apply two spray coats of lacquerINCH (0.0254 MM) MAXIMUM (C-203), light gull gray, color No. 36440, to allACCUMULATION PER COAT ON primed surfaces of areas B and C, exceptTOP SURFACE OF YOKE (AREA pillow bushing holes. Spray coats applied toC). area B (spindle radius) should be thin. Allow

to air dry one hour minimum between coats.(f) Apply two spray coats of lacquer

(C-203) light gull gray, color No. 36440, to all 14. Strap (9, figure 62-12).primed surfaces of areas B and C exceptpillow block bushing holes. Spray coats a. Replace strap if severely ruptured or ifapplied to area B (spindle radius) should be loose wire ends protrude through thethin. Allow to air dry one hour minimum urethane coating, exceeding the followingbetween coats. limits:

(2) Refinish procedures for second and (1) Fifty loose ends in any one corner.subsequent overhauls (first for paintedyokes). (2) A total of 400 loose ends over entire

surface.(a) Apply cleaner (C-344) to area A,

B, and C, figure 62-23, using a clean cloth. b. Loose ends should be snipped off flushRub briskly for approximately 30 to 60 with urethane coating and the number foundseconds. entered in hub historical record. If,

subsequent inspection reveals additional(b) Rinse thoroughly with clean loose ends, this number should be added to

flowing distilled water and wipe dry with a entry in hub record to determine disposition ofclean cloth. strap.

(c) Touchup any exposed surface in 15. Inboard fitting (15, figure 62-12) andareas B and C where primer and cadmium outboard fitting (27, figure 62-11).plating has been removed using brushcadmium plating solution (C-108). a. Polish out minor nicks and corrosion

damage (figure 62-20).(d) Apply minimum thickness of

0.0004 inch (0.01016 mm) of solid film b. Replace fitting if cracked or badlylubricant (C-005) to area A (spindles). (Refer corroded.to BHT-ALL-SPM.) Do not apply solid filmlubricant to area B (spindle radius). 16. Backup ring (17, figure 62-12).

a. Polish out minor nicks, scratches, andNOTE dents.

If oven equipment necessary to bake b. Replace ring if cracked or distorted.solid film lubricant (C-005) is notavailable, lubricant, solid film (C- 17. Replace pin (16) or spacer (11), if021) may be used which can be corroded or crackedcured 150°F (66°C) by heat lamps orheat gun. 18. Nut (7).

(e) Lightly rub primed areas B and Cusing abrasive pad (C-407). Apply one coat of

62-00-00Page 66

BHT 212 CR&O

C

212-R-62-23

Figure 62-23. Main rotor yoke refinishing areas

a. Clean up minor damage to outer NOTEsurface.

Blade bolt bushings can only beb. Replace if cracked, damaged, or replaced by Bell Helicopter or

corroded. Authorized Repair Center.

19. Replace radius ring (23) if cracked, a. Polish out nicks, dents and corrosioncorroded, damaged or if outside diameter is on outer surface of grip (1), (figure 62-21 forless than 5.488 inches (139.40 mm). repair areas and limits.) Treat repairs with

brush chemical film material (C-100). Replace20. Replace bearings (2 and 6, figure 62- blade bolt bushing (4, figure 62-19) if worn,14) if rollers are broken, if spalling or damaged, or loose.brinelling is evident, if discolored due tooverheating or rough in operation. Replace b. Clean and coat all external surfaces ofbearings (2 and 6) if inner races (10 and 12, 204) and twofigure 62-12) are spalled or discolored due to spray coats of coat (C-245). Omit paintoverheating. spray coats of coating (C-245). Omit paintfrom all holes, bores, bushings, flanges, and

name plate.21. Replace plate (22, figure 62-14) if name plate.cracked, distorted or if bolt holes areelongated, or if shield contact area on plate (1) Vapor degrease grip using 1.1.1-reservoir drain port exceeds a depth of 0.150 trichloroethane (C-334) at 188 to 193°F (87 toinch (3.81 mm). 89C) and abrasive pad (C-407). After

cleaning apply a film of water to surface and22. Replace shims (25) if laminations are check for water break free surface. If acurled or damaged. flashout occurs within 25 seconds after flow

of water stops, repeat cleaning and testing.23. Replace cover (10) and sight glass (8) ifcracked or damaged. (2) Apply brush coat of chemical film

material (C-100) to surface. Rinse with clean24. Grip repair. water and dry with cheese cloth or tack rag.

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BHT-212-CR&0

(3) Apply primer (C-204) to surface. d. Replace blade bolt bushings if insidePrimer shall be overcoated in not less than diameter or gap between bushing flange and1.0 hour and not more than 8.0 hours. If grip tang exceeds limits of figure 62-19.primer was applied at elevated temperatures,apply overcoat in not less than 30 minutes (1) Deleted.and not more than 3 hours.

(2) Deleted.(4) Apply coating (C-245) within time

limits of step (3). Apply a second coat oflacquer after a minimum 30 minutes drying NOTEtime. Bushings can only be replaced by

repair facilities approved by BellNOTE Helicopter Textron.

Lacquer surfaces not overcoated e. Replace drag brace bolt bushings ifwithin one hour requires being tack inside diameter exceeds limits of figure 62-19.rag wiped prior to application of next

coat. (1) Deleted.

(5) Cure by air drying for one hour and (2) Deletedbaking at 160°F (71°C) for one hour.Alternate cure is air dry at room temperaturefor four to six hours. f. Replace grip if dimension between

tangs exceed limits of figure 62-19. If linersexceed dimensions in figure 62-19, liners can

c. Replace rosan inserts in grip if loose only be replaced by repair facilities approvedor threads are damaged. by Bell Helicopter Textron.

(1) Remove insert by drilling through g. Install grip tang buffer pads (1A, figurelockring with a drill which will just clean up 62-14) as follows:serrations on inside diameter. Use a squaretype extractor and remove insert. Collapseany remaining lockring and remove. NOTE

The 204-011-121-009 grip uses(2) Inspect and clean up threads and buffer pad P/N 212-010-121-101

counterbore. If threads are worn or hole is Grin 204-011-121-121 uses bufferbadly deformed, use next oversize insert. pad P/N 204-010-534-101.

(3) Coat mating surfaces with primer This repair applies to any grip with(C-201) or primer (C-202) and screw insert corrosion on the tang, less thaninto grip (using installation tool), while wet, 0.010 inch deep regardless of theuntil top of serrations are 0.010 and 0.020 area. Repair to be made ininch (0.254 to 0.508 mm) below surface of conjunction with normal overhaul/grip. Place lockring over insert, engage inspection requirements of theserrations on inside diameter with serrations CR&O manual. When accomplishedon insert, and drive flush with top of insert. the grip will be subject to original

service limits and balance of anyretirement life.

NOTEThe grip part number is to be altered

Bushings can only be replaced by by adding suffix characters "FM"repair facilities approved by Bell with vibrating stylus to end of partHelicopter Textron. number 204-011-121-ALL.

62-00-00Page 68 Rev. 4

BHT-212-CR&0

(1) Abrade buffer pads on side to be bores within 0.030 inch. Seal and fair edgesbonded to grip tangs with 180 grit abrasive around buffer pad ensuring no voids exist.cloth or paper. Clean pads thoroughly with Remove excess adhesive with clean clothclean cloths moistened with alphatic naphtha dampened with MEK (C-309).(C-305). Wipe surfaces dry with clean cloths.

(5) Apply bond line pressure over the(2) Clean surfaces to be bonded on grip full bond region throughout the cure cycle.

tangs with clean cloths moistened with Seal and fair squeeze out around buffer padalphatic naphtha (C-305). Wipe surface dry and during the curing cycle check for edgewith clean cloths. voids and fill and seal as necessary. Cure for

24 hours at 70 to 80°F (21 to 27°C), or for 60(3) Mix adhesive (C-331) thoroughly per minutes at 180 to 200°F (82 to 93 °C). Inspect

manufacturers instructions using 100 Part as bond lines, no voids or pin holes are"A" to Part "B". Pot life is 40 to 45 minutes. As permitted around pads, seal with adhesive.soon as possible after mixing adhesive, applyto each tang faying surface, extending (6) After bonding decontaminateapproximately 1/16 inch past edge diameter surfaces with naphtha and dry. Light sandingof buffer pad. is permissible.

(4) Press parts together firmly ensuring 25. Trunnion Repair.buffer pad is aligned with blade bolt bushing

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BHT-212-CR&O

3 SEE VIEW B

SEE VIEW A /

1.1245to 1.1255IN.(28.5623 to 28.5877 mm)

SURFACE B2.872 to 2.876 IN.

.+--- (72.9488 to73.0504 mm)

SURFACE A

-- ' 2.500 to 2.501 IN.(63.5 to 63.5254 mm)

VIEW A VIEW B

1. Blade bolt bushing2. Grip3. Drag brace bolt bushing 212-R-62-24

Figure 62-24. Main rotor hub grip bushing replacement

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BHT-212-CR&O

a. Polish out minor nicks and scratches on 29. Pillow Block Repair (24).surface of trunnion (3, figure 62-21) withcrocus cloth (C-500) not to exceed limits of a. Polish out minor nicks and scratches infigure 62-22. pillow block with crocus cloth (C-500). (See

figure 62-20.)b. Coat repaired areas with brush

cadmium plating solution (C-108). Refer to b. Coat repaired areas with brushBHT-ALL-SPM. chemical film material (C-100).

c. Clean up minor nicks, burrs and c. Replace pillow block if damaged,scratches on splines with fine India stone (C- cracked or damaged beyond limits in figure464). 62-20.

d. Replace trunnion if cracked, damaged 30. Replace liner (27, figure 62-16) ifor corrosion limits of figure 62-21 are cracked, warped or damaged. Replace helicoilexceeded. insert if loose or damaged.

e. Clean with cloth moistened with MEK 31. Replace buffer (1, figure 62-25) if torn or(C-309). Apply solid film lubricant (C-005) to worn through.trunnion spindle outside diameter, 0.0002 to0.0004 inch (0.00508 to 0.01016 mm) thick NOTEper surface (BHT-ALL-SPM).

Buffer is to be used only on pillow

NOTE blocks with existing buffer.

Allow solid film lube to dry 30 a. Remove remaining material andminutes at room temperature, then adhesive on the pillow blocks by carefullyheat to 350° ± 15°F (177° ± 9°C) for peeling and scraping with a plastic scraper.60 minutes. Wipe clean with MEK (C-309).

(1) Spindle diameter, after coating to be b. New buffer should be lightly sanded2.2490 to 2.2505 inches (57.1246 to 57.1627 using 320 grit or finer abrasive cloth or papermm). (C-423). Wipe clean with MEK (C-309).

(2) Apply corrosion preventive c. Cut bond spacer (3) using cerex (C-compound (C-101) to trunnion spindle inside 463) one-half inch (12.7 mm) larger thandiameter. pillow block.

26. Replace bearing inner race (7, figure 62- d. Spread adhesive (C-363) on buffer and16) and mating bearing if spalled or pillow block faying surfaces.discolored due to overheating. Replace innerrace mating bearing, and trunnion (3) if e. Place bond spacer between buffer anddamaged due to race turning on spindle (4). pillow block. Clamp pillow block and buffer inReplace bearing (25) if spalled, discolored a locally fabricated fixture. Cure for one hourdue to overheating, roller is broken or is at 175 to 190°F (79 to 880C).rough in operation.

f. When cured, trim around base of pillow27. Replace radius ring (5) if outer surface block.has corrosion or mechanical damage deeperthan 0.005 inch (0.127 mm), or if remainder of 32. Replace bearing (25, figure 62-16) andring is damaged or cracked. mating bearing if spalled, discolored due to

overheating, roller is broken or is rough in28. Replace reservoir (22) and cover (20) if operation.cracked or damaged.

62-00-00Page 70

BHT-212-CR&O

33. Replace any part if defects are found for 14, and 62-16, and install whilewhich no damage limits are established. primer is still wet (BHT-212-MM).

62-23. ASSEMBLY. NOTE

All torque values are standardMATERIALS REQUIRED unless otherwise specified (BHT-

ALL-SPM.)NUMBER NOMENCLATURE

1. Assemble yoke as follows:C-013 Lubricating Oil

C-015 Lubricant (Tube Pack) NOTE

C-017 Lubricant Following procedure is for one sideonly. Opposite side is identical and

C-101 Corrosion Preventive should be assembled at same time.Compound

a. Position yoke (13 or 13A figure 62-12) 1C-104 Corrosion Preventive on edge and temporarily install static stop

Compound (20).(20).C-127 Corrosion Preventive

Compound b. Position T101421 adapter plate, flatsurface down, on T101356 buildup bench.

C-204 Primer Place yoke on build-up bench and plate.

C-304 SolventNOTE

C-308 AdhesiveCoat inner diameter of yoke

C-309 Methyl-Ethyl-Ketone assembly with corrosion preventive(MEK) compound (C-101)or corrosion

-316 preventive compound (C-127).C-316 Acetone

C-322 Adhesive c. Install radius ring or shield assembly(23 or 23A, figure 62-12) as follows:

C-326 Alcohol(1) Clean inboard side of radius ring

C-328 Sealing Compound (23)/shield assembly (23A) and spindle radiusC-368 Tetra-Etch on yoke (13 or 13A) with a cloth dampened

with solvent (C-304).C-405 Lockwire

(2) Install packing (22) in radius ring(23) or shield assembly (23A).

~~~~NOTE (3) Place radius ring/shield assemblyApply corrosion preventive under heat lamp for approximately 30 minutescompound (C-101) or corrosion prior to installation.preventive compound (C-104) tofaying surfaces of parts specified in (4) Apply a bead of sealing compoundfigures 62-11, 62-12, 62-14, and 62- (C-328) to yoke spindle radius.16, during assembly. Apply primer(C-204) to faying surfaces of parts (5) Position radius ring/shield assemblyspecified in figures 62-11, 62-12, 62- and packing on yoke and tap lightly using a

nonmetallic drift to ensure seating on yoke

62-00-00Page 71

BHT-212-CR&O

'-0.475 ± 0.002 IN.(12.065 ± 0.0508 mm)

1. Buffer P/N 150-022-12. Pillow block 22R23. Bond spacer cerex 3607-21

Figure 62-25. Pillow block buffer

I spindle radius. Fair sealant squeeze-out to inner race (12) and install on spindle againstensure that no sealant voids exist between radius ring (23). Slide spacer (11) on spindleradius ring and adjacent yoke surfaces. with stepped end outboard. Install outer

bearing inner race (10) next to spacer. Notedirection of chamfer on bearing races (10 and

NOTE 12).

Bearing inner race (10) and bearinginner race (12) may be installed withchamfer inboard or outboard. Both CAUTIONinner race and bearing must beinstalled with chamfer in the same DO NOT REMOVE ANY YOKE

direction. MATERIAL OR TEFLON COATINGON BEARINGS (212-011-111-103

CAUTION INSTALLATION (A.S.B. 212-92-80).

e. After accomplishment of A.S.B. 212-92-DO NOT MIX LUBRICANT (TUBE 80 heat bearings to 150 to 200 °F (83 to 93PACK) (C-015) OR LUBRICANT (C- °C). Apply lubricating oil (C-013) to inner017). diameter of bearing inner races (10 and 12)

and yoke spindle bearing seats. Slide spacerd. Prior to accomplishment of A.S.B. 212- (11) on spindle with stepped end outboard.

92-80, apply lubricant (tube pack) (C-015) or Install outer bearing inner race (10) next tolubricant (C-017) to inner diameter of bearing spacer. Note direction of chamfer on bearinginner races (10 and 12) and to yoke spindle races (10 and 12).bearing seats. Apply heat lamp to bearing

62-00-00Page 72

BHT-212-CR&0

f. Using nuts (28, figure 62-11) as a (1) Clean seal sleeve (3) groove withwrench, install nut (7, figure 62-12) on MEK (C-309), and packing (1) with alcoholspindle, torque 85 to 170 foot-pounds (9.6033 (C-326).to 19.2066 Nm); tap nut with a nonmetallichammer to seat bearing races, spacer and (2) Clean seal (2) with acetone (C-316)radius ring. Retorque 85 to 170 foot-pounds or MEK (C-309). Treat with tetra-etch and(9.6033 to 19.2066 Nm). Back off nut (7) to rinse with acetone (C-316) or MEK (C-309).give 0.005 to 0.015 inch (0.127 to 0.381 mm)clearance between nut and inner race of (3) Coat sleeve internal groove andbearing. packing (1) and seal (2) faying surfaces with

adhesive (C-308).g. Install lockplate (6) and secure with

two screws (5), secure screws with lockwire (4) Install packing (1) and seal (2) in(C-405). sleeve (3). Wipe off excess adhesive (C-308)

with acetone (C-316) or MEK (C-309).

NOTE (5) Cure at room temperature for 72hours minimum with outboard strap fitting or

Lockplate may be installed on simulated fitting engaged. Alternate cure 170spindle of yoke with either face next to 180°F (77 to 82°C) for two hours minimum.to spindle to allow alignment withscrew holes in spindle end. I. Install packing (8) on seal sleeve (3).

h. Remove static stop (20), insert strap m. Coat external surface of seal sleeve(9) through spindle from outboard end. Place assembly (4) and internal mating surface ofbackup ring (17) over strap end in center of spindle with lubricating oil (C-017). Install sealyoke with flat surface inboard. Install packing sleeve assembly (4) into yoke spindle.(14) on fitting (15) and install fitting oninboard end of strap (9) with tabs on fittingdown. Insert pin (16) and slide backup ring(17) on fitting (15) tight against shoulder of After accomplishment of A.S.B. 212-fitting. Press fitting and strap assembly into 94-94 bond sleeve (3) and packingcavity of yoke spindle. (8) into yoke with adhesive (C-308).

i. Install static stop (20) on yoke and 1. Grip reassembly.secure with washers (18) and bolts (19).Tighten bolts and secure boltheads withlockwire (C-405). NOTE

j. Assemble seal sleeve assembly (4), Bearings (2 and 6, figure 62-14) mayS32979-341G99, as follows: be installed with chamfer inboard or

outboard, but bearings must beinstalled with chamfer in the same

NOTE direction as chamfer on inner races.

Seal does not require sealant. a. Position grip (1) tangs down, on asuitable bench. Clean preservative from

(1) Install expander (3, figure 62-26) in bearings (2 and 6) with clean solvent (C-304).groove of sleeve (1), and position toward Lubricate bearings (2 and 6) with approved oilpressure side of groove. and press bearings (6) into grip. Place

packing (5) on outboard end and packing (3)(2) Fold seal (2) and install in groove on on inboard end of spacer (4), slide spacer into

low pressure side of expander (3). grip firmly against outboard bearing. Pressinboard bearing (2) into grip firmly against

k. Assemble seal sleeve assembly spacer. Install bearings with smooth edge(4,figure 62-12), S12561-341, as follows: outboard.

62-00-00Rev. 4 Page 73

BHT-212-CR&O

SSYSTEM

PRESSURE

1. Sleeve2. Seal ring3. Expander

212-R-62-26

Figure 62-26. Seal installation (new style)

b. Position plate (22) flat side down, on and shims (25) to give 0.003 to 0.007 inchbench. Place packing (7) on reservoir surface (0.0762 to 0.1778 mm) clamp-up on bearings.of plate. Install packing (9) on cover (10). Clean OD of seal (19) with MEK (C-309).Place sight glass (8) on plate. Place cover on Install seal (19) in inboard side of plate (22)sight glass. Place two spring washers (14), a with bead of sealing compound (C-328)light steel washer (15), aluminum alloy around outside diameter of seal on inboardwasher (16), and packing (17) on bolt (13). side. Reinstall plate (22) and secure withInstall bolt (13) in cover (10) and torque bolt bolts (20) and washers (21). Install drain pluguntil spring washers (14) are completely (24) with packing (23) and relief fitting (18).compressed. Back bolt off one full turn (six, Secure drain plug and two bottom bolts (20)plus or minus 1/2 wrench flats). Install filler together with lockwire (C-405). Secureplug (12) and packing (11) in cover (10) and remaining bolt (20) in pairs with lockwire (C-secure plug to bolt (13), with lockwire (C- 405).405).

3. Trunnion and pillow block assembly.

CAUTION NOTE

Following procedure is for one sideSEALANT SHALL NOT COVER of trunnion and one pillow blockLUBRICATION PORTS IN PLATE only. Opposite side is identical and(22). should be assembled at same time.

c. Install plate (22) on grip with six bolts a. Install packing (6, figure 62-16) inand washers (21). Tighten bolts (20) snug radius ring (5) and press ring on trunnionand measure gap between grip and plate spindle (4). Apply lubricant (C-017) to spindleface. Remove plate and install packing (26) OD and inner race (7) ID and press inner race

62-00-00Page 74

BHT-212-CR&0

(7) (smooth face inboard) on trunnion tight NOTEagainst ring. Place packing (8) on lock (9) andinstall in trunnion (3) spindle. Install washer Procedure is given for one side only.(2) and nut (1) and torque 100 to 140 inch- Opposite side is identical and shouldpounds (11.298 to 15.8172 Nm). Clean be installed at same time.spindle in area of radius ring in seal contactarea with MEK (C-309). Apply a bead of (1) Position yoke on T101356 buildupadhesive (C-308) or equivalent to outside bench. Position grip (11, figure 62-11) ondiameter of trunnion spindle, and inboard side yoke spindle with tangs of grip approximatelyof radius ring (5). vertical. Press grip inboard and rotate

approximately 90 degrees clockwise, ifb. Clean preservative from bearing (25). applicable, to lock grip to radius ring (3) or

Press bearing (25) into liner (27). Secure with shield assembly (3A).retainer ring (34) and install seal (35). Checkthat seal is installed 0.22 inch (5.588 mm)below outboard surface of liner (27). Position NOTEpackings (36) in pillow block (24) and pressliner into pillow block with lubrication holes Grip installations on 204-012-101-aligned with holes in pillow block. Install four 23 mai rotor hub assemblies dobolts (11), with washers (12) under heads and not require 90 degree rotatonnuts (32). Install nuts (32) and washersfingertight. (2) Place packings (31) on outboard

fitting (27) and install on outboard end ofstrap (2) with keyway of fitting and grip

NOTE aligned. Secure fitting (27) with pin (30).Apply a bead of adhesive (C-308)

Shims (26) will not be installed until approximately 0.06 inch (1.524 mm) diametertrunnion centering operation, step 5. around each end of pin (30). Insert key (29)Use new shims at installation. into aligned keyway of grip. Lubricate fitting

(27) and nut (28) threads with corrosionc. Position pillow block (24) outboard preventive compound (C-104), and install nut

side down, drop washer (10) through liner (BHT-212-MM). (Final setting of nut (28) willbearing. be accomplished in step 6.) Install blade bolt

(1), washer (21) and nut (22). Tighten nutd. Press trunnion assembly into liner. fingertight.

e. Install packing (23), reservoir (22), (3) Apply corrosion preventivepacking (21) and cover (20). Place washers compound (C-104), to ID and threaded partson bolts (16) in this order: two spring washers of drag brace assembly (37). Assemble nuts(15), one thin steel washer (14) and one (33 and 35) on barrel (34). Note that threadsaluminum alloy washer (13). Install bolts and on barrel must match nut. Install clevis (36)torque bolts until spring washers (15) are on data plate end of barrel and fitting (32) oncompletely compressed. Back bolt off one full opposite end. Adjust drag brace length to aturn (6, plus or minus 1/2 wrench flats). 19.02 inch (483.108 mm) dimension between

hole centers in clevis and fitting. Check forf. Install filler plug (18) with packing (19) 0.620 inch (15.748 mm) thread exposure at

and relief fitting (17) in cover (20). clevis end of drag brace. Torque nuts (33 and35) 275 to 325 foot-pounds (372.845 to

4. Main rotor hub final assembly. 440.635 Nm). This is initial setting only(Figure 62-27). Apply corrosion preventive

a. Install grip on yoke as follows: compound (C-101) to external surfaces ofdrag brace assembly (37).

(4) Attach drag brace to grip (11, figure62-11) with bolt (9), washer (10), washer (19),

62-00-00Rev. 4 Page 75

BHT-212-CR&O

and nut (20). Torque nut 125 to 150 foot- (c) Perimeter of pillow block (4) andpounds (169.475 to 203.37 Nm). yoke mating surface.

(5) Apply primer (C-204) to faying (d) Pillow block bolt nuts (8) andsurfaces of pitch horn (14) and grip (11). adjacent yoke surface.Position pitch horn (14) on grip (11) andsecure with bolts (15) and washers (16). c. Tighten nut (28) until grip (11) isTorque bolts 160 to 190 inch-pounds (18.077 inboard as far as it will go. Striking outboardto 21.467 Nm)and secure boltheads with end of grip with a plastic mallet while nut islockwire (C-405). being tightened will aid in seating parts.

b. Install pillow block and trunnion d. Place packing (18) over drain hole andassembly on yoke as follows: install drain plug (17) in drain hole of grip

(11). Tighten drain plug (17) and secure with

(1) Apply to following areas: lockwire (C-405).

(a) Inside and outside diameters of e. Fill both grip and pillow block(a) Inside and outside diameters ofbushing (5). reservoirs with approved oil to show one-half

full in the sight glass. Work out air as oil isadded.

(b) Bottom surface of pillow block (4)and pillow block bushing bores. 5. Center trunnion assembly as follows:

(c) Top surface of yoke which a. Remove hub assembly from T101356contacts pillow blocks. buildup bench. Turn T101421 adapter plate

so the flat surface is up and replace hub on(2) Coat shanks of new bolts (6) with . stand. (Figure 62-28.)

NOTE ~b. Position T101450 arbor in center oftrunnion with nut and washer removed. Place

Torque on nuts (8) differ after T101400 support on pillow blocks and secureaccomplishment of A.S.B. 212-92- trunnion arbor to support. Adjust pillow block80. liners (27, figure 62-16) to permit tools to

align. Bolts (11) may be loose to permitalignment.(3) While coatings are still wet, hold

assembly securely, and mount on yoke withbushings (5), new bolts (6), new washers (7) ,bushings (5), new bolts (6), new washers (7), and pillow block (24) to provide a pinch fit of

and new nuts (8) Prior to accomplishment of 0.000 to 0.004 inch (0.000 to 0.1016 mm) onA.S.B. 212-92-80, torque nuts 65 to 79 foot- trunnion. This can be accomplished bytrunnion. This can be accomplished bypounds (88.127 to 107.1082 Nm). Afterpounds (88.127 to 107.1082 Nm). After tightening eight bolts (11) and nuts (32) untilaccomplishment of A.S.B. 212-92-80 torque the thrust washers (10) contact the trunnionnuts 116 to 133 foot-pounds (157.18 to without distortion of the liner. Measure the

180.215 Nm). clearance between each liner and pillow blockwith a feeler gage. Prepare shims of the same

(4) Wipe following areas clean with thickness less 0.002 inch (0.0508 mm). Thiscloth dampened with solvent (C-304) and will provide a 0.004 inch (0.1016 mm) preloadapply a bead of adhesive (C-308) to following on the trunnion. The trunnion centerline mustareas. coincide with the yoke spindle axis within

0.003 inch (0.0762 mm). Tighten nuts (32),(a) Pillow block bushing (5) flanges except the bolt and nut with T101402 link

and adjacent pillow block surface. attached.

(b) Boltheads (6) and adjacent d. Remove arbor, support and hub frombushing surface. buildup stand. Reverse T101421 adapter

62-00-00Page 76 Rev. 4

BHT-212-CR&O

FITTING

NUT

BARRELL

19.02 IN.(483.108 mm)

5.3 IN.(134.62 mm)

0.620 IN.

(15.748 mm)

(76.597 mm)

CLEVIS

212-R-62-27

Figure 62-27. Drag brace assembly

62-00-00Rev. 4 Page 77

BHT-212-CR&O

plate (flat surface down) and adjust main rotor NOTEgrips (step 6). If the 0.062 inch (1.5758 mm)6. Adjust main rotor grips as follows: dimension cannot be obtained or

grip binding occurs, a gap up toa. Position hub on level T101356 buildup 0.162 inch (4.1148 mm) is

bench (8, figure 62-29). With T101865 flap acceptable. Assure grip spacing isstops (5) installed use bubble protractor to the same on both grips within 0.002check for zero degrees flap. Determine if the inch (0.0508 mm).top surface of trunnion is parallel to thespanwise top surface of the yoke. f. Rotate gage (2) and plug (3) to the

opposite grip and accomplish steps c. and e.b. Install T101402 grip positioning links

(6). Place a bubble protractor chordwise on g. Install lock (9), clamp (10), washertop surface of yoke to establish reference (11), and bolt (12) to secure nut (13) on eachplane, then place the protractor chordwise on grip. Lockwire bolts (12). Install blade bolt (1,grip top surface just outboard of blade bolt figure 62-11), washer (21), and nut (22) onbushing. Adjust links to position grips to zero each end of grip. Do not torque nuts (22).degrees angle. Remove grip spacing tools.

7. After installation of bolts and torquing,~~NOTE ~coat boltheads, nuts and washers with

When positioning protractor on the corrosion preventive compound (C-101).grip surface ensure that theprotractor is parallel to the 8. Balance main rotor hub (paragraph 62-protractors position on the yoke 23).surface. Orient protractor in thesame direction as when the plane 62-24. BALANCING.was determined.

c. Tighten nut (13) until hub grip is fully MATERIALS REQUIREDseated inboard and then back off nut (13) onefull turn. Tap grip outboard using a heavyNOMENCLATUREplastic mallet to aid in seating hub parts.Repeat on opposite side of hub. C-304 Solvent

d. Insert plug (3) in trunnion bore and C-405 Lockwireback off bolt (4) to secure plug in trunnion.Set adjustable end of gage (2) to the 2.0 inch(50.8 mm) dimension shown in detail A, figure Balancing procedures are for Bell Helicopter62-29. Position gage on plug and secure gage balancing tools. Step 2. is an alternateto plug at hole marked 204-012-101. Locate procedure using Marvel balancing tools.the adjustable end of gage on grip bushingflange and position blade bolt (1) as shown in 1. Main rotor hub balancing using Bellfigure 62-29. Helicopter balancing tools.

e. Check dimension between tip of gage a. Install T101402 grip positioning links (6,(2) and barrel of bolt (1). Adjust nut (13) until figure 62-29) on each side of hub.gap between gage and bolt is 0.062 inch(1.5748 mm). Tap grip outboard after each b. Install T101865 flap stops (1, figure 62-adjustment and recheck dimension. 30) on each side of trunnion.

c. Position T101458 balance set onT101356 buildup bench, with stud of

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BHT-212-CR&O

1. T101402 Link2. T101400 Support Assembly3. T101450 Arbor4. T101421 Adapter Plate5. T101356 Build-Up Bench 21 2-R-62-281. T101402 Link2. T101400 Support Assembly3. T101450 Arbor4. T101421 Adapter Plate5. T101356 Build-Up Bench

212-R-62-28

Figure 62-28. Centering trunnion on hub

62-00-00Page 79

BHT-212-CR&O

(50.8 mm)

0.062 to 0.162 IN.(1.5748 to 4.1148 mm)GAP (AS REQUIRED)

DETAIL

13

1. Blade bolt 8. T101356 buildupbench2. T101559gripspacinggage 9. Lock3. T101559-3 plug 10. Clamp4. Knurled bolt 11. Washer5. T101865 flap stop 12. Bolt6. T101402 grip positioning link 13. Nut7. T101421 adapter plate 212-R-62-29

Figure 62-29. Main rotor hub grip spacing

62-00-00Page 80

BHT-212-CR&O

1. T101865 Flap Stop 4. Hub Assembly2. Level, Bull's-Eye (810550) 5. T101356 Build-Up Bench3. T101458-3SocketandT101458-7Spacer 6. T101458-5 Plug

212-R-62-30

Figure 62-30. Main rotor hub balancing

62-00-00Page 81

BHT-212-CR&O

balancing plug (6) in socket on top of buildup d. Install adapter (3), heavy endstand. downward, over top of fixture (1) and seat on

top of sleeve (2). Lock adapter in this positiond. Using a plastic mallet, tap on heads of by tightening adapter setscrew (4).

blade retention bolts to seat grips in theiroutward positions. e. Before positioning hub on fixture,

alternately hold grips down to bleed air frome. Position drag braces to symmetrical grip. Continue filling reservoir and bleed until

angular positions (equal angles relative to grips are filled, thereby equalizing oil in bothgrips by measuring from blade retention bolt grips. Secure filler plugs with lockwire (C-to blade drag brace bolt hole). 405).

f. Fill reservoirs with approved oil. An f. Carefully lower rotor hub assembly (8)equal amount of oil should be in each grip. over fixture (1) aligning inside diameter of

splined trunnion with piloting diameter ofg. Position hub assembly on T101458 adapter (3), and ensuring that cone surface of

balance set. splined trunnion seats firmly on cone surfaceof adapter (3).

h. Place a sensitive spirit level (2) on topsurface of T101458 balance set. Balance hub g. Install T101402 grip positioning linksspanwise by inserting lead weight into cavity and adjust blade grips to symmetrical pitchof the appropriate blade bolt, as required, to positions. To accomplish this, place a bubblecenter bubble in spirit level. Install and secure protractor on flat top surface of rotor hubplugs in blade bolts with lockwire (C-405). across the grip pitch axis; adjust protractor to

center bubble. Transfer protractor, keeping iti. Balance hub assembly chordwise by in same transverse position, to bottom inside

attaching balance weights (28, figure 62-16) surface of either blade grip fork and align(16 maximum) and/or AN970-6 washers (29) protractor base with the transverse milled line(16 maximum), as required, to bolt in center in the fork surface. Adjust grip pitch only toof liner (27). Use AN bolts (31) of sufficient again center protractor bubble. Transferlength and washer (30) to secure weights and protractor in same transverse position towashers without bottoming of bolt in liner. opposite grip fork and repeat grip pitch

adjustment.j. Color code the parts for future

assembly. h. Place a block of wood against theheads of rotor blade retention bolts, tape the

k. Remove hub from balancing stand. block moving the grips in radially outwardRemove flap stops and grip positioning links. direction to ensure blade grips are fully

seated in their radially outward position.2. Main rotor hub balancing using Marvelbalancing tools. (Alternate procedure.)

NOTEa. Assemble 7A050 balancing kit (1, figure

62-31) with 2769 tube assembly (3), instead Spot clean hub with solvent (C-304)of 2288 tube assembly (2) to provideadditional hoist arm length. i. Install yoke (5), legs downward, over

top end of arbor (6) and positioned so that theb. Center 2337 fixture (1, figure 62-32) on top surface of its locking collar (sensitivity

work stand. setting reference) aligns with arbor scale (7)at 14.75 inches (374.65 mm). Lock yoke (5)

c. Install 2467 sleeve (2) over top of firmly in this position on arbor with its collarfixture (1) and seat sleeve on upper shoulder screws, using a 3/16 inch (4.76250 mm) hexof fixture's central projection. wrench. (7HEL061 kit).

62-00-00Page 82

BHT-212-CR&O

1. 7A050 Balancing kit2. 2288 Tube assembly3. 2769 Tube assembly

212-R-62-31

Figure 62-31. Balancing kit

62-00-00Page 83

BHT-212-CR&O

1. Fixture(2337, 7HEL054 Kit)

2. Sleeve(2467, 7HEL054 Kit)

3. Adapter(2588, 7HEL061 Kit)

4. Adapter set screw5. Yoke

(2589, 7HEL061 Kit)6. Balancing arbor

(2259, 7A050 Kit)or

(2293, 7BAL052 Kit)7. Arbor scale8. Rotor hub assembly9. Spacer (2201)

10. Drag strut11. Drag strut position

gage (2486, 7HEL061

12. Gage inner position SEE VIEW A13. Gage outer position14. Handwheel (2215)

Figure 62-32. Main rotor hub balancing (alternate procedures)

62-00-00Page 84

BHT-212-CR&O

j. Install arbor (6) downward through rotor diameter of table, it may betrunnion and fixture (1) assembly, seating necessary to adjust level of stand byboth yoke (5) legs firmly on flat top surface of installing suitable wood blocks orrotor hub, in line with blade grip pitch axis. spacers under the two tubular stand

legs.k. Install 2201 spacer (9) over lower end

of arbor (6). Install 2215 hand wheel (14) in n. Balance hub spanwise by inserting leadbottom end of arbor and tighten to clamp yoke into cavity of blade retention bolt to achieve(5) firmly against top surface of rotor hub. balance within limits.

I. Using drag strut position gage (11), as o. Balance hub chordwise by attachingillustrated, adjust drag struts (10) to weights and/or small washers, as required, tosymmetrical angular position. Use gage outer pillow block liner. A maximum of 16 weightsposition (13). Remove gage from rotor may be attached with an AN bolt of sufficientassembly during balance check. length to secure weights without bottoming

bolt in liner.m. Install quick-disconnect assembly with

3/16 inch (4.76250 mm) cable on arbor (6). p. Install and safety wire plugs in bladeSuspend rod-end and engage cable in lifting bolts.plate of hydraulic pump assembly (7A050 kit).Hoist entire assembly approximately 1/4 inch q. Color band parts to maintain their(6.35 mm) off workstand. Check to ensure respective positions.that suspended assembly is free frominterference with workstand and other objects r. Remove main rotor hub from balancingand note balance conditions indicated by stand.black indicator disc at top end of arbor (viewA, figure 62-32).

NOTE

To ensure hand wheel is free ofinterference within the inner

62-00-00Page 85/86

BHT-212-CR&O

MAIN ROTOR CONTROLS

62-25. MAIN ROTOR CONTROLS. sleeve, swashplate and support, collectivelevers, and pitch change link.

The main rotor controls that are covered inthis section are: stabilizer bar, scissors and

62-00-00Page 87/88

BHT-212-CR&O

STABILIZER BAR

62-26. STABILIZER BAR. 3. Remove 212-010-302 mixing levers (35)by removing nuts (33), washers (34), bolts(30), bushing (37), special washer (36), and

NOTE shim washers (29). Remove mixing lever (35)and special washers (40).

Overhaul of 204-011-326 and 212-010-300 stabilizer bars are the sameexcept where noted in text or 4. Remove tube assembly (12) from eachillustration. end of centerframe (19) by removing bolts

(23), washers (24), and nuts (18).

62-27. Disassembly. 5. Cut lockwire, loosen nut (10) from weight(9) until lock (11) is free from weight. Removenuts (5), retainer (6), bushing (7), and washer(8) from cable assembly (3). Remove weight

Refer to BHT-ALL-SPM for specification and (9) and nut (10) from tube (12).source.

NOMENCLATURE 66. Remove bolt (4), stat-o-seals (2), nut (1),and pull cable assembly (3) from tube. Cut

C-304 Solvent lockwire and remove screws (13), bearingretainer (16), and bearing (17).

NOTECAUTION

Review Mandatory RetirementSchedule in BHT-212-MM, and retireall items scheduled for retirement. SEAL OR PLUG TUBE ENDS TO

PREVENT CLEANING MATERIALIf stabilizer bar is being FROM ENTERING TUBE.disassembled for replacement ofpart/s instead of overhaul,disassemble only to extent 7. Thoroughly clean stabilizer bar withnecessary to replace parts. solvent (C-304).

Overhaul of stabilizer bars 204-011-326 and 212-010-300 is the same 62-28. Inspection.except where noted in text orillustration.

NOTE

1. Remove nuts (14, figure 62-33), bolts If records or physical appearance(25), and washers (15). Remove supports indicate that the stabilizer bar has(22). been subjected to an accident or

incident outside the realm of normalusage, perform Conditional

2. Remove 204-011-301 mixing levers (32) Inspection, paragraph 62-29. Ifby removing nuts (33), washers (34), bolts stabilizer bar does not require the(30), and shim washers (29). Remove mixing Conditional Inspection, proceed withlevers (32). Normal Inspection, paragraph 62-30.

62-00-00Rev. 4 Page 89

BHT-212-CR&O

62-29. Conditional Inspection. Index Nomenclature CodeNo.

1. Apparent deformation of a tube assemblyis cause for scrapping the stabilizer bar 12 Tube M (Seeassembly. step 8)

2. If there is no evidence of tube 19 Centerframe Fdeformation, accomplish Normal Inspection,

I paragraph 62-30. 22 Support F

32 Lever F62-30. Normal Inspection. (204-011-301)(204-011-301)

1. Visually inspect parts for obvious defects 35 Lever Fthat would render the part unserviceable. (212-010-302)

2. Inspect parts for mechanical andcorrosion damage (figures 62-34, 62-35 and 5 Inspect bushing ID and OD, as62-36). applicable, for scoring not to exceed 0.002

inch (0.0508 mm) maximum depth.3. Inspect cable assembly (3, figure 62-33).

6. Inspect lube fittings in centerframe (19)a. Corrosion and mechanical damage on and lever (32 or 35) for security and damage.

cable end fittings shall not exceed 0.010 inch(0.254 mm) depth after cleanup. 7. Visually inspect retainer (6), bushing (7),

b. Replace assembly if crimps, excessive washer (8), weight (9), key type lock (11), andb. Replace assembly if crimps, excessive bearing retainer (16) for damagecorrosion damage, or frayed wires are foundon cable.

NOTE4. Inspect the following parts by magneticparticle (Code M) or fluorescent penetrant If ac magnetic particle inspection(Code F), as applicable. Demagnetize parts equipment is used, use 60 percentafter magnetic particle inspection. Index of dc amperes specified:numbers are keyed to figure 62-33.

8. Magnetic particle inspection of stabilizerNOTE bar tube (12). The stabilizer bar tube must be

inspected by all of the following steps usingwet continuous method. Use of fluorescent

performed usinsg the wet coated particles with ultra violet light iscontinuous, fluorescent method mandatory. The length of any indication shall(BHT-ALL-SPM). The length of any be determined by residual method ofindications may be determined by magnetization.the residual method ofthe magnetization. method. Thoroughly degrease stabilizer barmagnetization. tube.

NOTE b. Place stabilizer bar tube longitudinallybetween contact heads of the inspection

The following general formula shall equipment and pass 1000 amperes of dcbe used for determining ampere- current through stabilizer bar tube.turns: number of coil turns (on coilplate) x amperage (meter). c. Inspect completely for indications.

EXAMPLE: For a 5 turn coil, 11,000 d. With stabilizer bar tube placed as inampere turns - 5 coil turns = 2,200 step b., pass 3000 amperes of dc currentamperes. through stabilizer bar tube.

62-00-00Page 90 Rev. 4

BHT-212-CR&O

6

3

14. Bolt 17. Bearing 30. Bolt 212-010-310)

. 24· 23

34 19 SEE DETAIL A and B

1. Nut 14. Nut 27. Bearing 38. Cotter pin2. Stat-o-seal 15. Washer 28. Bushing 39. Bushing3. Cable assembly 16. Retainer, bearing 29. Washer/s(shim) 40. Special washer (P/N4. Bolt 17. Bearing 30. Bolt 212-010-310)5. Nut 18. Nut 31. Bearing 41. Stabilizer (P/N6. Retainer 19. Centerframe 32. Mixing lever (P/N 212-010-300)7. Bushing 20. Bushing 204-011-301) 42. Stabilizer (P/N8. Washer 21. Bushing 33. Nut 212-011-326)9. Weight 22. Support assembly 34. Washer 43. Nut

10. Nut 23. Bolt 35. Mixing lever (P/N11. Lock, keytype 24. Washer 212-010-302)12. Tube, assembly 25. Bolt 36. Special washer13. Screw 26. Bushing 37. Bushing212-R-62-33-1

Figure 62-33. Stabilizer bar (Sheet 1 of 2)

62-00-00Page 91

BHT-212-CR&O

MINIMUM TUBE ENGAGEMENT INWEIGHT TO BE FLUSH WITHSHOULDER WITHIN 0.03 IN. 0.005 IN. (0.127 mm)

10.762 MINIMUM GAP

ADHESIVE

DETAIL A

52.8 IN.(1341.12 mm)

ASSEMBLY DIMENSION PRIOR TO BALANCE

DETAIL B

212-R-62-33-2

Figure 62-33. Stabilizer bar (Sheet 2)

e. Inspect fitting end of stabilizer bar tube mm). Magnetize stabilizer bar tube usingcompletely for indications. 10,000 ampere-turns.

f. Place stabilizer bar tube in the coil with k. Inspect stabilizer bar tube completelylongitudinal axis or stabilizer bar tube for indications.perpendicular to the plane of the coil andfitting end of stabilizer tube protruding Acceptance criteria.approximately two inches (50.8 mm) from coil.Magnetize stabilizer bar tube using 10,000 (1) Magnetic particle indicationsampere-turns interpreted as cracks are rejectable.ampere-turns.

g. Inspect stabilizer bar tube completely NOTEfor indications. A broad hazy circumferential

indication, located approximately 5-h. Reposition stabilizer bar tube in coil 1/2 inches (139.7 mm) from fitting

with fitting end of stabilizer bar tube end of stabilizer bar tube, willprotruding from the coil approximately 17 normally be detected. This broadinches (431.8 mm). Magnetize stabilizer bar hazy indication is acceptable.tube using 10,000 ampere-turns.

m. After completion of inspection,i. Inspect stabilizer bar tube completely demagnetize stabilizer bar tube and check

for indications. with pocket field indicator or compass toassure demagnetization.

j. Reposition stabilizer bar tube in coil withthreaded end of stabilizer bar tube protrudingfrom coil approximately seven inches (177.8

62-00-00Page 92

BHT-212-CR&O

62-31. REPAIR. brush cadmium plating solution (C-108) torepair areas where cadmium plating wasremoved.

MATERIALS REQUIRED removed.

3. Treat internal surface of tube assemblyNUMBER NOMENCLATURE (12, figure 62-33) to prevent corrosion as

follows:C-100 Chemical Film Material

a. Degrease tube (12) with 1.1.1-C-101 Corrosion Preventive trichloroethane (C-334) or equivalent.

Compound

C-201 Primer c. Plug one end of stabilizer bar tube. Fillthe tube approximately 3/4 full of epoxy/zinc

C-202 Primer coating (C-208), plug open end, invert tubeand rotate until surfaces are coated. Remove

C-203 Lacquer plugs and allow the excess material to flowC-204 Primer out. (Refer to BHT-ALL-SPM for application of

epoxy/zinc coating.)C-208 Epoxy/Zinc Coating

d. Apply a coat of corrosion preventiveC-304 Solvent compound (C-101) to outer inside 0.630 inch

(16.002 mm) of 212-010-311 tube (12, figureC-334 1.1.1-Trichloroethane 62-38).

C-406 Aluminum Oxide Cloth406 Aluminum Oxide Cloth 4. Replace parts found defective byC-423 Abrasive Cloth or magnetic particle or fluorescent penetrant

Paper inspection.

5. Replace bearing set (17, figure 62-33),1. Repair mechanical and corrosion damage stat-o-seals (2) and all self-locking nuts.by polishing out the damage and blend repairsmoothly into surrounding area. Do not 6. Replace parts if mechanical or corrosionexceed depth and area limits of figures 62-34 damage exceeds reparable limits.and 62-35.

7. Replace defective bushings (20, 21, 26,and 28) as follows:I~C~AUTION *a. Place part on suitable support andpress bushing out. Inspect bore for scoring.

2. Coat repair areas on aluminum parts withchemical film material (C-100) and apply

62-00-00Page 93

BHT-212-CR&O

d. Line ream bushing ID to the followingdimensions, as applicable. Bushing indexnumbers are keyed to figure 62-33.

62-00-00Page 94

BHT-212-CR&O

MIXING LEVER SUPPORT

DAMAGE LOCATION SYSMBOLS


MECHANICAL(Before and after repair) 0.010 IN. (0.254 mm) 0.035 IN. (0.889 mm) 0.035 IN. (0.889 mm)

CORROSION(Before repair) 0.005 IN. (0.127 mm) 0.017 IN. (0.4318 mm) 0.017 IN. (0.4318 mm)

(After repair) 0.010 IN. (0.254 mm) 0.035 IN. (0.889 mm) 0.035 IN. (0.889 mm)

AREA OF FULL 0.10 SQ. IN. 0.25 SQ. IN. 0.25 SQ. IN.

DEPTH REPAIR (64.52 SQ. mm) (161.3 SQ. mm) (161.3 SQ. mm)

NUMBER OF REPAIR One per segment One per segment Two

AREAS

BORE DAMAGE * 0.002 IN. (0.0508 mm) 1/4 of circumference

NOTE

All edges may be radiused or chamfered 0.060 IN. (1.524 mm) to remove nicks and dents.212-R-62-34

Figure 62-34. Stabilizer bar mixing lever and support damage limits

62-00-00Page 95

BHT-212-CR&O

TUBE (TYPICAL)

FRAME



MECHANICAL ANDCORROSION 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) See Note

(Before and after repair)

MECHANICAL 0.035 IN. (0.889 mm) 0.020 IN. (0.508 mm)(Before and after repair)

CORRISION(Before repair) 0.017 IN. (0.4318 mm) 0.010 IN. (0.254 mm)(After repair) 0.035 IN. (0.889 mm) 0.020 IN. (0.508 mm)

MAXIMUM AREA PER () 0.25 SQ. IN. 0.50 SQ. IN.FULL DEPTH REPAIR (161.3 SQ. mm) (322.6 SQ. mm)


NUMBER OF REPAIRS D Two Not critical

Not critical Two per segment

EDGE CHAMFER Not applicable 0.030 IN. (0.762 mm)

0.100 IN. (2.54 mm) 0.050 IN. (12.7 mm)

THREAD DAMAGE: DEPTH: One-third of threadLENGTH: One-quarter inch (6.35 mm)NUMBER: Two

NOTE

Small nicks and dents may be suitably treated by coating with primer (C-201). 212-R-62-35

Figure 62-35. Stabilizer bar tube and frame damage limits

62-00-00Page 96

BHT-212-CR&O

CONTROL TUBE212-010-404-5


NICKS AND DENTS 0.005 In. (0.127 mm) 0.005 In. (0.127 mm)

CORROSIONBEFORE REPAIR 0.0025 In. (0.0635 mm) 0.0025 In. (0.0635 mm)

AFTER REPAIR 0.005 In. (0.127 mm) 0.005 In. (0.127 mm)

AREA OF FULL DEPTH REPAIR 0.10 Sq. In. (64.516 Sq. mm) 0.50 Sq. In. (322.58 Sq. mm)

NUMBER OF REPAIR AREAS One per lug Two per segment

EDGE CHAMFER 0.020 In. (0.508 mm) 0.040 In. (1.016 mm)

BORE DAMAGE: 0.001 In. (0.0254 mm) for 1/4 circumference

NOTE

Width of repair at any section of tube should not exceed one third of circumference.

212-R-62-36

Figure 62-36. Stabilizer bar control tube damage limits

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BHT-212-CR&O

Bushing Index No. Bushing ID g. Ream sleeve 1.2485 to 1.2490 inch(31.7119 to 31.7246 mm) diameter. Clean

20 (Centerframe) 0.2495 to 0.2500 Inch sleeve thoroughly.(6.3373 to 6.3500 mm)

h. Apply primer (C-201) or primer (C-204)21 (Centerframe) 0.3745 to 0.3750 Inch to mating surface of bearing and sleeve.

(9.5723 to 9.5250 mm) Press bearing into sleeve.

26 (Support) 0.6242 to 0.6247 Inch i. Select a staking tool to accomplish a(15.85468 to 15.86738 ring stake (BHT-212-CR&O). The tool shall bemm) so designed to have a 90 degree ring stake,

using a ring radius equal to the retaining hole28 (Lever) 0.3744 to 0.3747 Inch plus 1/2 the thickness of the sleeve, within

(9.50976 to 9.51738 plus or minus 0.0025 inch (0.0635 mm)mm) tolerance. Ring stake sleeve both sides.

39 (Lever) 0.3745 to 0.3750 Inch j. Support lever on a suitable support and(9.5723 to 9.5250 mm) proof load bearing 500 to 800 pounds (2224

to 3558.4 N) in each direction. Ensure thatload is applied to outer race of bearing.

8. Replace bearing (31) as follows: Check bearing for smooth operation.

a. Support lever on a suitable support 9. Replace bearings (27, figure 62-33).having clearance for bearing and sleeve. Apply coat of primer (C-201) or primer (C-Press bearing and sleeve out of lever. 204) to mating surface of new bearing and

liner and install bearing.b. Remove any burrs from replacement

sleeve with 320 grit or finer aluminum oxide 10. Using primer (C-202) prime all exteriorcloth (C-406). Ensure edges are not rounded surfaces of 212-010-311 tube except asor chamfered by sanding. shown in figure 62-38.

c. Clean lever bore.and sleeve with 11. Paint primed exterior surfaces withsolvent (C-304). Inspect bore for scoring. lacquer (C-203) except as shown in figure 62-Score marks shall not exceed 0.002 inch 38.(0.0508 mm) depth after cleanup and 1/4 thecircumference. 12. Paint support assembly (22), mixing

lever (32 or 35), and centerframe (19) asd. Apply primer (C-201) or primer (C-204) follows:

to mating surfaces of sleeve and bore oflever. a. Apply chemical film material (C-100) as

required (BHT-ALL-SPM).e. Press sleeve into lever. Check that

sleeve extends approximately 0.015 to 0.020 b. Prime all surfaces and holes with oneinch (0.381 to 0.508 mm) on each side of coat of primer (C-204). Overcoat shall belever bore. applied in not less than one hour or more

than eight hours (BHT-ALL-SPM).f. Remove lube fitting from lever. Using

lube fitting hole as a guide, drill a 0.090 inch c. Paint all surfaces, except bushings and(2.286 mm) hole through sleeve. Ensure that holes, with two coats of lacquer (C-203) lightfitting hole is not enlarged during drilling. gull gray, except bearing bores and lubeInstall lube fitting. fittings (BHT-ALL-SPM).

13. Repair stabilizer bar control tube asfollows:

62-00-00Page 98

BHT-212-CR&0

a. Polish out (longitudinal direction) 3. Assemble centerframes (19) and tubemechanical and corrosion damage that is assemblies (12) with bushings (20) inwithin limits of figure 62-36 using fine to centerframes down and keyway in threadedmedium grade abrasive cloth or paper (C- portion of outer tube assemblies (12) up.423). Install bolts (23) with one washer (24) under

bolt head and one washer (24) under nutsb. Edges may be radiused or chamfered (18). Install AN175-11A bolts in inboard

to remove nicks or dents to limits of figure 62- positions and AN175-10A bolts in outboard36. positions. Ensure that minimum of one thread

of bolts is exposed after tightening nuts.c. Remove paint from part.

4. Place washer (15) on bolt (25) and insertd. Apply chemical film material (C-100) through inboard side of support (22). Position

as required (BHT-ALL-SPM). support on inboard side of centerframe (19).Install washer (15) and nut (14) on bolt. Install

e. Prime all surfaces and holes with one cotter pins (38) after balancing has beencoat of primer (C-204). Overcoat shall be accomplished.applied in not less than one hour or morethan eight hours (BHT-ALL-SPM). Do not 5. Install 204-011-301 mixing lever (32) asprime bushings. follows:

f. Paint all surfaces, except bushings and a. Install stabilizer bar on a trunnion orholes, with two coats of coating (C-245) light other suitable fixture to establish a 5.200 inchgull gray, except bushings (BHT-ALL-SPM). (132.08 mm) dimension between inboard

faces of support assemblies (22). Positionmixing lever (32) between centerframes with

62-32. ASSEMBLY lubrication fittings up and install bolts (30)through bearings (27) in mixing lever and

MATERIALS REQUIRED through bushings (21) in centerframe (19).

Refer to BHT-ALL-SPM for specification and b. Install nut (33) on one bolt and tightensource. enough to secure bearing (27) against

bushing (21) in centerframe (19).NUMBER NOMENCLATURE

c. Move lever (32) in direction of sideC-007 Bearing Grease with loose bolt (30) and bushing (21) to

ensure no gap exists between bolthead (30)and bearing (27). With lever (32) in this

C-309 Methyl-Ethyl-Ketone position, measure gap between bearing (27)(MEK) and bushing (21) in centerframe.

C-405 Lockwire d. Determine number of washers (AN960-616 and/or AN960-616L) required to fill gap.Divide washers into two groups equal in depth

1. Wash preservative from bearing set (17, within one AN960-616L washer. AN960-616figure 62-33) with solvent (C-304) and air-dry. washers are 0.063 inch (1.6002 mm) plus orHand pack bearings with bearing grease (C- minus 0.010 inch (0.254 mm) thick. AN960-007). 616L washers are 0.032 inch (0.8128 mm)

plus or minus 0.010 inch (0.254 mm) thick.2. Install bearing (17) in centerframe (19).Position bearing retainer (16) and install e. Remove nut (33) and bolts (30).screws (13). Secure screwheads with lockwire(C-405). Install opposite bearing set in same f. Install bolt (30) through bearing (27) inmanner. mixing lever (32) with one group of washers

between bearing (27) and bushing (21).Repeat installation on opposite side with

62-00-00Rev. 4 Page 99

BHT-212-CR&O

remaining group of washers. Install nuts on with inner race of bearing (5). Remove andthe mixing lever bolts with one AN960-616 divide washers/shims (9) into two groups towasher (34) under each nut. Torque nuts (33) fill equal space on each side of mixing lever95 to 110 inch-pounds (10.7331 to 12.4278 (3) within one thin washer/shim.Nm) and install cotter pins (38).

f. Remove bolt (7), washer (6), bushingsg. Perform steps a. through f. on opposite (8) and positioning bolt. Install bolts (7) with

mixing lever. washers (6), bushings (8) and measuredgroup of washers/shims (9) through bearings

6. Install 212-010-302 mixing lever (35) as (5). Push bolts (7) through bushings (8) infollows: centerframes (2). Install washers (12) and

nuts (1). Torque nuts (1) 95 to 100 inch-a. Install stabilizer bar on a trunnion to pounds (10.7331 to 11.298 Nm), install cotter

establish 5.200 inch (132.08 mm) dimension pins (13).between inboard faces of support assemblies(22). NOTE

b. Install washer (11, figure 62-37) over When properly shimmed and withshouldered bushing (10) in centerframe. hardware torqued, there should be

no free movement (float) of mixingc. Position mixing lever (3), grease fitting lever (3) relative to centerframe (2).

up, between centerframes.g. Perform steps a. through f. for opposite

d. Install bolt (7), washer (6), and bushing mixing lever (35, figure 62-33).(8) through one bearing (5) in mixing lever (3)to engage bushing (10). Install nut (1) and 7. Position cable assembly (3) in tubetighten enough to secure inner race stack assembly (12) with cable threads outboard.against bushing (10) in centerframe (2). See Align holes on cable fitting of cable assemblydetail A. (3) and tube (12) and install bolt (4) with one

stat-o-seal (2) under bolt (4) head and onee. Arrange opposite side of lever as under nut (1). Install bolt with head up and

follows: through hole in cable assembly. Installopposite cable assembly in same manner.

(1) Install a 3/8 inch (9.52500 mm)positioning bolt through centerframe (2) from 8. Install weight on 204-011-328 tubeoutside. Install bushing (8) through bearing assembly as follows:(5) in lever (3). See detail B.

a. Clean weight (9) ID, outboard endNOTE fitting of cable assembly (3) and outboard end

of tube assembly (12) ID with MEK (C-309).Slightly reducing the outsidediameter of the (AN960-616 and b. Install nut (10) and lock (11) on eachAN960-616L) washers/shims (9) end of tube assembly (12) with lock in keywaymay be required to allow them to and pierced end inboard. Thread nut (10) inslide through bearing (5). past middle of tube threads. Thread weight

(9) on each end of tube with slotted side(2) While holding mixing lever (3) inboard until 52.8 inch (1341.12 mm)

against centerframe (2), slide floating bushing dimension is obtained as shown in detail B.(8) against fixed bushing (10) in centerframe Check that end of tubes are flush with(2). Insert threaded end of a 3/8 inch (9.5250 shoulder in weight within 0.03 inch (0.762mm) diameter positioning bolt flush with mm) as shown in detail A.inside race of bearing (5). Measure space byplacing washers/shims (9) flat against bushing c. Turn nuts (10) outboard and engage(8) to fill space between bushing (8) and flush locks (11) in slot of weights. Install washer

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BHT-212-CR&0

SHIM WASHERS TO PROVIDE FOR A FLUSHSURFACE TO 0.032 IN. (0.8128 mm) RECESS

DETAIL B

2

I 3

2. Centerframe 7. Bolt 12. Washer3. Mixing lever 8. Bushing 13. Cotter pin4. Liner 9. Washers/shims5. Bearing 10. Shouldered bushing 212R62-37

Figure 62-37. Shimming procedure for 212-010-302 mixing lever

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BHT-212-CR&O

(8), bushing (7), retainer (6) and nuts (5) on 1. Remove supports (22, figure 62-33) fromeach end of tube. Finger torque nuts (5). centerframes. Insert a round bar, smaller thanTorque nuts (10) 133 to 158 foot-pounds the inside diameter of the pivot bearing set(180.3214 to 214.2164 Nm) and lockwire nuts (17), through the center of the bearings andto locks (11). Lubricate stabilizer bar with support the bar on a reasonably level surfacebearing grease (C-007) at all lube fittings. in such a manner that the stabilizer bar is

suspended (figure 62-39).9. Install weight on 540-011-319 or alternateP/N 212-010-311 tube as assembly asfollows:

There is too much friction in thea. Clean internal threads of weight (1, support bearings to properly balance

figure 62-38), external thread of cable (4), the bar while resting on theand outboard end of tube (12) with MEK (C- supports; therefore, a rod smaller309). than the bearing inside diameter

must be used.b. Install nut (9) and lock (11) on end of

tube (12) with lock in keyway. Position nut (9) 2. Support the lever assemblies by insertingin past the center of tube threads. Install bolts of equal length through the outboardweight (1) on tube with slotted end inboard. bearings and resting the bolts on theAdjust weight to 51.8 inches (1315.72 mm) centerframes. (Figure 62-39.)from center of bolt. (See detail A.)

3. Check balance of 204-011-326 stabilizerc. Turn nut (9) outboard and engage lock bar and if necessary adjust as follows:

(11) into nearest slot of weight (1). Installpacking (8) on bushing (7), slide bushing (7) a. Cut lockwire, if installed, loosen nutonto cable (4) and into tube (12) as shown in from weight, adjust weights (9, figure 62-33)detail A. Install bushing (2) onto cable (4) until balance is obtained at nearest lockuntil it is against bushing (7). Install retainer position. Maintain minimum tube engagement(3) on cable (4) until it covers bushing (2). shown in detail A. Turn nut (10) outboard andInstall nut (6), torque nut (6) 1 to 40 inch- engage lock (11) in slot of weight.pounds (0.11298 to 4.5192 Nm). Install nut(5), torque 60 to 85 inch-pounds (6.7788 to b. Leave bar at rest for two to three9.6033 Nm). Torque nut (9) 133 to 158 foot- minutes to determine if it will remain level.pounds (180.3214 to 214.2164 Nm) and Torque nut (10) 133 to 158 foot-poundssecure with lockwire (C-405) to lock (11). (180.3214 to 214.2164 Nm). Secure nut to

lock with lockwire (C-405).d. Lubricate stabilizer bar bearings withbearing grease (C-007) at all lubrication c. Apply adhesive (C-308) to outboardfittings. ends of stabilizer bar as follows:

10. Balance stabilizer (paragraph 62-33).NOTE

62-33. BALANCING. Adhesive has a pot life of two hoursand will cure at room temperature in

MATERIALS REQUIRED 72 hours. An accelerated cure maybe obtained by allowing one hourdrying at room temperature and then

NUMBER NOMENCLATURE applying 167 to 173°F (75 to 78°C)heat for two hours.

C-308 Adhesive

C-405 Lockwire (1) Remove nuts (5), retainer (6),bushing (7), and washer (8). Ensure thatlocation of weights (9) are not disturbed.

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BHT-212-CR&O

Apply adhesive (C-308) to inside of weights at 62-34. INSPECTION AND REPAIR OFshoulder of weight and end of tube and in the STABILIZER BAR DAMPERS ANDgap between cable fitting and tube ID. ADAPTERS.

(2) Assemble washer (8), bushing (7), MATERIALS REQUIREDretainer (6), and nuts (5) on stabilizer bar.Insert a screwdriver in slotted end of cable to NUMBERNOMENCLATUREprevent cable from twisting and torqueinboard nut (5), 1 to 40 inch-pounds (0.11298 C-109 Protective Oilto 4.5192 Nm) and torque outboard nut 60 to - lvnt85 inch-pounds (6.7788 to 9.6033 Nm).Maintain 0.005 inch (0.127 mm) minimum gap C-242 Paint Removerbetween retainer (6) and weight (9). Recheckstatic balance and correct balance as 1. Inspect lever arm (6, figure 62-40) forrequired by using AN960-516 and/or AN960- scratches, nicks, dents, and corrosion (Figure516L washers between nuts (5) and retainer 62-41).(6).

2. Inspect adapters (4, figure 62-40) and(3) Place washer on bolt (25) and insert damper assembly (1) for scratches, nicks,

through inboard side of support assembly dents, and corrosion (figure 62-41).(22). Position support on inboard side ofcenterframe (19). Install washer and nut (14) 3. Replace dampers that show indications ofon bolt. Torque nut 500 to 700 inch-pounds leakage beyond recommended rates.(56.49 to 79.086 Nm), and install cotter pin 4. Clean levers, dampers, and adapter(38). splines with solvent (C-304) and dry

thoroughly. Protect areas of dampers and4. If necessary, adjust weight on 212-010- levers that are not to be stripped and clean300 stabilizer bar as follows: aged metalset adhesive from wingshaft and

lever splines with paint remover (C-242).a. Remove lockwire, loosen nut (9, figure Apply with brush and allow to soak for 30

62-38) from weight (1). Adjust weight (1) to minutes maximum. Repeat applications andthe closest locking position. Turn nut (9) scrub with a stiff bristled brush, as necessary,outboard and engage locks (11) in weight to remove adhesive. Rinse thoroughly withslots. water, then apply a low pressure and small

volume of water directly into a clean scrubb. With stabilizer bar balanced, leave bar brush while brush splines. Dry thoroughly.

at rest for two to three minutes to determine ifit will remain level. 5. Check splined area of shaft for chipped or

broken teeth. Up to nine chipped and/or

riffler file or equivalent.d. Back off nut (5) one turn and check

torque on nut (6) to be 1 to 40 inch-pounds 6. Using a ten X magnifying glass, visually(0.11298 to 4.5192 Nm). Bring nut (5) against inspect the end and teeth of the shaft fornut (6), torque nut (5) 60 to 85 inch-pounds cracks. No cracks in the body of the shaft are(6.7788 to 9.6033 Nm). acceptable. Small cracks in splined tooth area

will be removed by using a small handgrinder, rubber abrasive wheel and/or emerycloth. (Restrictions will be in accordance withstep 5). Dye penetrant inspect shafts for bodycracks. Apply a film of protective oil (C-109)to areas of wingshaft and lever which wereaffected by paint remover.

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BHT-212-CR&0

P/N 212-010-311 TUBE OR SEE DETAIL

51.8IN.(1316.72mm) - \THIS SIDE SAME ASSEMBLY DIMENSION WEIHTEXCEPT OPPOSITE PRIOR TO STATIC BALANCEN 212-010-306 WEIGHT

MINIMUM TUBE ENGAGEMENT IN WEIGHT TO BEFLUSH WITH SHOULDER WITHIN 0.03 IN. (0.762 mm).

1 lo 9 8 7

DETAIL A

1. Weight 7. Bushing2. Bushing 8. Packing3. Retainer 9. Nut4. Cable 10. Lockwire5. Nut A 11. Lock6. Nut A 12. Tube

NOTES

A Tubes P/N 212-010-311 and P/N 540-011-319-1 must be installed in pairs.

/ Omit epoxy/zinc coating and coat with corrosion preventive compound (C-101).

/ Omit primer and paint.

A Permissible to use a maximum of two (2) AN960-516 washers and a maximum oftwo (2) AN970-5 washers between retainer (3) and nut (6) to achieve balance ofstabilizer bar assembly. If a combination of washers is used, the AN970-5 washeris to be placed inboard and the AN960-516 washer to be used outboard.

212-R-62-38

Figure 62-38. Tube assembly 212-010-311 or 540-011-319

62-00-00Page 104 Rev. 4

BHT-212-CR&O

212-R-62-39

Figure 62-39. Stabilizer bar balancing

62-00-00Page 105

BHT-212-CR&O

7S

3. Retainer rings (2)1. Damper assembly2. Adapter bolts3. Retainer rings (2)4. Adapter5. Damper mounting bolts6. Lever arm7. Filler plug8. Retaining bolt

212-R-62-40

Figure 62-40. Stabilizer bar dampers

62-00-00Page 106

BHT-212-CR&O

LEVER212-010-301



NICKS, SCRATCHES, 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)AND SHARP DENTS

CORROSION 0.002 IN. (0.0508 mm) 0.005 IN. (0.127 mm)Before Repair Before Repair0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm)After Repair After Repair

AREA OF FULL 0.10 SQ. IN. 0.25 SQ. IN.

DEPTH REPAIR (64.52 SQ. mm) (161.3 SQ. mm)

NUMBER OF REPAIR One per segment Not Critical

AREAS

EDGE CHAMFER 0.040 IN. (1.016 mm) 0.060 IN. (1.524 mm)

BORE DAMAGE 0.002 IN. (0.0508 mm) 1/4 of circumference

SPLINE DAMAGE: Depth: 1/3 of SplineLength: 1/2 of SplineNumber: Three

212-R-62-41

Figure 62-41. Damper lever damage and repair limits

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BHT-212-CR&0

DAMPER ADAPTER TUBE204-010-937-9 204-010-922-5, 7 204-010-925-9


NICKS, SCRATCHES AND 0.010 IN. (0.254 mm)AND SHARP DENTS

CORROSION 0.005 IN. (0.127 mm) before repair0.010 IN. (0.254 mm) after repair

AREA OF FULL DEPTH REPAIR 0.10 SQ. IN. (64.52 SQ. mm)

NUMBER OF REPAIR AREAS

NOTES

Maximum number of repairs is two.

For rod ends repair refer to BHTI-ALL-SPM. Maximum number of repairs Is two.

Not critical. 212-R-62-42

Figure 62-42. Damper, damper tube, and adapter damage and repair limits

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BHT-212-CR&O

SCISSORS AND SLEEVE

62-35. SCISSORS AND SLEEVE. spacer (21) as it is released. Remove bearing(25) from scissor (8).

62-36. DISASSEMBLY. 4. Remove bolts (44) washers (43) andremove flange (45) and drive plate (46).

NOTE Remove screws (50) and remove lockplate(49).

Review Mandatory RetirementSchedule in BHT-212-MM, and retire 5. Install T101392 wrench on nut (37). Invertall items scheduled for retirement. hub and sleeve and secure wrench in a vise.

Using T101493 wrench turn nut (40) out ofCheck all pivot joints for binding hub (48). Remove tools from assembly.before disassembly. If severebinding exists, scrap the entireassembly. If scissors and sleeve are CAUTIONbeing disassembled for replacementof part(s) instead of overhaul,disassemble only to extent ENSURE THAT BEARINGS WILLnecessary to replace part(s). CLEAR T101369 SUPPORTS

DURING PRESSING OPERATION.1. Check spline wear of drive plate (6, figure62-43) prior to disassembly, as follows: 6. Place assembly upright on a press with

T101369 support halves located under huba. Install scissors and sleeve assembly (48). Place small end of T101382 ram adapter

onto a suitable mast, engaging drive plate in top of collective sleeve (2) and presssplines with splines of mast. sleeve out of hub. Remove seal (47) and

shoulder ring (42).b. Attach dial indicator (2, figure 62-43) to

mast with indicator probe (4) in contact with a 7. Remove pin (36), install T101392 wrenchflat of bolthead (3). Chuck hub assembly (5), with pins engaged in holes of nut (37). Insertin plane of rotation, and measure amount of T101424 bar in holes at lower end of sleeve.radial play present. Maximum radial play Hold bar and remove left-hand threaded nutallowed between mast (1) and drive plate (6) (37).is 0.040 inch (1.016 mm) at point ofmeasurement. 8. Place sleeve on a press with T101369

support halves under lower bearing set (39).2. Remove nut (34, figure 62-44), washer Place small end of T101382 ram adapter in(31 and 33), bolt (30) and remove link (32) upper end of sleeve and press sleeve fromfrom scissor. Remove shim (28), housing bearing set (39) and spacer set (38). Removeassembly (27) and thrust washer (29). seal (41) from nut (40) with T101382 ramRemove inner race (20). adapter.

3. Remove nuts (17) and washers (18) and 9. Remove liner (9) from scissors assembly.remove cover plate (16). Remove nut (19) Use T101424 bar and press out shims (10and spacer (14) from bolt (5 or 6). Support and 12), bearing set (11) and spacer (13)scissor assembly (3 or 8) and remove bolt (5 from. liner (9).or 6) with washer (26) and special washer (7)or roller bearing inner race (4). Remove 10. Use T101424 bar to remove bearingsscissor from hub assembly (1), removing (24 and 22) and spacer (23) from scissors.

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BHT-212-CR&O

62-37. INSPECTION. 6. Accomplish Normal Inspection (paragraph62-38).

NOTE62-39. Normal Inspection.

If records or physical appearanceindicate that the scissors and sleeveassembly have been subjected to an 1. Inspect parts for mechanical or corrosionaccident or incident, perform damage (figures 62-45 and 62-46).Conditional Inspection (paragraph62-37). If assembly does not require 2. Inspect bearing set (39, figure 62-44) andconditional inspection, accomplish spacer set (38) as follows:Normal Inspection (paragraph 62-38). a. Inspect bearings for roughness and

brinelling.

62-38. Conditional Inspection.NOTE

1. Carefully inspect the assembled brinelling visible under a fiveAny brinelling visible under a fivecomponent visually for any apparent damage magnification or of sufficientor abnormal appearance. Obvious defects poer agncaton or o suentewhich are cause to scrap the entire assembly deth to cause roughns hnare: bearing is rotated, shall be cause for

rejection.

a. Severe bind in any of the pivot joints. bb. Inspect for galled or flaked area onballs and raceways under a strong light.

b. Severe bind between the hub and Inspect for broken or fractured retainers.sleeve.

c. Inspect spacer set (38) for damage and2. Any detail part within the scissors and corrosion.sleeve assembly which has sustained surfacedamage shall be subject to surface damageinspection as outlined in paragraph 62-38 3. Inspection bearings (11, 25, and 51) fo(Normal Inspection). Surface damage that smooth operation and damaged seals oshield. Inspect bearing (51) and liner forexceeds limits, will require scrapping only the shield. Inspet bearing (51) and liner for

damaged part looseness. Any looseness will require removalof liner and checking the mating hole. Edgingof the hole not to exceed 0.001 inch (0.0254

3. An unworn bolt must fit freely through the mm) for 30 degrees is acceptable.bushings in the drive link. Any bind is causefor scrapping the drive link. 4. Inspect bearings (22 and 24) for smooth

operation. Inspect rollers for looseness due to4. With a straight edge check the cylindrical wear, flaked or flat spots, pitting or scoring.portion of the collective sleeve for Inspect seals for damage.deformation. Warpage in excess of 0.001 inch(0.0254 mm ) per inch (25.4 mm) is reason toscrap the sleeve. 5. Inspect inner races (4 and 20), and thrust

washer (29). If other than a smooth, unscoredsurface is found, replace parts as required.5. All machined flat surfaces surrounding

lugs, holes, and bushings in the entireassembly should be checked with a straight 6. Inspect spacers (13, 14, 21, and 23) andedge for deformation. Deviations from flat in liner (9) for cracks, corrosion, and wear.excess of 0.002 inch (0.0508 mm) per inch(25.4 mm) will require scrapping only the 7. Inspect drive plate (46) for splinedamaged part. damage.

62-00-00Page 110

BHT-212-CR&O

1. Mast2. Dial Indicator3. Bolt Head4. Indicator Probe5. Hub Assembly6. Drive Plate7. Magnet

212-R-62-43-1

Figure 62-43. Drive plate wear check

62-00-00Page 111

BHT-212-CR&O0.010 IN 7 5(0.254 mm) 26

AS REQD FOR 0.010 IN.(0.254 mm) MINIMUM GAPBETWEEN 7 AND 8

DETAIL B

7

2 8

SHIM FOR 0.000 TO 0.002 IN.

0.003 TO 0.009 IN. DETAIL C

19. Nut5 30.003 TO 0.009 IN.(0.0762 TO 0.2286 34 32 20. Inner race

3.990 TO 4.000 IN. 21. Spacer101.346 TO 101.6 mm) 22. Bearing (with seal)

23. Spacer24. Bearing25. Bearing26. Washer

1. Hub assembly 10. Shim 27. Housing assembly2. Collective sleeve 11. Bearing set 28. Shim3. Scissor assembly (P/N 212-010-407) 12. Shim 29. Thrust washer4. Roller bearing inner race 13. Spacer 30. Bolt5. Bolt (P/N 212-010-411-1) 14. Spacer 31. Washer6. Bolt (NAS464P8-90) 15. Cotter pin 32. Link7. Special washer 16. Cover plate 33. Washer8. Scissor assembly (P/N 204-011-406) 17. Nut 34. Nut9. Liner 18. Washer 35. Cotter pin

212-R-62-44Figure 62-44. Scissors and sleeve (Sheet 1 of 3)

62-00-00Page 112

BHT-212-CR&O

DRIVE LINK


I


MECHANICAL 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.035 IN. (0.889 mm)before and after repair before and after repair before and after repair before and after repair

CORRISIONBefore Cleanup 0.0025 IN. (0.0635 mm) 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.0175 IN. (0.4445 mm

before and before and before and before andAfter Cleanup 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.0350 IN. (0.889 mm)

after repair after repair after repair after repair

AREA OF FULL 0.10 SQ. IN. 0.10 SQ. IN. 0.25 SQ. IN. 0.40 SQ. IN.DEPTH REPAIR (64.52 SQ. mm) (64.52 SQ. mm) (161.3 SQ. mm) (258.08 SQ. mm)

NUMBER OF One One Per Lug Not Critical Not CriticalREPAIR AREAS

EDGE CHAMFER 0.020 IN. (0.508 mm) 0.030 IN. (0.762 mm) 0.040 IN. (1.016 mm) 0.060 IN. (1.524 mm)

BOLT HOLE DAMAGE: * 0.002 IN. (0.0508 mm) for 1/4 circumference for 1/2 bore length.

NOTE

Damage limits are for all approved scissors and drive links. 212-R-62-44-2

Figure 62-44. Scissors and sleeve (Sheet 2)

62-00-00Rev.3 Page 113

BHT-212-CR&O

37 r LEFT- H A N D THREADED NUT 44

39. Bearing set Mlll \ 503 |40. Nut41. Seal42. Shoulder ring43. Washer44. Bolt45. Flange46. Drive plate47. Seal48. Hub49. Lockplate 250. Screw

DETAIL E

212-R-62-44-3

Figure 62-44. Scissors and sleeve (Sheet 3)

62-00-00Page 114

BHT-212-CR&O

TYPBEFORESTAKING 52A

INSTALL FLUSH TO 0.010 (0.254 mm)

AS SHOWN, WITHIN 15H

DETAIL G 51. Bearing52. Housing assembly52A. Fitting52B. Washer

54. Sleeve DETAILH55. Bushing56. Bushing

212-R-62-45

Figure 62-45. Scissors and drive link damage limits

62-00-00Rev.3 Page 115

BHT-212-CR&O

204-011-405

SLEEVE204-011-408


TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREA ALLOWED

MECHANICAL ANDCORROSION(Before and after repair) 0.010 IN. (0.254 mm) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

AREA OF FULL 0.15 SQ. IN. 0.50 SQ. IN. 0.25 SQ. IN.DEPTH REPAIR (96.78 SQ. mm) (322.6 SQ. mm) (161.3 SQ. mm)

NUMBER OF REPAIR One per lug Not critical Not criticalAREAS

EDGE OF CHAMFER 0.020 IN. (0.508 mm) 0.020 IN. (0.508 mm) 0.040 IN. (1.016 mm)

THREAD DAMAGE DEPTH: One-third of threadLENGTH: One quarter inchNUMBER: Two per segment

212-R-62-46

Figure 62-46. Hub and sleeve damage limits

62-00-00Page 116

BHT-212-CR&O

8. Inspect sleeve (2) and hub (48) for thread MATERIALS REQUIRED (CONT)damage (figure 62_46).

NUMBER NOMENCLATURE9. Inspect flange (45), lockplate (49), NUMBER NOMENCATUshoulder ring (42), housing assembly (27),cover plate (16), and pin (36) for damage or C-201 Primerdeformation.

C-309 Methyl-Ethyl-Ketone10. Score marks on the ID of holes and (MEK)bushings not to exceed 0.002 inch (0.0508 C-363 Adhesivemm) are acceptable.

C-406 Aluminum Oxide Cloth11. Inspect studs in scissor (3 or 8) for C-423 Abrasive Cloth orlooseness or damaged threads. Paper

12. Inspect the following parts by magnetic C-493 Tubingparticle method (code M) or fluorescentpenetrant method (code F). Index numberspenetrant keyed to figur . Index numbers 1. Replace seals (41 and 47, figure 62-44)are keyed to figure 62-44. and seal in housing (27).

and seal in housing (27).

NOTE 2. Replace parts when wear limits areexceeded (figure 62-47).

Refer to BHT-ALL-SPM for approvedfluorescent penetrant material. 3. Replace parts that fail magnetic particle

or penetrant inspection.

Index No. Nomenclature CodeIndex No. Nomenclature Code 4. Replace bolts (5 or 6 and 30, figure 62-

2 Sleeve M 49), nuts (19 and 34) and washers.

3 or 8 Scissors F 5. Replace parts having nonreparable thread

32 Link F damage (figure 62-46).

37 Nut M 6. Replace unserviceable bearings. Bearingset (11, figure 62-44) must be replaced as a

40 Nut M serialized set.

48 Hub M 7. Repair acceptable corrosion andmechanical damage. Polish steel parts only toa depth sufficient to remove corrosion and

13. Inspect parts dimensionally if any aluminum parts twice depth of deepest pit, notphysical evidence of wear is present (Figure to exceed limits of figures 62-45 and 62-46.62-47). Use fine to medium grade aluminum oxide

cloth (C-406) and final polish to a scratch free62-40. REPAIR finish with crocus cloth. Score marks on

bushing ID may be polished if damaged andsubsequent repair does not exceed 0.002

MATERIALS REQUIRED inch (0.0508 mm) depth. Apply brush brushcadmium plating solution (C-108) to repairs

NUMBER NOMENCLATURE

C-100 Chemical Film Material

C-108 Brush CadmiumPlating Solution

62-00-00Rev.3 Page 117

BHT-212-CR&O

on cadmium plated surfaces and chemical pounds (226.8 kg) in each direction. Applyfilm material (C-100) aluminum surfaces. load to outer race of bearing. Check bearing

for freedom of movement.8. Replace link bushings (55 and 56, figure62-44) if wear limits are exceeded, as follows: g. Check scissors for cracks.

a. Properly support tangs of link and 10. Replace defective bearing sleeve (54) inpress out bushings (55 and 56) as required. scissor (8) as follows:

b. Coat mating surfaces with primer (C- a. Support scissors and press sleeve out.201) support tang and press in new bushing.

b. Remove all traces of adhesive fromc. Line ream two bushings (56) 0.3120 to scissors bore with a plastic scraper. Clean

0.3125 inch (7.9248 to 7.9375 mm) after bore with MEK (C-309) and wipe dry with ainstallation, clean cheesecloth.

d. Line ream two bushings (55) 0.4995 to c. Abrade sleeve OD with 180 grit0.5000 inch (12.6873 to 12.700 mm) after abrasive cloth or paper (C-423) and wipe withinstallation. a dry, clean cloth to remove sanding residue.

9. Replace defective scissors bearing (51) d. Mix adhesive (C-363) peras follows: manufacturers instructions and apply

adhesive to faying surfaces of sleeve anda. Position scissors over a suitable scissors bore. Install sleeve in scissors and

support having clearance for bearing and cure at 180°F (82C) for one hour or at roomsleeve. Press bearing and sleeve out of temperature for 24 hours.scissors lever.

11. Replace defective housing assemblyb. Clean lever bore with MEK (C-309). (52, figure 62-45) in scissor (3, figure 62-44)

Inspect bore for scoring. Depth of score shall as follows:not exceed 0.002 inch (0.0508 mm) aftercleanup. a. Remove fitting (52A) from housing

assembly (52).c. Apply primer (C-201) to mating

surfaces of replacement sleeve and sci ssors b. Support scissor tang and press housingbore. Support scissors and press sleeve into assembly out.scissors bore. (Detail F, figure 62-44)

c. Remove all traces of adhesive fromd. Remove lube fitting from lever and scissor bore with a plastic scraper. Clean

using lube fitting hole as a guide, drill 0.092 bore with MEK (C-309) and blot dry with cleanto 0.098 inch (2.3368 to 2.4892 mm) hole in cheesecloth.sleeve. Exercise caution not to increase fittinghole size. Press new lube fitting in lever. d. Abrade faying surface of housingReam sleeve 1.2488 to 1.2493 inch (31.71952 assembly and scissor with 180 grit abrasiveto 31.73222 mm) diameter. Clean sleeve bore cloth or paper (C-423) and wipe dry with awith MEK (C-309). dry, clean cloth to remove sanding residue.

e. Apply primer (C-201) to mating e. Remove protective cover from washersurfaces of bearing and sleeve. Press (52B) and strip (52C).bearing into sleeve.

f. Trim strip to fit diameter of housingf. Ring stake sleeve both sides (Detail F). assembly with end gap of 0 to 0.010 inch

Proof load ring staking of bearing to 500 (0.254 mm).

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BHT-212-CR&O

g. Abrade faying surfaces of washer and approximately two wraps of heat shrinkablestrip with 180 grit abrasive cloth or paper (C- tubing (C-493) around assembled parts. Cure423) and wipe with clean dry cloth to remove at 175 to 190°F (79.4 to 87.8°C) for 1 hour.sanding product.

j. Remove tape.

NOTE k. Mix adhesive (C-363) in accordancewith manufacturers instructions and applyParts must be bonded within 4 hours adhesive to faying surfaces of housing

h. Mix adhesive (C-363) in accordance Cure at 180°F (82°C) for one hour or roomwith manufacturers instructions and apply temperature for 24 hours.adhesive to faying surfaces of washer andhousing assembly, use 40 psi bonding I. Press roller bearing assembly (53) intopressure. Cure at 170 to 190°F (76.6 to housing assembly (52). Press bearing on87.8°C) for 1 hour. marked end. Press flush to 0.010 inch (0.254

mm) below surface, (detail G).i. Apply adhesive to faying surfaces of

strip and housing assembly. Use

0

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BHT-212-CR&O

6

MIN. MAXITEM NOMENCLATURE inches mm inches mm

1. Hub ID 5.2496 133.27126 5.2520 133.40082. Hub bolt hole 0.4995 12.6873 0.5015 12.73813. Sleeve bearing seat OD 4.2480 107.8992 4.2507 107.967784. Link bushing ID 0.4995 12.6873 0.5010 12.72545. Inner race ID 0.4995 12.6873 0.5010 12.72546. Bearing liner ID 1.1249 28.57246 1.1270 28.62587. Link bushing ID 0.3120 7.9248 0.3140 7.9756

212-R-62-47

Figure 62-47. Scissors and sleeve wear limits

62-00-00Page 119

BHT-212-CR&O

12. Repair nuts (37 and 40, figure 62-44) as d. Install shim (12) and spacer (13) infollows: liner (9). Check that spacer (13) extends

0.003 to 0.009 inch (0.0762 to 0.2286 mm)a. Nicks, scratches, sharp dents, and beyond outer face of liner (9). (See detail A.)

corrosion may be polished out to maximum Peel shim (12), as required, to obtain desireddepth of 0.005 inch (0.127 mm). dimension A.

b. Maximum area of full depth repair is e. Accomplish steps a. through d. on0.25 square inch (161.3 sq mm). opposite scissor.

c. Maximum of two repairs per nut. 2. Assemble collective sleeve (2) on hub(48) as follows:

d. Edge chamfer 0.020 inch (0.508 mm).a. Install new seal (41) (with lip of seal

e. Thread damage: Maximum of two with facing down) in nut (40) using T101382 rama length of 1/4 inch (6.35 mm) and a depth of adapter. Place nut (slotted side down) on1/3 of a thread. collective sleeve (2), below shoulder. Apply

coat of corrosion preventive compound (C-101) to threads of nut.

62-41. ASSEMBLY.b. Clean bearing set (39) with solvent (C-

MATERIALS REQUIRED 304), air dry and hand pack bearings withbearing grease (C-007). Assemble bearing setand spacer set (38) with V-mark on bearing

NUMBER NOMENCLATURE races aligned and pointing up. (See detail E.)Use a T1013882 ram adapter and press two

C-007 Bearing Grease lower bearings (39) on collective sleeve (2).Press spacer set (38) and upper two bearings

C-101 Corrosion Preventive on sleeve. Ensure that V-mark is pointing up.Compound

C-304 Solvent c. Apply coat of corrosion preventivecompound (C-101) to nut (37) threads. Start

C-405 Lockwire nut (37) (left-hand thread) on collective sleeve(2). Install T101392 wrench with pins engagedin holes of nut. Hold collective sleeve (2) with

1. Assemble scissor (3 or 8, figure 62-44) as T101424 bar and torque nut (37) 150 to 200follows: foot-pounds (203.37 to 271.16 Nm). Align

holes of nut and sleeve (one location) anda. Remove preservative from bearings install pin (36). (See detail D.) Install lockwire

(11, 22, and 24) with clean solvent (C-304). (C-405) through hole in pin in space betweenAir-dry and hand-pack bearings with bearing nut and sleeve (detail D).grease (C-007).

d. Press new seal (47) (lip of seal up) intob. Use a T101424 bar and press bearing top of hub (48) with T101382 adapter. Press

(24), spacer (23) and bearing (22) (seal side seal flush with or slightly below top surface ofoutboard) into scissor liner. hub seal bore.

c. Install shim (10) and bearing set (11) (V e. Place collective sleeve (2) on a suitablemark on outer races pointing inboard) into press with T101369 support halves underliner (9). Install liner in scissors and check for lower bearing set (39). Place shoulder ringa dimension of 3.990 to 4.000 inches(101.346 to 101.600 mm) between inner raceof bearing set (11) and inside face of shortleg of scissors. (See detail A.) Peel shim (10)as required to accomplish correct dimension.

62-00-00Page 120 Rev.3

BHT-212-CR&O

(42) on upper bearings (39) and press hub (4) Install spacer (14) and nut (19).down over bearings. Torque nut (19) 200 to 400 inch-pounds

(22.596 to 45.192 Nm) and install cotter pinf. Install T101392 wrench on top of hub. (15).

Invert the hub and sleeve and secureT101392 wrench in a vise. Start nut (40) into (5) Check that nut (19) has nothub and using T101493 wrench torque nut bottomed out on bolt (6) and that scissors to400 to 500 foot-pounds (542.32 to 677.90 hub clamp-up is correct as follows:Nm). Install lockplate (49) with tabs engagedin nut (40). Install two screws (50) and secure (a) Use a torque wrench on head ofheads together with lockwire (C-405). Turn bolt (6) and attempt to turn clockwise. Boltassembly upright and remove tools. should not rotate at less than 180 inch-

pounds (20.3364 Nm).

NOTE (b) If bolt rotates at less than 180

If lockplate (49) does not align, inch-pounds (20.3364 Nm), remove cotter pinsecure a new plate and drill two and nut (19).holes, 0.198 to 0.204 inch (5.0292 to5.1816 mm) diameter to match the (c) Place one AN960-816 washer ontwo holes in hub (48). bolt (6) and reinstall nut (19). Torque nut 200

to 400 inch-pounds (22.596 to 45.192 Nm)

g. Apply corrosion preventive compound and install cotter pin.(C-101) on bolts (44). Install plate (46) andflange (45) on top of hub and secure with (d) Repeat step (a) to ensure bolt (6)bolts (44) and washers (43). Secure will not rotate at less than 180 inch-poundsboltheads in sets of three with lockwire (C- (20.3364 Nm). If bolt still rotates at less than405) 180 inch-pounds (20.3364 Nm), remove

scissors from hub and reinstall, following step

3. Install scissors assembly as follows: 3. (a).

a. Install 204-011-406 scissor assembly (6) Install cover plate (16) and secureas follows: with washers (18) and nuts (17).

(1) Position bearing (25) in short arm of (7) Accomplish steps 3.a. throughscissor assembly (8). 3.a.(6) on opposite scissor.

b. Install 212-010-407 scissor assemblyNOTE as follows:

Bearing (25) is intended to have a (1) Coat bolt (5) with corrosionloose fit in sleeve (54). preventive compound (C-101).

(2) Coat bolt (6) with corrosion (2) Place roller bearing inner race (4)preventive compound (C-101). Position on bolt (5).special washer (7) and standard or thin steelwasher (26), as required, to provide a 0.010 (3) Position scissor assembly (3) oninch (0.254 mm) minimum gap between hub assembly (1) with spacer (21) betweenscissor assembly (8) and special washer (7). bearing set (11) and hub assembly (1).(See detail B.)

(4) Insert bolt (5) with roller bearing(3) Position scissor assembly (8) on inner race (4) through scissor assembly and

hub assembly (1) with spacer (21) between hub assembly.bearing set (11) and hub assembly (1). Insertbolt (6), washer(s) (26) and special washer(7) through scissor and hub assembly.

62-00-00Page 121

BHT-212-CR&O

(5) Install spacer (14) and nut (19). opposite side of link and measure gapTorque nut (19) 200 to 400 inch-pounds between housing assembly (27) and tang of(22.596 to 45.192 Nm) and install cotter pin link (32).(15).

b. Peel shim (28) to dimension of gap(6) Check that nut (19) has not measured in step a. within 0.000 to 0.002

bottomed out on both (5) and that scissors to inch (0.0 to 0.0508 mm). (See detail C.)hub clamp-up is correct as follows: Remove bolt (30) and assembled parts from

link (32).(a) Use a torque wrench on head of

bolt (5) and attempt to turn clockwise. Bolt c. Coat new bolt (30) with corrosionshould not rotate at less than 180 inch- preventive compound (C-101).pounds (20.3364 Nm).

d. Insert inner race (20) in outboard end(b) If bolt rotates at less than 180 of scissors (3 or 8). Position link (32) on

inch-pounds (20.3364 Nm), remove cotter pin scissor with thrust washer (29), housingand nut (19). assembly (27) and shim (28), of previously

determined thickness, between forward tang(c) Place one AN960-816 washer on of link and scissor. Install bolt (30) with

bolt (5) and reinstall nut (19). Torque nut 200 washer (31) under head. Install washer (33)to 400 inch-pounds (22.596 to 45.192 Nm) and nut (34). Torque nut (34) 200 to 400 inch-and install cotter pin. pounds (22.596 to 45.192 Nm), install cotter

pin (35).(d) Repeat step (a) to ensure bolt (5)

will not rotate at less than 180 inch-pounds(20.3364 Nm). If bolt still rotates at less than180 inch-pounds (20.3364 Nm); remove If end play exceeds 0.090 inchscissors from hub and reinstall, following step (2.286 mm) replace thrust washer3.b. (29).

(7) Install cover plate (16) and secure e. Accomplish steps a. through d. towith washers (18) and nuts (17). install link on opposite scissor.

(8) Accomplish steps 3.b. through 5. Lubricate scissors and hub through lube3.b.(7) on opposite scissor. fittings with bearing grease (C-007).

4. Install link (32) on scissors (3 or 8) as 6. Check scissors and hub for freefollows: operation.

a. Install inner race (20), thrust washer 7. Coat all boltheads, washers, nuts, and(29) and housing assembly (27), between exposed joints with corrosion preventivetangs of link (32). Retain parts in place with compound (C-101).bolt (30). Hold assembled parts against

62-00-00Page 122

BHT-212-CR&O

SWASHPLATE AND SUPPORT

62-42. SWASHPLATE AND SUPPORT 2. Detach gimbal ring assembly (4) fromOVERHAUL. support (12) by removing two bolts (9) with

cotter pins, and special washers (11).

62-43. DISASSEMBLY.62-43. DISASSEMBLY. 3. Remove each of four bearing and linerassemblies (6 and 7) with shims (5) from

NOTE gimbal ring by removing lockwire and screws(8). Press bearing from each liner.

Review Mandatory RetirementSchedule in BHT-212-MM and retire 4. Remove 24 nuts and washers from studsall items scheduled for retirement. at top of swashplate. Lift off cover (14), outer

cap (18), inner cap (15), and two sets ofIf swashplate and support is being shims (16 and 19). Remove seal (17) fromdisassembled for replacement of outer cap.part/s instead of overhaul,disassemble only to extent 5. Lift outer ring (21) and thrust bearing (20)necessary to replace part/s. from inner ring (23). Remove bearing and

lower seal (22) from outer ring.

CAUTION I NOTE

A workaid is recommended to allowREFER TO CONDITIONAL removal of trunnions with lessINSPECTION, PARAGRAPH 62-46, possibility of damage to swashplatePRIOR TO DISASSEMBLY. rings (figure 62-48).

NOTE 6. Remove two trunnion assemblies (25,figure 62-48) from outer ring by removing

Slip type bushings (13, figure 62-48) bolts (24) with nuts and washers.are used only on swashplate with a204-011-402-21 inner ring.

1. Detach swashplate assembly (3, figure CAUTION62-48) from gimbal ring assembly (4) byremoving two bolts (2), with cotter pins, nuts, EXCESSIVE SPREADING OF THEwashers, and special washers (1). Secure TRUNNION CLAMP AREA OF THEbushings (13) to swashplate inner ring. RING COULD CAUSE A CRACK

RESULTING IN LOSS OF ROTOR

BOLTS (2 AND 9) ARE DIFFICULT TRUNNION (25, FIGURE 62-48)TO REMOVE DUE TO RETAINING CAN BARELY BE PULLED OUT.COMPOUND AND MUST BE IMMEDIATELY RELEASE SCREWDRIVEN OUT. SUPPORT THE TENSION AND REMOVELUGS OF INNER RING (23) AND WORKAID.SUPPORT (11) TO PREVENTDAMAGE DU R I NG BOLT 7. At each of three control horns of innerREMOVAL. ring (23), remove trunnion assemblies using

workaid shown in figure 62-48.

62-00-00Rev.3 Page 123

BHT-212-CR&O

62-44. CLEANING. which are cause to replace the entireassembly are:

MATERIALS REQUIREDa. Binding in any of the pivot joints.

NUMBER NOMENCLATURE b. Binding of outer ring on inner ring.

C-105 Corrosion Preventive 2. Any detail part which has sustainedC-304 Solvent surface damage shall be subject to surface

damage inspection as outlined in paragraph62-47. Surface damage that exceeds limits

1. Clean parts with solvent (C-304). Dry with will require replacing only the damaged part.filtered, compressed air.

3. Inspect the swashplate support, inner ringand outer ring as follows:

NOTEa. Swashplate support.Do not immerse shielded or sealed a. Swashplate

bearings in solvent. Wipe clean with (1) An unworn bolt must fit freely insolvent dampened cloth. both gimbal support and collective leversupport bushings. Any binding is cause for2. Remove fingerprints or similar replacing the support.

contamination from bearing surfaces andsteel liners or sleeves with corrosion (2) With aidpreventive (C-105) and final rinse with solvent check flat areas of gimbal straight lugs for

'check flat areas of gimbal support lugs fordeformation. Deviations from flat in excess of0.002 inch (0.0508 mm) per inch (25.4 mm)3. Clean bearing liners on inner and outer are cause to replace support.

rings by blasting with glass beads afterinspection. ^(3) The base surface of the support

shall be flat within 0.001 inch (0.0254 mm)4. Protect bearings from contamination. per inch (25.4 mm).

62-45. INSPECTION. b. Inner ring.

(1) An unworn bolt (2) must fit freely inNOTE gimbal ring attachment holes. Use bushing

f (13) when checking 204-011-402-21 innerIf records or physical appearance ofswashplate and support indicate that ring. Any binding is cause for replacing theswashplate and support indicate that

the assembly has been subjected toan accident or incident outside the

real normal usage, perform ( 2) With the aid of a straight edgerealm of normal usage, perform the check flat areas of gimbal support lugs forConditional Inspection, paragraph deformation. Deviations from flat in excess of62-46. If the assembly does not 0.002 inch (0.0508 mm) per inch (25.4 mm)require a conditional inspection,accomplish Normal Inspection, are cause to replace the inner ring.accomplish Normal Inspection,

paragraph 62-47. (3) Top surface must be flat within0.002 inch (0.0508 mm) per inch (25.4 mm).

62-46. Conditional Inspection.c. Outer ring.

1. Carefully inspect the assembledcomponent visually for any apparent damage (1) The bearing liner ID shall be roundor abnormal appearance. Obvious defects within 0.002 inch (0.0508 mm).

62-00-00Page 124

BHT-212-CR&O

VIEW B

204-011-402-21 ONLY

VIEW B /

1. Special chamfered washer (P/N 204-011-457-3)/2. Bolt 33. Swashplate assembly4. Gimbal ring assembly5. Shim6. Liner7. Bearing8. Screw9. Bolt

10. Special washer (P/N 204-011-457-1)/ 511. Washer12. Swashplate support

VIEW A

212-R-62-48-1

Figure 62-48. Swashplate and support assembly (Sheet 1 of 2)

62-00-00Page 125

BHT-212-CR&O

14. Cover 26. Bolt15. Inner cap 27. Plate16. Shim set 28. Trunnion

Page 1216 INRev.

~~~~~~DETAIL ~DETAIL B 212-R-62-48-222

62-00-00Page 126 Rev.3

BHT-212-CR&O

1.60 IN.

212-R-62-49

Figure 62-49. Trunnion removal and installation workaid

62-00-00Rev.3 Page 127Rev. 3 Page 127

BHT-212-CR&O

(2) Check several segments around the NOTEtop for flatness with a straight edge. Not morethan two studs should be outboard of the The trunnion bearings are differentstraight edge when performing a check. The from other bearings, which normallyring shall be flat within 0.001 inch (0.0254 can be feel-checked for roughnessmm) per inch (25.4 mm) over the length and ease of rotation. The trunnionmeasured. bearings are preloaded into the

cylinder portion of the trunnion with4. Accomplish Normal Inspection, paragraph a 0.0005-inch (0.0127 mm) tight to62-47. 0.0005-inch (0.0127 mm) loose

tolerance. The bearings are rollertype, with no separated roller cages

62-47. Normal Inspection. and angular-faced inner and outerraces. The normal feel of this

1. Inspect surfaces of parts for mechanical assembly is one of tightness, duedamage (scratches and nicks) and corrosion mainly to the 0.0005-inch (0.0127damage. Reject parts if surface damage mm) tight tolerance. The feeling ofcannot be polished out within the following roughness is due to the preloadedlimits: and the angular faces of the inner

and outer races. When grease isa. Maximum depths of surface damage applied to the assembly, as

before and after repair on swashplate inner required, the normal bearing feeland outer rings and support are shown on does not exist. The conditionsfigure 62-50 and 62-51. described are inherent in the

trunnion bearing assembly.b. Score marks on inside surface of holes Checking the bearing assembly for

or bushings may be polished out if not more tightness should be accomplished bythan 0.002 inch (0.0508 mm) deep. hand movement only of the barrel

and the crosshead.

2. Inspect parts dimensionally if visualindications of wear are found (figure 62-49). 5. Inspect the following parts by magnetic

particle (Code M) or fluorescent penetrant3. Inspect thrust bearing (20, figure 62-48) method (Code F). Index numbers are keyedfor dents, deformation, cracks, corrosion, to figure 62-48. Demagnetize parts aftersigns of overheating, and looseness due to magnetic particle inspection.wear. Check by feel for indications of internaldamage (brinelling, spalling, and cracked or NOTEbroken balls) by placing cleaned thrustbearing flat on a clean surface and applying Refer to BHT-ALL-SPM for approvedeven pressure with palms and heels of hands fluorescent penetrant material (Postwhile turning bearing slowly. Emulsified Penetrant System).

jCAUTION J Index No. Nomenclature Code

RAPID OR CONTINUED ROTATION Gimbal Ring MWILL SCORE RACES OFUNLUBRICATED BEARING. 12 Support F

4. Inspect trunnion for general condition. 21 Outer Ring FCheck for axial play, not to exceed 0.020 inch(0.508 mm). 23 Inner Ring F

62-00-00Page 128

BHT-212-CR&O

INNER RING204-011-402

204-011-403

TRUNNION BORE0.002 IN. (0.0508 mm)

TRUNNION BORE

DAMAGE LOCATION SYMBOLS 0.002 IN. (0.0508 mm)


MECHANICAL 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.020 IN. (0.508 mm) 0.030 IN. (0.762 mm)(Before andafter repair)

CORRISION(Before repair 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.010 IN. (0.254 mm) 0.015 IN. (0.381 mm)(After repair) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.020 IN. (0.508 mm) 0.030 IN. (0.762 mm)

MAXIMUM AREA 0.10 SQ. IN. 0.50 SQ. IN. A Not criticalPER FULL DEPTH (64.52 SQ. mm) (322.6 SQ. mm)REPAIR

NUMBER OF Two per lug Two per arm A Not CriticalREPAIR AREAS

EDGE CHAMFER 0.030 IN. (0.762 mm) 0.100 IN. (2.54 mm) 0.100 IN. (2.54 mm)

TRUNNION BORE: 0.002 IN. (0.0508 mm) for 1/4 circumference

THREAD DAMAGEDEPTH: One-third of threadLENGTH: One-quarter inch of circumferenceNUMBER: One

NOTE

/ Surface corrosion may be cleaned up over the entire surface of the liner. Corrosion requiring fulldepth repair is limited to one-fourth of the total area. Segments of full depth repair should notexceed 2.0 inches (50.8 mm) in length and should maintain 0.50 inch (12.7 mm) minimumseparation. 212-R-62-50

Figure 62-50. Swashplate inner and outer ring damage limits

62-00-00Page 129

BHT-212-CR&O

6. Inspect studs of inner and outer rings as aluminum oxide cloth (C-406) or a fine Indiafollows: stone (C-464), and final polish to smooth

scratch-free surface with crocus cloth (C-a. Maximum permissible wobble or side- 500). No surface shall be repaired by use of

to-side looseness is 0.010 inch (0.254 mm) grinding wheel, plugging or patching.per inch (25.4 mm) of stud height asmeasured from the mounting surface. b. Corrosion damage, on aluminum, shall

be polished out to twice depth of pit. butb. Maximum permissible axial or up-andmechanical damage shall be polished out only

down looseness is 0.003 inch (0.0762 mm). deep enough to remove traces of damage. Donot exceed limits of figures 62-51 and 62-52.

c. Looseness in excess of the abovefigures requires replacement of studs and c. Where anodized surface is removed byinspection of the tapped holes. repairs (not to exceed 10 percent total

surface area) restore finish with chemical filmd. Any signs of corrosion or damage to treatment (BHT-ALL-SPM). Anodize part if

the parent material in the tapped holes or more than 10 percent of surface area wasaround the stud lock ring in excess of limits removed.reflected on figure 62-50 is cause for rejectionof the ring assembly. d. Where cadmium plating is removed by

repairs, restore finish with brush cadmium

62-48. REPAIR. plating solution (C-108).

2. Replace defective bushing in inner ring asMATERIALS REQUIRED follows: (Figure 62-53)

NUMBER NOMENCLATURE

C-007 Bearing Grease

C-108 Brush Cadmium USE SUITABLE SUPPORT TOPlating Solution BACK UP LUG OF INNER RING

WHEN PRESSING OUT BUSHING.C-201 Primer

C-203 Lacquer NOTE

C-204 Primer Three different part number innerrings are in use on 212 helicopters.

C-304 Solvent The different bushing installations

C-306 Toluene are covered in the following stepsand are shown on figure 62-53.

C-309 Methyl-Ethyl-Ketone(MEK) a. Heat inner ring with a heat lamp and

tap or press out bushings.C-406 Aluminum Oxide Cloth

b. Check bores in inner ring for scoringC-500 Crocus Cloth and cracks. Maximum depth of scores after

C-464 India Stone cleanup shall not exceed 0.002 inch (0.0508mm).

1. Corrosion and mechanical damage repair. c. Install bushings in 212-011-402-17inner ring as follows: (Figure 62-53, Detail A)

a. Remove no more material thannecessary, using fine to medium grades of

62-00-00Page 130

BHT-212-CR&0

NOTE facing outboard) into hole in lug. Ensure thatbushings are fully seated.

The latest replacement bushings forthe 212-011-412-17 inner ring have (3) Hone or lap bore if required toan inner diameter of 0.3125 to obtain 0.3120 to 0.3130 inch (7.9248 to0.3135 inch (7.9375 to 7.9629 mm) 7.9502 mm) inner diameter.and do not require reaming afterinstallation. After installation these (4) Coat replacement flangelessbushings, 204-011-464-1 and 204- bushings and bores with primer (C-201).011-495-111, may be lapped or Press flangeless bushings into each end ofhoned, if required, to obtain 0.312 to outboard holes until bushing is flush to 0.0050.313 inch (7.9248 to 7.9502 mm) inch (0.127 mm) below surface.inner diameter.

(5) Ream flangeless bushings 0.4375 to(1) Heat inner ring with a heat lamp. 0.4380 inch (11.1125 to 11.1252 mm)

diameter in line with 0.3120 to 0.3130 inch(7.9248 to 7.9502 mm) diameter holes.

CAUTION (6) Inspect inner ring for cracks.

e. Install bushing in, 204-011-402-127,inner ring as follows: (Figure 62-53, Detail C)

BACK UP LUG OF INNER RINGWHEN PRESSING IN BUSHING. (1) Heat inner ring with heat lamp.

(2) Coat replacement bushings and (2) Coat replacement bushings andinner ring bores with primer (C-201). While bores with primer (C-201).primer is still wet press the longer bushings ineach end of the outboard holes and press theshorter bushing (flange facing outboard) intohole in lug. Ensure that bushings are fully CAUTIONseated (detail A).

(3) Hone or lap bore if required to USE SUITABLE SUPPORT TOobtain 0.312 to 0.313 inch (7.9248 to 7.9502 BACK UP LUG OF INNER RINGmm) inner diameter. WHEN PRESSING IN BUSHING.

(4) Inspect inner ring for cracks. (3) Press shortest bushing, 204-010-495-113, (flange facing outboard) into hole in

d. Install bushings in, 204-011-402-21, lug.inner ring as follows: (Figure 62-53, Detail B)

(4) Press bushing with thickest flange,(1) Heat inner ring with heat lamp. 204-010-495-115, into inboard end of hole.

(5) Press other bushing, 204-010-495-CAUTION 111, into outboard end of hole.

(6) Ensure all bushings are fully seated.

USE SUITABLE SUPPORT TOBACK UP LUG OF INNER RING NOTEWHEN PRESSING IN BUSHING.

These bushings are manufactured(2) Coat replacement flanged bushings with an inner diameter of 0.3125 to

and bores with primer (C-201). While primer 0.3135 inch (7.9375 to 7.9629 mm)is still wet, press the flanged bushings (flange and do not require reaming. After

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BHT-212-CR&O

installation these bushings may be are 204-011-404-17, 204-011-404-lapped or honed, if required, to 121, and 204-011-404-125. Theobtain 0.312 to 0.313 inch (7.9248 to different bushing installations are7.9502 mm) inner diameter. covered in the following steps and

are shown on figure 62-54. The 204-(7) Machine flange of bushing, 204-011- 011-404-17 support (slip bushing

464-007, as required to obtain 0.558 to 0.560 type) is no longer used on 212inch (14.1732 to 14.224 mm) dimension helicopters.shown in detail C.

a. Heat support with heat lamp. Use a(8) Inspect inner ring for cracks. suitable support and back-up tang. Press out

bushings.3. Replace defective collective leverattachment bushings in support as follows: b. Inspect bores for crack or scores.(Figure 62-54) Maximum depth of scores after cleanup shall

not exceed 0.002 inch (0.0508 mm).a. Warm support with heat lamp. Using a

suitable support, back up tang and press ortap out bushing. Inspect bores for cracks and CAUTIONscoring. Scoring not to exceed 0.002 inch *(0.0508 mm) depth after cleanup.

USE SUITABLE SUPPORT TOb. Coat new bushings and hole ID with BACK UP TANG WHEN PRESSING

primer (C-201). Apply heat lamp to support IN BUSHING TO PREVENTand insert bushings. Ensure bushings are DAMAGE TO SWASHPLATE.fully seated.

c. Coat replacement bushings and boresc. Check dimension between faces of in support with primer (C-201). Support tang

outboard bushings in support arms. Mill and press bushings into support while primerbushing flanges an equal amount to establish is still wet. Install bushing with thickest flange5.868 to 5.870 inch (149.0472 to 149.0980 in outboard tang as shown on figure 62-54.mm) dimension as shown.

d. Line ream bushings 0.4995 to 0.5005 NOTEinch (12.6873 to 12.7127 mm). Check thatbushing ID is true to surface A within 0.002 Bushings used in supports 204-011-inch (0.0508 mm) per inch (25.4 mm). 404 and 00 0125

an inner diameter of 0.3125 to4. Replace defective gimbal ring attachment 0.3135 inch (7.9375 to 7.9629 mm)bushings in support as follows: (Figure 62-53) and do not require reaming after

installation. Bushings may be honed,if required, to obtain 0.312 to 0.313

............. inch (7.9248 to 7.9502 mm) innerCAUTION diameter after installation.

d. On 204-011-404-121 and 204-011-404-USE SUITABLE SUPPORT TO 125 supports, machine flange of outboardBACK UP TANG WHEN PRESSING bushing as required to obtain 0.558 to 0.560OUT BUSHING TO PREVENT inch (14.1732 to 14.224 mm) dimensionDAMAGE TO SWASHPLATE. shown in detail A.

NOTE 5. Replace loose or damaged studs in theinner and outer ring as follows:

Three different part number supportsare used on 212 helicopters. They a. Measure height of stud to be replaced.

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DAMAGE LOCATION SYSMBOLS


MECHANICAL(Before and after repair) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.035 IN. (0.889 mm)

CORROSION(Before repair) 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.017 IN (0.4318 mm)(After repair) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm) 0.035 IN. (0.889 mm)

MAXIMUM AREA PER 0.10 SQ. IN. 0.25 SQ. IN. 0.50 SQ. IN.FULL DEPTH REPAIR (64.52 SQ. mm) (161.30 SQ. mm) (322.6 SQ. mm)

NUMBER OF REPAIR One per lug Not critical Not criticalAREAS

EDGE CHAMFER 0.040 IN. (1.016 mm) 0.060 IN. (1.524mm) 0.100 IN. (2.54 mm)

BORE DAMAGE 0.002 IN. (0.0508 mm) in depth for 1/4 circumference.212-R-62-51

Figure 62-51. Swashplate support damage limits

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b. Remove loose or damaged stud. b. Mask inner surfaces of trunnion holesand bolt hole, and other surfaces not to becoated.

NOTE

These instructions are applicable to c. Spray apply a wet coat of lacquer (C-the studs which have a serrated 203) to exterior surface of three control arms,locking ring. The locking ring inner to include areas one inch (25.4 mm) inboardteeth engage a serrated collar of the of large holes in tops and bottoms of arms.stud; the locking ring outer teethbroach into the material of the case. d. Air-dry at room temperature for 30Special tools for removal/installation minutes minimum.are available from the manufacturerof the studs. When such tools are e. Apply second coat.not available, replacement can beaccomplished with other tools f. Cure by one of the following methods:provided that careful workmanship isapplied. (1) Air-dry 48 hours minimum at room

temperature.c. Removal of stud: Select a hollow mill

with outside diameter 1/64 inch (0.39688 mm) (2) Air-dry for 15 minutes and cure atless than root diameter of outer serrations of 150°F (66°C) for one hour.locking ring. Mill to depth equal to ringthickness. Remove stud and remaining 7. Replace gimbal ring bearings, seals,portion of ring. If a hollow mill is not available, bolts, nuts, and cotter pins on assembly.saw stud off and use drill and extractor. Replace all unserviceable parts.

d. Check condition of tapped hole and 8. Lubricate the following parts beforecounterbore. Holes are tapped with a assembly.standard class 3 tap and the counterbore hasa 90 degree shoulder. If necessary, clean up a. Hand pack thrust bearing (20, figureminor damage but avoid enlargement of 62-48) with bearing grease (C-007). Afterholes. assembly of swashplate, use a suitable gun at

two lube fittings on outer ring and purgee. Coat faying surface of new stud with grease past seals to ensure bearing

primer (C-204) and install into tapped hole lubrication.until top surface of serrated collar is 0.010 to0.020 inch (0.254 to 0.508 mm) below surface b. After assembly, purge lubricateof parent metal. Driving torque for stud is 50 trunnions with hand gun through fittingsto 95 inch-pounds (5.649 to 10.7331 Nm). provided on each rod end and swashplate

horn.f. Coat new locking ring with primer (C-

204) and position on stud with teeth aligned.Drive locking ring into swashplate ring until 62-49. ASSEMBLY.flush with top of stud collar.

MATERIALS REQUIRED6. Apply lacquer (C-203) on all exteriorsurfaces of inner ring, from tips of arms to aminimum of four inches (101.6 mm) inboard, NUMBER NOMENCLATUREas follows:


a. Thoroughly clean surfaces with cloth C-101 Corrosion Preventivesaturated with toluene (C-306) or solvent (C- Compound304)MEK (C-309). Wipe surface dry withclean cloth before solvent evaporates. C-201 Primer

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9 10 11

MIN. MAXITEM NOMENCLATURE inches mm A inches mm

1. Outer ring ID A 10.2500 260.35 /1\10.2540 260.45162. Bearing OD /1\10.2460 260.5024 A10. 2 5 0 0 260.353. Bearing ID A 8.9990 228.5746 /1\9.0030 228.67624. Inner ring OD 8.9960 228.4884 8.9990 228.57465. Gimble ring ID 1.3750 34.925 1.3770 34.97586. Bearing liner OD 1.3730 34.8742 1.3748 34.919927. Bearing liner ID 1.2490 31.7246 1.2505 31.76278. Bushing (support or inner ring) ID 0.3120 7.9248 0.3150 8.0019. Bushing (204-010-496-3) floating OD 0.4368 11.09472 0.4373 11.10742

10. Bushing (204-010-497-3) fixed ID 0.4375 11.1125 0.4380 11.125211. Bushing (204-010-495-3) fixed ID 0.3120 7.9248 0.3130 7.9502

NOTES

A Indicates average dimension.

A Used on swashplate with 204-011-402-21 inner ring.

A Used on all other swashplates.212-R-62-52

Figure 62-52. Swashplate and support wear limits

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0.3120 TO 0.3130 IN.

SECTIONAL VIEWINNER RING ASSEMBLY

204-011-402-17

0.4375 TO 0.4380 IN.(11.1125 TO 11.1252 mm)DIA., FOUR HOLES IN LINE

DETAIL B

SECTIONAL VIEWINNER RING ASSEMBLY

204011-402-21

0.312 TO 0.313 IN.(7.9248 TO 7.9502 mm)DIA., TWO HOLES IN LINE. 0.3120 0.3130 IN.

(7.9248 TO 7.9502 mm)

0.0675 TO 0.685 IN.(1.7145 TO 1.7399 mm)REF 2 PLACES -

DETAIL CDETAIL , r - C-0.558 TO 0.560 IN.

SECTIONAL VIEW (14.1732 TO 14.224 mm)INNER RING ASSEMBLY 2 PLACES

204-011-402-127 212-R-62-53

Figure 62-53. Inner ring bushing replacement dimensions

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0.0675 TO 0.0685 IN. 0.558 TO 0.560 IN.(1.7145 TO 1.7399 mm) (14.1732TO 14.224mm)REF. 2 PLACES REF. 2 PLACES

NOTE

\ THICK FLANGE BUSHING204-011-464-111 FOR 204-011-404-121204-011-497-103 FOR 204-011-404-125204-011-464-109 FOR 204-011-404-121204-011-497-101 FOR 204-011-404-125

DETAIL A

0.3120 TO 0.3130 IN.17.9248 TO 7.9502 mm)DIA. FOUR HOLES IN LINETO BE TRUE TO SURFACE AWITHIN 0.002 PER INCH(0.0508 mm)

5.868 TO 5.870 IN.(149.047 TO 149.098 mm)

0.4995 TO 0.5005 IN.(12.6873TO 12.7127 mm) SEE DETAIL A FORDIA. TWO HOLES IN LINE TO 121 -121 AND -125 SUPPORTBE TRUE TO SURFACE AWITHIN 0.002 PER INCH(0.0508 mm)

9.250 ± 0.010(234.95 ± 0.254 mm)

2.750 0.010(69.85 ± 0.254 mm)

SURFACE A SUPPORT ASSY 212-R-62-54

Figure 62-54. Support bushing replacement dimensions

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MATERIALS REQUIRED (CONT) NOTE

A workaid is recommended to allowNUMBER NOMENCLATURE installation of trunnions with less

possibility of damage to swashplateC-309 Methyl-Ethyl-Ketone rings (figure 62-49).

(MEK)

C-325 Adhesive b. Align bolt grooves and holes. Coatbolts (24, figure 62-48) with primer (C-201).

C-320 Sealant Install two bolts with a washer next to eachbolthead and nut. Torque nuts 50 to 70 inch-

C-405 Lockwire pounds (5.649 to 7.9086 Nm).

1. Apply adhesive (C-325) on outside 4. Install trunnion assemblies and attachingdiameter of upper seal (17, figure 62-48). parts in three control horns of inner ring (23).Press seal, with seal lip pointing up, into topof outer cap (18). Install seal (17) until flush a. Apply a light coat of corrosionwith lip on outer cap (18). Remove any preventive compound (C-101) to trunnionexcess adhesive. barrel and insert a trunnion into each of three

horns of inner ring. Align trunnion bolt2. In same manner, install lower seal (22) grooves with holes in horn.with lip pointing down, into lower side of outerring (21). NOTE

3. Install trunnion (25) on each mounting Apply a primer (C-201) on all boltpoint of outer ring as follows: shanks and on inner faces of all

plates and brackets before installing.a. Lightly coat outside of trunnion barrel

with corrosion preventive compound (C-101) b. Place plate (33) and bracket (36) onand insert into outer ring. swashplate horn as shown in detail A. Install

two bolts (32) with washers under bolthead. .......... . . .. and nut. At lower hole insert spacer (34)

CAUTION between faces of horn and install bolt (37)......... ****** . with bolthead outboard. Install nuts and

torque evenly 50 to 70 inch-pounds (5.649EXCESSIVE SPREADING OF THE Nm to 7.9086 Nm).TRUNNION CLAMP AREA OF THERING COULD CAUSE A CRACK c. Assemble on horn (detail B) two platesRESULTING IN LOSS OF ROTOR (29), spacer (30), and bolts (32) with oneCONTROL. INSERT TANGS OF washer under bolthead and nut. Install nutsTOOL INTO SLOT AND TIGHTEN and torque evenly 50 to 70 inch-poundsSCREW UNTIL TRUNNION CAN (5.649 to 7.9086 Nm).BARELY BE INSTALLED (FIGURE62-50). AFTER INSTALLATION OF d. Position plates (27) on aft horn (detailBOLTS (24, FIGURE 62-48), C) and install bolt (26) in lower hole withIMMEDIATELY RELEASE SCREW washer under bolthead and nut. At the twoTENSION AND REMOVE upper holes, measure the gap both sidesWORKAID. BOTH BOLTS (24) between the plates and horn. Shim the gapMUST BE INSTALLED BEFORE with AN960JD416L washers, as required, toTIGHTENING NUTS. obtain a 0.000 to 0.016 inch (0.0 to 0.4064

mm) maximum clamp-up on each side. Installbolts (26) with washer under bolthead andnut. Torque nuts evenly 50 to 70 inch-pounds(5.649 to 7.9086 Nm).

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BHT-212-CR&O

5. Press four bearings (7) into liners (6). bearing inner races. Place a special washer(10) on bolt (9) and special washer (1) on bolt

6. Fit bearing liner assemblies to gimbal ring (2) with chamfer toward bolthead and applyand mating parts to determine shims required sealant to bolt shanks. Do not allow sealant toto center bearings between bushings of contact bushings (13) or their faying surface.mounting points:

8. Install swashplate assembly (3), anda. Place two liners (6) in opposite sides of gimbal ring assembly (4) to swashplate

gimbal ring assembly (4) without shims or support (12) as follows:retaining screws.

a. Position gimbal ring to mounting pointsb. Mount gimbal ring on support (12) with of support, observing match-marks. Install two

bolts (9) inserted through support bushings bolts (9) with special chamfered washers (1)and gimbal bearings. Tap gimbal ring to one next to heads, from inboard through supportside of support. Use feeler gage at opposite and bearings. Install special washers (10) andside to measure clearance between gimbal nuts. Torque nuts 90 to 120 inch-poundsring and bearing liner flange. (10.1682 to 13.5576 Nm) and install cotter

pins.c. Prepare two shims (5), each shim one-

half as thick as measured total clearance. NOTENOTE

d. Match-mark gimbal ring and support at Accomplish step b. if inner ring isone place. Remove gimbal ring. attached to gimbal ring without using

slip bushings, all inner rings excepte. Remove both bearing liner assemblies. 204-011-402-21. Accomplish step c.

Apply corrosion preventive compound (C-101) if inner ring is attached to gimbalto liner surface which will touch gimbal ring, ring using slip bushings, inner ringand reinstall with shims in place and retaining 204-011-402-21.screws (8). Secure screws, in pairs, withlockwire (C-405). b. Position inner ring (23) over support

with control horns located as illustrated andf. In the same manner, fit and install gimbal ring bearings aligned in mounting

remaining two bearing liners in gimbal ring, points of inner ring. Make sure that elevatorwith shims peeled, as required, to center horn (aft horn of inner ring) is located farthestbearings in mounting points of inner ring (23). away from collective lever mounting boses of

swashplate support (12). Install two bolts (2),7. Prepare parts for final assembly: with special washers (1) next to heads, from

inboard through bearing and inner ring. Installa. Thoroughly clean shanks of four bolts washers (11) and nuts. Torque nuts 90 to 120

(2 and 9, figure 62-48), and inside diameters inch-pounds (10.1682 to 13.5576 Nm) andof gimbal ring bearings and bushings in install cotter pins.mounting points of inner ring and support withMEK (C-309). c. Position inner ring (23) over support,

with control horns located as illustrated andgimbal ring bearings aligned in mounting

CAUTION points of inner ring. Make sure that elevatorhorn (aft horn of inner ring) is located farthestaway from collective lever mounting bosses of

KEEP SOLVENTS AND RETAINING swashplate support (12). Install two bushingsCOMPOUNDS OUT OF WORKING (13, view B) in inner ring. Install two bolts (2),PARTS OF BEARINGS. with special washer (1), next to heads, from

inboard through bearing and inner ring. Installb. Apply sealant (C-320) evenly but washers (11) and nuts. Torque nuts 90 to 120

sparingly on ID surfaces of bushings and

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BHT-212-CR&O

inch-pounds (10.1682 to 13.5576 Nm), and than measured dimension, to provide clamp-install cotter pins. up on bearing race.

13. Determine height of bearing inner race~~~NOTE above top surface of inner ring, by methods

After 30 minutes curing time, tilt similar to step 12. Peel four-section shim (16)swashplate all directions to ensure 0.009 to 0.012 inch (0.2286 to 0.3048 mm)there is no binding caused by thinner than measured dimension.retaining compound entering gimbalbearings. Sealant shall cure 12 14. Place prepared shim on inner ring studs.

Fill gaps between shim sections withhours at 75°F (24°C) before service Fill gaps between shim sections withuse. corrosion preventive compound (C-101).

Place inner cap (15) on studs.9. Apply light coatings of corrosionpreventive compound (C-101) on inside and 15. Place prepared shim on outer ring studs.preventive compound (C-101) on inside andoutside diameters of thrust bearing (20) and Apply corrosion preventive compound (C-101)on mating surfaces of outer ring liner (21) and to fill gaps between ends of shim sectionsliner on inner ring (23). Hand-pack bearing Install outer cap (18) with 12 washers and(20) with bearing grease (C-007). nuts on studs. Tighten nuts evenly.

10. Seat outer ring assembly over inner ring, 16. Install cover (14) with washers and nutstaking care that lower seal passes on inner ring studs. Tighten nuts evenly.undamaged over shoulder on inner ringsleeve.sleeve 17. Lubricate thrust bearing with bearing

grease (C-007) applied with hand gun through11. Align etched arrows on outer race of fittings on outer ring. Purge grease past sealsthrust bearing (20). Install bearing between to ensure lubrication. Purge lubricateinner and outer rings, and tap evenly until trunnions through fittings on rod-ends and onseated. control horns.

18. Check swashplate assembly for freedom12. Determine height of bearing outer race 18 heck swashplate assembly for freedomabove top surface of outer ring, either by of movement.using a depth gage or by placing outer racecap on bearing and measuring gap with a 19. Coat all boltheads, washers, nuts, andcap on bearing and measuring gap with afeeler gage. Peel four-section shim (19) 0.009 exposed joints with corrosion preventiveto 0.012 inch (0.2286 to 0.3048 mm) thinner compound (C-101).

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BHT-212-CR&O

COLLECTIVE LEVER

62-50. COLLECTIVE LEVER. b. Place lever (2) on a suitable support.

62-51. INSPECTION AND REPAIR. c. Press bearing (3) into liner (4).62-51. INSPECTION AND REPAIR.

MATERIALS REQUIRED NOTEPin should not be removed unless

NUMBER NOMENCLATURE damage or wear exceeds limitsshown on figures 62-56 and 62-57.

C-101 Corrosion PreventiveCompound 6. Remove pin (1, figure 62-55) as follows:

a. Place collective lever (2) on a suitable1. Inspect lever (1, figure 62-55) for damage support having clearance for pin (1).and corrosion (figure 62-56). Replace lever iflimits are exceeded. b. Press pin from lever. Do not drive pin

by impact.2. Inspect bearing (3, figure 62-55) forroughness or wear.

NOTE

NOTE For approved fluorescent penetrantmaterial, refer to BHT-ALL-SPM.

Replace bearing in collective lever ifaxial or radial looseness exceeds 7. Inspect area around hole where pin (1)0.005 inch (0.127 mm) or if bearing was removed for cracks by fluorescentfeels rough when inner race is penetrant method. Replace lever if cracks arerotated. found.

3. Remove bearing as follows: 8. Repair collective lever (2) in accordancewith damage and repair limits shown on

a. Place lever (2, figure 62-55) on a figures 62-56 and 62-57.suitable support having clearance for bearing.

9. Install pin (1, figure 62-55) in collectiveb. Press bearing (3) from lever, press on lever (2) as follows:

outer race.a. Apply corrosion preventive compound

4. Repair inside of bearing liner (4) not to (C-101) to collective lever (2) and pin (1).exceed depth of 0.0020 inch (0.0508 mm) formechanical or corrosion damage. Repaired b. Place lever on a suitable support.liner ID not to exceed 1.1245 inch (28.5623mm) diameter. If limits are exceeded replace c. Press new pin (1) into collective levercollective lever. (2). Bottom pin in lever.

5. Install bearing (3) as follows:

a. Apply corrosion preventive compound(C-101) to new bearing (3) and inner diameterarea of liner (4).

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BHT-212-CR&O

/

1. Pin

2. Collective lever3. Lever bearing4. Liner

212-R-62-55

Figure 62-55. Collective lever



NICKS, SCRATCHES, SHARP DENTS 0.020 IN. (0.508 mm) 0.010 IN. (0.254 mm)

CORROSION(Before repair) 0.010 IN. (0.254 mm) 0.005 IN. (0.127 mm)(After repair) 0.020 IN. (0.508 mm) 0.010 IN. (0.254 mm)

MAXIMUM AREA OF FULL 0.10 SQ. IN. (64.52 SQ. MM) 0.10 SQ. IN. (64.52 SQ. MM)DEPTH REPAIR

NUMBER OF NONOVERLAPPING 4 One per segmentREPAIR AREAS

EDGE OF CHAMFER 0.060 IN. (1.524 mm) 0.030 IN. (0.762 mm)

BORE DAMAGE 0.001 IN. (0.0254 mm) for 1/4 of circumference 212-R-62-56

Figure 62-56. Collective lever damage limits

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BHT-212-CR&O

ITEM NOMENCLATURE MIN. MAX1 Pin 0.6243 IN. 0.6250 IN.

(15.85722 mm) (15.875 mm)

212-R-62-57

Figure 62-57. Collective lever wear limits

0

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BHT-212-CR&O

MAIN ROTOR PITCH CHANGE LINK

62-52. PITCH CHANGE LINK. 62-54. REPAIR.

62-53. INSPECTION. MATERIALS REQUIRED

1. Check universal bearings for a maximumlooseness of 0.017 inch (0.4318 mm) axial NUMBERand 0.0085 inch (0.2159 mm) radial. C-201 Primer

2. Check rod end bearings for a maximum C-204 Primerlooseness of 0.010 inch (0.254 mm) axial andradial. The 0.010 inch (0.254 mm) can be C-423 Abrasive Cloth orextended to 0.020 inch (0.508 mm), provided Paperexcessive vertical vibration does not occur inmain rotor operation. 1. Polish out acceptable damage, removing

no more material than necessary to blend3. Inspect pitch change link for corrosion,cracks, nicks, and scraches Figure 62-58 for repair smoothly into surrounding surface.cracks, nicks, and scratches. Figure 62-58 for Mechanical damage shall be polished onlydamage and repair limits. deep enough to remove traces of damage.4. Inspect for any bent dented or distorted Corrosion damage should be polished out to4. Inspect for any bent, dented, or distorted

link parts. twice the depth of the deepest pit, providedthe maximum limits of figure 62-58 are notexceeded.5. Inspect thread and shoulder area of clevis

for cracks using a 5X magnifying glass. Anysuspected crack indication requires magnetic

paper (C-423) to remove damage to ascratch-free surface. Do not attempt repairs

6. A pitch change link clevis exhibiting crack by using a grinding wheelindications shall be inspected using the wet 3. No thread or surface damage iscontinuous magnetic particle inspectionble if will interfere with thread

acceptable if repair will interfere with threadmethod consisting of: engagement.engagement.

a. A head shot of 1000 amps. 4. Replace any bent, dented, or distortedlink parts, or any parts having cracks.b. A coil shot of 1500 amps.

5. Apply brush cadmium plate to repaired7. Inspect for cracks using a 10X magnifying Applysurfaces which have plating removed (BHT-glass and a black light. No cracks are

permissible. If no cracks are found, ALLdemagnetize and clean part. 6. Mask threaded areas and fill and drain

barrel and drilled hole in clevis with primer (C-201) or primer (C-204) (BHT-ALL-SPM).

7. Apply a protective coating of primer (C-204) to all repaired surfaces which have hadplating removed (BHT-ALL-SPM).

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TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREA ALLOWED

NICKS, SCRATCHES, 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)AND SHARP DENTS

CORROSION 0.005 IN. (0.127 mm) 0.010 IN. (0.254mm) 0.020 IN. (0.508 mm)

AREA PER FULL 0.25 SQ. IN. 0.10 SQ. IN. 0.10 SQ. IN.DEPTH REPAIR (161.3 SQ. mm) (64.52 SQ. mm) (64.52 SQ. mm)

NUMBER OF REPAIRS Two per zone Two per zone One per zone

EDGE CHANGER 0.020 IN. (0.508 mm) 0.020 IN. (0.508 mm) 0.040 IN. (1.016 mm)

THREAD DAMAGE:DEPTH One-third of threadLENGTH One-quarter inchNUMBER Two per segment

NOTES

1. The width of repair at any section shall not exceed one-third of the circumference.

2. Damage limits in drilled hole of clevis shank are 0.010 inch (0.254 mm).

3. Apply primer (C-201) to internal surface of barrel and clevis.

212-R-62-58

Figure 62-58. Pitch change link damage and repair limits

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BHT-212-CR&0

CHAPTER 63 - MAIN ROTOR DRIVE SYSTEM

CONTENTS - MAINTENANCE PROCEDURES


63-1 Main rotor drive .................................. 63-00-00 9

MAIN DRIVESHAFT

63-2 Main driveshaft .................................. 63-00-00 1163-3 Main driveshaft 212-040-005-003, -007, and

-103 .............................................. 63-00-00 1163-4 Lubrication ..................................... 63-00-00 1163-4F Replacement - coupling temperature

indicator "TEMP-PLATES" .................... 63-00-00 12B63-4G Overhaul ......... .. ...................... . 63-00-00 1363-12 Main driveshaft (212-040-005-011) ............... 63-00-00 2963-13 Lubrication ......... .. ..................... 63-00-00 2963-13E Overhaul ....................................... 63-00-00 31

ADAPTER

63-21 Adapter (engine-to-driveshaft) .................... 63-00-00 4363-22 Maintenance ................................... 63-00-00 43

MAIN ROTOR MAST

63-26 Main rotor mast .................................. 63-00-00 4763-27 Overhaul procedures ........................... 63-00-00 47

TRANSMISSION

63-35 Transmission ..................................... 63-00-00 6563-36 Overhaul instructions .......................... 63-00-00 6563-45 Transmission cases ............................ 63-00-00 9463-53 Planetary gear assemblies ..................... 63-00-00 109

TRANSMISSION QUILLS

63-59 Transmission quills ............................... 63-00-00 13363-60 Main input driven gear quill .................... 63-00-00 13363-66 Main input quill (212-040-363) ................. 63-00-00 14663-72 Main input quill (212-040-263-101) ............ 63-00-00 16063-78 Main input quill (212-040-263-107) ............ 63-00-00 17063-84 Hydraulic pump drive quill ..................... 63-00-00 18763-90 Offset accessory drive quill .................... 63-00-00 19363-96 Accessory drive and sump ..................... 63-00-00 19963-103 Accessory case input quill ..................... 63-00-00 207

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BHT-212-CR&0

CONTENTS - MAINTENANCE PROCEDURES (Cont)


63-109 Rotor brake drive quill (205-040-300) .......... 63-00-00 21363-116 Rotor brake drive quill (412-040-123-101

and -103) ...................................... 63-00-00 21763-122 No. 1 hydraulic pump and tachometer

drive quill ...................................... 63-00-00 22763-128 Tail rotor drive quill ............................ 63-00-00 24063-133A Replacement -- coupling temperature

indicator "TEMP-PLATES" ..................... 63-00-00 246A

TRANSMISSION OIL PUMP

63-134 Transmission oil pump ........................... 63-00-00 25163-135 Overhaul ....................................... 63-00-00 251

TRANSMISSION MOUNT COMPONENTS

63-141 Transmission mount components ................ 63-00-00 25563-142 Friction damper ................................ 63-00-00 25563-146 Lift link ......................................... 63-00-00 25563-148 Pylon isolation mount bolt ..................... 63-00-00 256

FIGURES


63-1 Main rotor drive ....................................................... 1063-2 Main driveshaft lubrication 212-040-005-003, -007, and -103 ......... 12A63-2A Main driveshaft coupling "TEMP-PLATE" installation .................. 12C63-3 Main driveshaft 212-040-005-003, -007, and -103 ..................... 1763-4 Main driveshaft wear patterns ......................................... 1863-5 Main driveshaft wear limits ............................................ 2063-6 Inner coupling inspection ................... .......................... 2163-7 Outer coupling inspection ............................................ 2263-8 Outer coupling spline teeth ............................................ 2363-9 Main driveshaft corrosion areas ....................................... 2663-10 Main driveshaft painting requirements ................................. 2763-11 Material removal area for driveshaft balancing ........................ 2863-12 Deleted ................................................................63-13 Main driveshaft (212-040-005-011) lubrication ........................ 3263-14 Main driveshaft (212-040-005-011) .................................... 3463-15 Main driveshaft wear limits (212-040-005-011) ........................ 3663-16 Main driveshaft corrosion areas ....................................... 3863-17 Main driveshaft painting requirements ................................. 4063-18 Material removal area for driveshaft balancing ........................ 41

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BHT-212-CR&0

FIGURES (Cont)


63-19 Main driveshaft seal installation tool .................................. 4263-20 Main driveshaft adapter ............................................... 45/4663-21 Main rotor mast ....................................................... 4963-22 Main rotor mast bearing workaid ...................................... 5063-23 Main rotor mast wear limits ........................................... 5563-24 Main rotor mast damage limits ........................................ 5763-25 Main rotor mast liner damage limits ................................... 5963-26 Mast upper bearing shimming measurement .......................... 6063-27 Mast liner and bearing installation workaid............................ 6263-28 Transmission external components .................................... 6763-29 Transmission electrical (prior to 212-040-001-059) .................... 6863-30 Transmission electrical (212-040-001-059 and sub.) .................. 6963-31 Transmission jets, manifolds, and main input quill .................... 7063-32 Transmission and quills ............................................... 7263-33 Transmission manifold ................................................ 7663-34 Transmission wear limits .............................................. 8063-35 Roller bearing wear pattern ........................................... 8263-36 Transmission sun gear wear pattern .................................. 8463-37 Main input quill workaid ............................................... 8563-38 Input quill backlash indicator support workaid ......................... 8763-39 Mast installation dimensional check ................................... 8963-40 Transmission sealant application ...................................... 9263-41 Transmission main case .............................................. 9663-42 Transmission case inspection ......................................... 9763-43 Transmission case corrosion damage limits ........................... 10063-44 Main case center web ................................................. 10363-45 Transmission main support case repair limits ......................... 10763-46 Transmission main support case bushing replacement (212-

040-054-005) .......................................................... 11063-47 Transmission main support case bushing replacement (212-

040-054-013) .......................................................... 11163-48 Lift link fitting damage limits .......................................... 11263-49 Planetary ring gear .................................................... 11563-50 Upper planetary ....................................................... 11763-51 Lower planetary ....................................................... 11863-52 Upper planetary wear limits ........................................... 12263-53 Lower planetary wear limits ........................................... 12363-54 Lower planetary gear wear pattern .................................... 12463-55 Upper planetary gear wear pattern .................................... 12563-56 Upper planetary lockwiring ............................................ 12763-57 Lower planetary bearing............................................... 12963-58 Lower planetary lockwiring ............................................ 13063-59 Main input driven gear quill ........................................... 13563-60 Main input driven gear quill case corrosion damage areas............ 13663-60A Damage limits - spiral bevel gear mounting holes (204-040-

701) ................................................................... 136A63-61 Main input driven gear quill wear pattern ............................. 13763-62 Main input driven gear quill shaft magnetic inspection areas.......... 139

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BHT-212-CR&0

FIGURES (Cont)


63-63 Main input driven gear quill wear limits ............................... 14063-64 Main input driven gear quill (204-040-362-013 and -105)

shimming .............................................................. 14463-65 Main input driven quill (204-040-362-103) shimming .................. 14563-66 Main input quill ..................................................... 14863-67 Clutch assembly ....................................................... 15063-68 Main input quill wear limits ............................................ 15463-69 Main input quill sealing ................................................ 15863-70 Main input quill (212-040-263-101) ................................... . 16363-71 Main input gear quill (212-040-263-101) wear pattern ................. 16463-72 Main input quill (212-040-263-101) wear limits ........................ 16763-73 Main input quill (212-040-263-101) pinion copper plating area ........ 16963-74 Main input quill (212-040-263-107) .................................... 17363-75 Tool application -- T101588 wrench set ............................... 17463-76 Tool application -- T101912 plate set ................................. 17563-77 Main input drive quill (212-040-263-107) pinion damage limits ........ 17663-78 Main input drive quill (212-040-263-107) sleeve damage limits ....... 17763-79 Main input quill (212-040-263-107) cap assembly damage limits ..... 17863-80 Main input quill (212-040-263-107) seal retainer damage limits ....... 17963-81 Main input quill curvic coupling adapter damage limits ................ 18063-82 Magnetic seal damage limits .......................................... 18163-83 Main input quill processing requirements .............................. 18263-84 Hydraulic pump drive quill ........................................... 18963-85 Hydraulic pump drive quill wear limits ................................. 19263-86 Offset accessory drive quill ........................................... 19563-87 Offset accessory drive quill gear wear pattern ........................ 19663-88 Offset accessory drive quill wear limits ................................ 19863-89 Accessory drive sump quill and oil pump ............................. 20063-90 Accessory drive sump components and shims ....................... 20163-91 Sump and accessory drive inspection areas .......................... 20363-92 Accessory case input quill ............................................. 20963-93 Accessory case wear limits ........................... ............... 21063-94 DELETED ..................................................... ....63-95 Rotor brake quill (205-040-300) ........................... ........... 21563-96 Rotor brake drive quill damage limits ................................. 21863-97 Quill assembly ........................................................ 22163-98 Rotor brake drive quill (412-040-123) ........................... ...... 22463-99 Rotor brake quill (412-040-123) damage limits ........................ 22563-100 Rotor brake quill ...................................................... 22863-101 Rotor brake quill ...................................................... 23163-102 Rotor brake disc inspection arbor ..................................... 23363-103 Rotor brake drive quill ................................................. 23463-104 No. 1 hydraulic pump and tachometer drive quill ...................... 23663-105 No. 1 hydraulic pump and tachometer drive quill wear limits.......... 23763-106 Tail rotor drive quill ................................................... 24363-107 Plastic seal installation workaid ..................................... . 246A63-108 Tail rotor drive coupling wear pattern ........................... ...... 248 063-109 Tail rotor drive quill coupling TEMP-PLATE installation ............... 249

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BHT-212-CR&0

FIGURES (Cont)


63-110 Workaid for lubrication of tail rotor drive coupling ..................... 25063-111 Transmission oil pump ................................................ 253/25463-112 Friction damper assembly ............................................ 25763-113 Lift link damage and repair limits...................................... 25863-114 Pylon isolation mount bolt damage and repair limits .................. 259

TABLES

Table PageNumber Title Number

63-1 Main driveshaft (212-040-005-003, -007, -103) damage limits ........ 1663-2 Main driveshaft (212-040-005-011) damage limits ..................... 3563-3 Main case required dimensions ....................................... 10963-4 Magnetic particle inspection ........................................... 260

CONSUMABLE MATERIAL LIST

The following consumable materials are required to perform the maintenance procedures withinthis chapter.


C-001 Grease, Aircraft General Purpose, MIL-G-81322 (AeroshellNo.22 or Mobil No.28) Commercial

C-007 Grease, Oscillating Bearing, MIL-G-25537 Commercial

C-010 Lubricating Oil, Turbine Engine, MIL-L-7808 Commercial

C-015 Lubricant (Tube Pack) 204-040-755-5 97499

C-024 Ultrachem Assembly Fluid No. 1 56385

C-028 Lubricant, Dry (Permalon 327) 8M506

C-100 Chemical Film Material (Alodine 1200 or 1201) MIL-C-81706,Class 1A, Form II (Dip Tank) or III (Brush-on). Apply perMIL-C-5541. Commercial


C-103 Chromic Acid (Brush-On Solution) Chromic Acid and CalciumSulfate. Commercial


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BHT-212-CR&0



C-105 Corrosion Preventive; Fingerprint Remover, MIL-C-15074 98308

C-108 LHE Cadmium Plating Solution (For Brush Cadmium Plating) 13929

C-112 Cadmium Chromate Conversion Coating Micro BronzeNo. 1 or 76071

Enthox 280 or 02258Alumigold orNo. 6 CD orDalc 5005

C-116 Chromic Acid (Technical), O-C-303-1 Commercial

C-201 Zinc Chromate Primer, TT-P-1757 Commercial

C-202 Epoxy (Super-Koropon) Primer 22873

C-203 Acrylic Lacquer, MIL-L-81352. Refer to text for color. Commercial

C-204 Epoxy Polyamide Primer, MIL-P-23377, MIL-P-85582, Type I.Refer to text for color. Commercial

C-206 Thinner for Acrylic Nitrocellulose Lacquer, MIL-T-19544 (Usewith item C-216) Commercial

C-208 Epoxy/Zinc Coating, Code 2320-CL-5 06613

C-211 Shellac, TT-S-300, Type 1, Grade B, Body 2 Commercial

C-215 Aluminum Lacquer, MIL-L-7178 Commercial

C-221 Phosphatize Material, Bonderite 32 and Accelerator No. 131 45738

C-242 Paint Remover, Epoxy Polyurethane, Dechem 2236A Commercial

C-246 Coating, Epoxy Primer, Waterborne, MIL-P-85582 81349

C-298 Adhesive, Epoxy, Devcon 2-Ton Commercial

C-304 Solvent, Drycleaning, P-D-680, Type II, pH Insignificant Commercial

C-305 Aliphatic Naphtha, TT-N-95, Type II Commercial

C-308 Adhesive, Sealant, 299-947-107, Type III, Class 7, MIL- 97499S-8802, Class B2 or 83527

Proseal 890 83574

C-309 Methyl-Ethyl-Ketone (MEK), TT-M-261B, pH Insignificant Commercial(Alternate where MEK use prohibited: RHO SOLV 756) 83527

C-311 Adhesive, 299-947-107, Type II, Class 4 or 97499EC2126 76381

C-317 Adhesive, Magnobond 6398 (299-947-100, Type II, Class 2) 2212197499

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BHT-212-CR&0



C-318 Cleaning Compound, Alkaline Base, MIL-C-87936, pH Value12 Max. (Detergent) Commercial

C-327 Adhesion Promoter, A-934-BXTT 1H543

C-328 Sealing Compound, Pro-Seal 706, Class B-2 or PRC-1321, 83574Class B-2, or CS3300B, MIL-S-8784 21509

C-334 1.1.1-Trichloroethane, MIL-T-81533 (Vapor) or O-T-620(Cold) Commercial

C-344 Alcoholic Phosphoric Cleaner (Turco W.O. 1) pH 7 61102

C-345 Grease Removing Primer, Scotch-Weld 3911 0496376381

C-352 Sealant, Anaerobic Retaining Compound, MIL-R-46082, Type1 (Loctite RC/609) 05972

C-363 Adhesive, 299-947-100, Type II, Class 3 (Hysol EA956) 97499

C-405 Lockwire, MS20995C32 (0.032 Inch Dia.) Commercial

C-406 Aluminum Oxide Cloth, P-C-451 Commercial

C-407 Abrasive Pad, Nylon Web (Scotchbrite) L-P-0050, Type I, 27713 orClass 1, Size 1 76381

C-409 Use Item C-500

C-411 Steel Wool Commercial

C-423 Abrasive Cloth (P-C-458) or Paper (P-P-101) (All Grits) Commercial

C-427 Barrier Material, Greaseproofed and Waterproofed, Flexible,MIL-B-121 Commercial

C-435 Paint Remover, General, Chlorinated Hydrocarbon, MIL-R- 6D015 or25134 2E289

C-436 Paint Remover, Alkaline Type, General, MIL-R-81294 or 80244MIL-R-8633A or 81349Turco No. 5469 61102

C-440 Antiseize Compound, White Lead Base Commercial

C-464 India Stone, SS-S-736 Commercial

C-470 Glass Beads, MIL-G-9954 (Size specified in text) Commercial

C-486 Cheesecloth (Bleached), CCC-C-440 Commercial

C-490 Cork Stopper, LL-S-731, Type I, Grade A, Class 2 (Sizespecified in text) Commercial

C-500 Crocus Cloth, Abrasive Coated, A-A-1206 Commercial

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BHT-212-CR&O

MAIN ROTOR DRIVE SYSTEM

63-1. MAIN ROTOR DRIVE.

Principle components of the power train are:main driveshaft (3, figure 63-1), main rotormast (2) and transmission (1).

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BHT-212-CR&O

'

212-R-63-1

Figure 63-1. Main rotor drive

63-00-00Page 1063-00-0

BHT-212-CR&O

MAIN DRIVESHAFT

63-2. MAIN DRIVESHAFT. 63-4B. Cleaning.

MATERIALS REQUIREDThe following procedures are applicable to MATERIALS REQUIREDdriveshafts P/N 212-040-005-003, -007, and -103 (paragraphs 63-3 through 63-11) and NUMBER NOMENCLATUREdriveshaft P/N 212-040-005-011 (paragraphs C-30463-12 through 63-20). C-304olvent

63-3. MAIN DRIVESHAFT 212-040-005-003, -007, AND -103. CAUTIO

DO NOT WASH ELASTOMERIC63-4. LUBRICATION. BOOT OR ASSEMBLED

DRIVESHAFT IN SOLVENT. WASHONLY THE COUPLING (5) WHICH

NOTE CAN BE COMPLETELY DRIEDBEFORE REASSEMBLY.

This procedure is to be used forlubrication of main driveshaft when 1. Clean removed outer coupling (5, figurespecified by Lubrication Chart. 63-2) by wiping with clean, dry cloths or by

washing in solvent (C-304). Dry thoroughlywith filtered, compressed air.

Refer to paragraph 63-12 forlubrication of 212-040-005-011 2. Clean inner coupling (7) by wiping withdriveshaft. clean, dry, lint-free cloths.

63-4A. Disassembly. 63-4C. Inspection.63-4A. Disassembly.

1. Place driveshaft (11, figure 63-2) in MATERIALS REQUIREDsuitable support. Remove retaining ring (1),retainer plate (2) with packing (3), and spring NUMBER NOMENCLATURE(4) from coupling assembly. Discard packing.

C-464 India Stone

NOTE C-500 Crocus Cloth

Record serial number of couplings tofacilitate reassembly of eachcoupling with same mating coupling.

2. Remove bolts (10) and washers (9).Remove outer coupling (5) from boot (8).

2A. Inspect grease for being very viscous(thick) and having a strong pungent odor.Refer to paragraph 63-4B, step 1d.

63-00-00Rev.3 Page 11

discoloration of epoxy is found, replaceTEMP-PLATES in accordance with paragraph

1. Inspect outer coupling (5, figure 63-2) 63-4F.temperature indicator TEMP-PLATES (13) forevidence of overtemperature indication. If

followsi: oet m ea eis e in as other suitable material to reflect light. Iffollows:defects are found on inner coupling, outercoupling will also be damaged. Refer to figure

a. Inspect outer coupling cadmium plating 63-4 for typical main driveshaft wear patterns.for being discolored (circumferential tan orlight brown band) or blistered. If cadmiumplate discoloration or blistering is found, 4 in retainerreplace outer coupling and inner coupling. (2, figure 63-2) and surface in outer coupling

(5), contacted by packing (3), for nicks andburrs. Remove any such defects with fine

NOTE

d. Inspect grease from couplings for beingvery viscous (thick) and having a strong It is recommended 212-040-176-007pungent odor. If grease is found to be viscous boots be replaced each 1200 hours(thick) and having a strong pungent odor, of operation.replace outer coupling and inner coupling.

6. Inspect inside of driveshaft for corrosion.NOTE If corrosion is evident, refer to paragraphs 63-

8 and 63-9.

If TEMP-PLATES are to be replaced,replace TEMP-PLATES after 7. Visually inspect threaded parts forcompleting entire inspection damage.

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BHT-212-CR&O

4TH GROOVE 11

13

DETAIL A

SEE TABLE 63-1

12

SEE DETAIL A

NOTE

Installed with boot (8) 212-040-176-101.

1. Retaining ring 8. Boot2. Retainer plate 8A. Retainer3. Packing 9. Washer

4. Spring 10. Bolt5. Outer coupling 11. Driveshaft6. Packing 12. Nut7. Inner coupling 13. Temperature indicator

TEMP-PLATES

212-R-63-2

Figure 63-2. Main driveshaft lubrication 212-040-005-003, -007, and -103

63-00-00Rev.3 Page 12A

BHT-212-CR&O

8. If TEMP-PLATES (13) are to be replaced, aligned with holes in coupling (5) withoutInstall replacement TEMP-PLATES at this stretching or twisting boot.time, after inspection and prior to lubricatingcouplings. Refer to paragraph 63-4E for 2. Verify packing (6) is in groove of boot (8).replacement procedure. Assemble coupling (5) and boot (8) with bolts

(10) and washers (9).

63-4D. Lubrication. 3. Spread remaining one-fourth tube of Ilubricant (tube pack) (C-015) into outer

MATERIALS REQUIRED coupling (5) of 212-040-005-003 or -007driveshaft. Spread grease evenly over

NUMBER NOMENCLATURE coupling splines.

C-015 Lubricant (Tube Pack) 4. Spread one tube of lubricant (tube pack) I(C-015) into outer coupling (5) of 212-040-005-103 main driveshaft. Spread grease

NOTE evenly over coupling splines.

Two tubes of lubricant (tube pack) 5. Coat spring (4) with a thin film of lubricant I(C-015) are necessary for lubricating (tube pack) (C-015) and seat spring (4) indriveshaft couplings on 212-040- boss of retainer behind nut (12) in driveshaft005-003 and -007 driveshafts. Three (11). Coat new packing (3) with lubricanttubes of lubricant (tube pack) (C- (tube pack) (C-015) and install packing on015) are required for lubricating retainer plate (2). Carefully press retainerdriveshaft couplings on 212-040- plate in position at end of coupling (5).005-103 driveshaft.

1. Squeeze one fourth tube of lubricant NOTE(tube pack) (C-015) into boot (8, figure 63-2) After installation of new packing (3),of 212-040-005-003 or -007 driveshaft. ensure no rubber slivers are presentSpread grease to coat inner surface of boot indicating packing was damaged(8). during installation.

I 2. Squeeze one-half tube of lubricant (tube 6. Install spiral retaining ring (1) in groove of Ipack) (C-015) into boot (8) and outer coupling outer coupling (5). Inspect ring for proper(5) of 212-040-005-103 driveshaft. Handpack seating in groove.grease evenly over outer coupling (5) andbehind dam in boot (8). 7. Accomplish lubrication of opposite end of

driveshaft (11) by repeating paragraphs 63-463-4E. Assembly. thru 63-4E

MATERIALS REQUIRED 63-4F. REPLACEMENT - COUPLINGTEMPERATURE INDICATOR TEMP-PLATES.

NUMBER NOMENCLATURE

C-015 Lubricant (Tube Pack) MATERIALS REQUIRED

NUMBER NOMENCLATURENOTE

C-298 Epoxy AdhesiveRetainer (8A) is used with boot (8,figure 63-2) 212-040-176-101. C-309 Methyl-Ethyl-Ketone

(MEK)1. Install new packing (6) in boot andreinstall outer coupling (5) on same inner C-318 Cleaning Compoundcoupling (7) from which removed. Ensure C-436 Paint Remover

I holes in boot, retainer (8A) if necessary are

63-00-00Page 12B Rev. 3

BHT-212-CR&O

1. Remove epoxy coating and TEMP- dries, wipe the surface dry with a clean cloth,PLATES (figure 63-2A) using paint remover The cleaned surface should be at least 0.500(C-436). Repeat process until no trace of inch (12.70 mm) larger than the TEMP-epoxy is present. PLATES. Refer to figure 63-2A for location of

TEMP-PLATES on outer coupling.

CAUTION 3. Accomplish a water break-free test on theprepared bonding surface by applying distilledor demineralized water from a suitable

BONDING SURFACE AND TEMP- dispenser (such as a squeeze bottle). ThePLATES MUST BE FREE OF ALL water must flow into a continuous film withoutC O N T A M I N A T I O N . A N Y gathering into distinct water droplets within 25CONTAMINATION COULD ALLOW seconds after application on the surface.THE TEMP-PLATES TO COME OFF Wipe dry with a clean cloth. Ensure theO R I N D I C A T E F AL S E bonding surfaces are not subsequentlyTEMPERATURES. contaminated.

2. Prepare outer coupling surface for 4. If the coupling bonding surface will notbonding by scrubbing surface clean with a meet the water break-free test requirementscloth moistened with an authorized cleaner, and you have ensured the cleaning materialssuch as MEK (C-309) to remove all are not contaminated, clean coupling bondingcontamination. Before the cleaner solvent surfaces as follows:

6000-1 TEMP-PLATE (RED BORDER)

2 REQD 180 ° APARTSEE VIEW A - 1.081 IN.

\ (27.457 m) (LOCATED 90 ° FROM THE 6000-2 TEMP-PLATES)REF (4TH GROOVE) \ LOCATE 6000-1 TEMP-PLATES AND

6000-2 TEMP-PLATESEQUALLY SPACED WITHIN 0.25 IN. (6.35 mm)

c I i--- SLIGHT TEMP-PLATELIFT-OFF ACCEPTABLE

VIEW A THIS AREA ONLY.LIFTING SHOULD

NOT EXCEED 0.030 IN.(0.762 mm) ESTIMATED

6000-2 TEMP-PLATE (YELLOW BORDER)2 REQD 180 ° APART(LOCATED 90 ° FROM THE 6000-1 TEMP-PLATES)LOCATE 6000-2 TEMP-PLATES AND6000-1 TEMP-PLATES

EQUALLY SPACED WITHIN 0.25 IN. (6.35 mm)

212-R-63-2A

Figure 63-2A. Main driveshaft coupling TEMP-PLATE installation

63-00-00Rev. 3 Page 12C

BHT-212-CR&O

NOTE 6. Remove protective backing from theTEMP-PLATE and carefully position onto the

Follow the manufacturers surface prepared in step 2.recommendations for proper watermixtures.

7. Using a clean cloth or cotton swab, work

a. Using an authorized alkaline cleaning the TEMP-PLATE into the contour of thecompound such as cleaning compound (C- coupling. A thoroughly cleaned firm rubber318) and cloth, scrub the coupling bonding (edge of a block type eraser) work aid may be

utilized to work TEMP-PLATE into full contactsurface clear. Follow cleaning with a thorough te to or TETE into fuwater rinse. with the coupling surface. Ensure the TEMP-

PLATE is in full contact with the couplingb. Thoroughly dry coupling surfaces. surface. Do not press or rub the TEMP-

PLATE with bare fingers.

c. Repeat water break-free test as statedabove. NOTE

CAUTION than Devcon 2-Ton is notauthorized.

IN ORDER TO PREVENT 8. Prepare Devcon 2-Ton epoxy adhesiveCONTAMINATION OF THE TEMP- epoxy adhesive (C-298) as follows:PLATES ADHESIVE BACKING,ENSURE THAT WORK AREA AND a. Pour equal amounts of epoxy Part AHANDS ARE THOROUGHLY and Part B into a solvent proof container.CLEANED BEFORE WORKINGWITH TEMP-PLATES.WITH TEMP-PLATES. b. Vigorously mix Part A and Part B with a

DO NOT PRESS OR RUB THE brush such as an artist brush.TEMP-PLATES WITH BAREFINGERS DURING INSTALLATION c. Mix a few drops of authorized thinner,ON THE COUPLING AS THIS WILL such as MEK (C-309), may be added to theCONTAMINATE THE SURFACES. epoxy during the mixing operation to reduceAPPLY EPOXY COATING TO THE the viscosity to a level that permits uniformTEMP-PLATES IMMEDIATELY brush application of the epoxy mixture. Do notFOLLOWING INSTALLATION OF thin this mixture such that it runs whenTHE TEM P-PLATES ON applied to a vertical surface. The finalCOUPLING. viscosity of the epoxy should be similar to a

heavy bodied paint. Too thin of a mixture may5. Carefully prebend the temperature seep into the temperature indicator TEMP-indicator TEMP-PLATES to match the V PLATE and cause the indicator dots to turncontour of coupling surface. Do not crease black (in which event, the TEMP-PLATE mustthe TEMP-PLATES sharply. be removed and replaced). Working time for

the mixture is approximately fifteen minutes.

~~~NOTE ~9. Using a soft-bristled brush, uniformlyWorking one TEMP-PLATE at a apply the epoxy coating over the TEMP-time, repeat steps 6 and 7 until all PLATES to a thickness of approximatelyTEMP-PLATES are installed on 0.002 to 0.004 inch (0.0508 to 0.1016 mm)coupling. (similar to a coat of paint). The coating should

be uniform in appearance, totally cover thesurface of the TEMP-PLATES and extendapproximately 0.25 inch (6.35 mm) beyondthe edges of the TEMP-PLATES.

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BHT-212-CR&O

12. Following the cure, the TEMP-PLATESCAUTION should conform to the contour of the coupling

and be free of lifted edges except as in noteabove. Indicating dots on TEMP-PLATES

DO NOT EXPOSE THE EPOXY must remain the original white or light graywith no full or partial black discoloration.COATING TO OIL, GREASE,

CLEANING SOLVENT OR OTHER 13. Accomplish an adhesion test on eachCHEMICALS DURING CURE. TEMP-PLATE installation. Press a 1 inch

(25.4 mm) wide strip of high adhesion tape

10. Allow epoxy coating to cure at room onto the TEMP-PLATE and epoxy overcoatThe tape should extend beyond the edge oftemperature (approximately 60 to 100° F) for shouldthe epoxy overcoat. Grasp one end of the

a minimum of six hours prior to aircraft tape at approximately 90 degrees from theoperation. For best results, allow epoxy to surface and remove tape in one abruptcure overnight prior to operating aircraft or motion. Lifting or peeling of the epoxy coatingexposing to oil or grease. or TEMP-PLATE is not acceptable. If lifting or

peeling is detected, remove and replaceTEMP-PLATE by repeating procedure.

NOTE

14. Repeat procedure for opposite coupling.An alternate source of heat can beused if the temperature does not 63-4G. OVERHAULexceed 180° F.

63-5. Disassembly.11. After one hour epoxy curing time atroom temperature, the epoxy coating totalcuring time can be accelerated by placing thecoupling in a temperature controlled oven forone to two hours at a temperature of 150 to NUMBER NOMENCLATURE180° F (66 to 82° C).

L-122 Extension bar

NOTE T101306 Splined wrench

T101588 WrenchSome lifting at the extreme ends ofthe TEMP-PLATES installed ongrooved couplings is acceptable.See figure 63-2A, view A foracceptable lifting limits. Lifting ispermitted only as shown and shouldnot exceed 0.30 inch (0.762 mm)estimated.

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BHT-212-CR&O

NOTE 63-6. Cleaning.

Refer to paragraph 63-12 foroverhaul of 212-040-005-011 main MATERIALS REQUIREDdriveshaft.

NUMBER NOMENCLATUREIf main driveshaft is beingdisassembled for replacement of C-304 Solventpart(s) instead of overhaul,disassemble only to extentnecessary to replace part(s). 1. Clean driveshaft parts, except boots, with

solvent (C-304).1. Place shaft in suitable support.

2. Dry parts with dry, filtered, compressed2. Remove retaining ring (15, figure 63-3), air.retainer plate (14), packing (13), and spring(12) from coupling assembly. Discard 3. Clean boots (3, figure 63-3) with clean,packing. dry, lint-free cloth.

3. Remove locking spring (11) from nut (10).63-7. Inspection.

4. Insert T101306 splined wrench in nut (10)and install T101588 wrench on coupling (1). NOTE

5. Insert L-122 extension bar through If records or physical appearance ofT101588 and engage T101306 splined main driveshaft indicates assemblywrench. Hold T101588 and remove nut (10) has been subjected to an accidentand spring retainer (9). Remove tools. or incident outside realm of normal

usage, perform Conditional6. Remove couplings (1 and 8) from shaft. Inspection (paragraph 63-8). If

Conditional Inspection is notrequired, accomplish Normal

NOTE Inspection (paragraph 63-9).

Recording of coupling serialnumbers to facilitate reassembly is 63-8. Conditional inspection.not required. However, it is adesirable maintenance practice tomatch serial numbers of couplings in 1. Visually inspect driveshaft for externalorder to reassemble couplings into damage.original position.

2. Visually inspect male and female7. Remove washers (4) and bolts (5). couplings for chipped, dented, or crackedSeparate coupling (1), packing (2), boot (3) teeth or for galling caused by excessiveand retainer (3A) if installed. Discard packing. misalignment.

8. Repeat steps 1. through 7. for 3. With couplings (1 and 8, figure 63-3)disassembly of opposite coupling (7). removed from both ends of shaft, mount shaft

on centers and check shaft runout. Runout9. Inspect grease for being very viscous shall not exceed 0.020 in. (0.508 mm) TIR at(thick) and having a strong pungent odor. mid-point of shaft nor 0.010 in. (0.254 mm)Refer to paragraph 63-9 for overtemperature TIR when checked at 7.0 in. (177.8 mm) frominspection. either end.

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BHT-212-CR&O

NOTE b. Inspect gear teeth of outer couplingand inner coupling for being discolored

Any evidence of yielding, exceeding (brown or blue) in the normally bright contactlimits of step 3., renders the entire patterns. If discoloration is found, replacecomponent unserviceable and outer coupling and inner coupling.nonreparable. Scrap driveshaft.

c. Inspect outer coupling and innercoupling under 5x to 10x magnification for4. If no evidence of conditions of steps 1. 5 to 10X magnification forteeth exhibiting signs of metal smearing orthrough 3., is found, accomplish Normalthrough 3., is found, accomplish Normal tearing in the contact patterns. If smearing or

I Inspection (paragraph 63-9).I Inspection (paragraph 63-9). tearing is found replace outer coupling andinner coupling.

63-9. Normal inspection.d. Inspect grease from couplings for being

very viscous (thick) and having a strongMATERIALS REQUIRED pungent odor. If grease is found to be viscous

(thick) and having strong pungent odor,

NUMBER NOMENCLATURE replace outer coupling and inner coupling.

C-108 Brush Cadmium NOTEPlating Solution

If TEMP-PLATES are to be replaced,C-407 Abrasive Pad replace TEMP-PLATES after

C-423 Abrasive Cloth or completing entire inspection andPaper_ repair procedures and couplings

Paper have been determined serviceableC-464 India Stone and prior to assembly.

C-500 Crocus Cloth 1A. Inspect outer coupling (1) temperatureindicator TEMP-PLATES (16) fordeterioration, debonding or discoloration of

NOTE epoxy coating that prevents interpretation ofindicating dots. If deterioration, debonding, or

Overtemperature indicator dots on discoloration of epoxy is found, replacetemperature indicator TEMP- TEMP-PLATES in accordance with paragraphPLATES are of a white or light gray 63-4F.color and turn black when exposedcolor and turn black when exposed 2. Inspect couplings (1 and 8) for defective,to an overtemperature condition.to an overtemperature. excessively worn, dented, burned, or pittedChemical contamination can also teeth. Use a white card or other suitablecause the indicating dots to turn material to reflect light. If defects are found

black. on inner coupling, outer coupling will also bedamaged. Small defects, which cannot be felt

1. Inspect outer coupling (1, figure 63-3) with a 0.020 in. (0.508 mm) radius probe, aretemperature indicator TEMP-PLATES (16) for acceptable on not more than threeevidence of overtemperature indication. If consecutive teeth or six total teeth. See figureovertemperature indication is noted, perform 63-7 for typical main driveshaft wear patternscoupling overtemperature inspection as and figure 63-6 for coupling damage limits.follows:

a. Inspect outer coupling cadmium platingfor being discolored (circumferential tan orlight brown band) or blistered. If cadmiumplate discoloration or blistering is found,replace outer coupling and inner coupling.

63-00-00Rev. 3 Page 14A/14B

BHT-212-CR&0

3. Inspect packing groove in retainer plate (0.254 mm) are acceptable. Remove(14, figure 63-3) and surface in outer coupling corrosion (BHT-ALL-SPM).(1) contacted by packing for nicks or burrs.Remove any such defects with fine India 7. Visually inspect threaded parts forstone (C-464) or crocus cloth (C-500). damage.Carefully remove any foreign material. If nicksdeep enough to permit passage of grease are 8. Inspect following parts by magneticfound, replace defective part. particle method (BHT-ALL-SPM).

4. Inspect area which contacts retaining Figure and Nomenclaturering (15) for excessive wear. Index No.

4A. Inspect retainer (3A) for excessive wear 63-3, 1 Outer couplingif installed. 63-3, 6 Driveshaft

63-3, 8 Inner coupling63-3, 10 Nut

CAUTION

9. Inspect parts dimensionally and replaceC H E C K BOOT D A T E OF parts that do not fall within inspection limitsMANUFACTURE. SCRAP ANY (figure 63-5)BOOT MANUFACTURED DURINGAUGUST OR SEPTEMBER 1994.

NOTE5. Inspect boot (3) for cracks, tears,wrinkles, and bands of heavy wear against Wear limits are provided to show

I shroud. No defects are acceptable. required fit between mating parts. Itis not intended all dimensions bechecked as a prescribed overhaul

NOTE procedure. However, parts exhibitingevidence of wear or physical

It is recommended that boot (3) be damage shall be checkedreplaced each 1200 hours of dimensionally.operation.

6. Inspect spring retainer (9) for corrosiondamage. Pits to a maximum depth of 0.010 in.

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BHT-212-CR&O

10. Visually inspect outer diameter ofdriveshaft (6) for nicks, scratches, and pitting(table 63-1).

Table 63-1. Main driveshaft (212-040-005-003, -007, -103) damage limits

DAMAGE REPAIR

Nicks and scratches running Not exceeding 0.004 in. (0.1016 mm) in depth are permittedparallel to, or within 15° without polishing out.of parallel to shaftaxis.

Not exceeding 0.008 in. (0.2032 mm) in depth or 1.5 in. (38.1mm) in length are permissible if polished out, provided totalpolished area does not exceed 10% of circumference at anypoint.

Nicks and scratches not Not exceeding 0.004 in. (0.1016 mm) in depth are permissiblerunning within 15° of on up to 100% of circumference of shaft if polished out.shaft axis shall be polishedout

Not exceeding 0.008 in. (0.2032 mm) in depth or 1.5 in. inlength are permissible provided total polished area does notexceed 10% of circumference at any point.

Corrosion pitting Not exceeding 0.008 in. (0.2032 mm) in depth is permissible ifpolished out. Maximum length of rework at any point shall notexceed 1.5 in. (38.1 mm) nor cover more than 10% ofcircumference at any point. Maximum permissible totalreworked area shall not exceed 4.0 sq. in. (2580.64 sq mm).

NOTE b. In area B, pits to a maximum depth of0.010 in. (0.254 mm) are acceptable without

Contact Bell Helicopter Textron, polishing out. Pits deeper than 0.010 in.Product Support if driveshaft has (0.254 mm) shall be polished out. Minimumcorrosion damage exceeding limits wall thickness, after rework, is 0.060 in.of table 63-1. (1.524 mm). Rework within this limit shall

completely clean up pits. Minimum radius in11. Visually inspect inside diameter of reworked area is 0.090 in. (2.286 mm) anddriveshaft (6) for corrosion. surface finish shall be 63 RMS or better.

a. In area A, figure 63-9, pits to a c. In area C, last two threads, pits aremaximum depth of 0.005 in. (0.127 mm) are acceptable to a maximum depth of 0.030 in.acceptable without polishing out. Pits greater (0.762 mm).than 0.005 in. (0.127 mm) in depth shall bepolished out. Maximum acceptable depth of 12. Visually inspect nut for corrosionrework is 0.010 in. (0.254 mm). Rework damage. Pitting to a maximum depth ofwithin these limits shall completely clean up 0.030 in. (0.762 mm) in area D is acceptable.pits. Minimum radius in reworked area shallbe 0.50 in. (12.7 mm) or greater and surfacefinish shall be 63 RMS or better.

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BHT-212-CR&O

T-SEE DETAIL A

\ ^2\ A 4 5

0* 4TH GROOVE SEE TABLE 63-1

DETAIL A

1. Outer coupling 6. Driveshaft 11. Locking spring2. Packing 7. Coupling assembly 12. Spring3. Boot 8. Inner coupling 13. Packing

3A. Retainer 9. Spring retainer 14. Retainer plate4. Washer 10. Nut 15. Retaining ring5. Bolt 16. Temperature indicator

TEMP-PLATES

NOTE

A Installed with boot (3) 212-040-176-101.212-R-63-3

0 Figure 63-3. Main driveshaft 212-040-005-003, -007, and -103

63-00-00Rev.3 Page 17

BHT-212-CR&O

A. Typical acceptable wear pattern on the InnerCoupling, Engine End.

B. Typical acceptable wear pattern on the InnerCoupling, Transimlssion End.

C. Typical unacceptable wear pattern on the InnerCoupling, Transmission or Engine End.

212-R-63-4COOOO

Figure 63-4. Main driveshaft wear patterns

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BHT-212-CR&O

13. Inspect and repair inner coupling (8,figure 63-3) as follows (figures 63-4 through CAUTION63-6):

a. Using a 0.020 in. (0.508 mm) radius IF MATERIAL IS REMOVED FROMprobe, inspect coupling teeth faces (area A) 212-040-688-3 COUPLING DURINGfor indentations, pitting, scratches, or scoring. REWORK, AN EQUAL AMOUNT OFFlaws exceeding 0.015 in. (0.381 mm) across MATERIAL SHALL BE REMOVEDin any direction are cause for rejection. Small 180° FROM REWORK LOCATIONdefects, which cannot be felt with probe are TO MAINTAIN COUPLINGacceptable on not more than threeconsecutive teeth or six total teeth. BALANCE. MATERIAL REMOVED

TO RESTORE BALANCE ISSUBJECT TO THE SAME DEPTH

b. Inspect areas A and B for corrosion.Light corrosion or corrosion staining which AND SIZE LIMITS SPECIFIED FORcan be removed by hand using nylon web CORRESPONDING REPAIRS.abrasive pad (C-407) is acceptable.

a. Inspect spline area (area A) forc. Using a 0.1440 in. (3.66 mm) diameter corrosion and spalled, chipped, pitted, or

pin ground to 0.1150 in. (2.921 mm) (figure dented teeth. Using a 0.020 in. (0.508 mm)63-5), measure spline wear (area B, figure radius probe, inspect coupling teeth faces.63-6). Small defects, which cannot be felt with

probe, are acceptable on not more than threed. Inspect areas C and D for corrosion consecutive teeth or a total of six teeth. Light

pitting and mechanical damage. Damage corrosion or corrosion staining which can beshall not exceed 0.005 in. (0.127 mm) in removed by hand using abrasive pad (C-407)depth not affect more than 10 percent of thetotal area of any surface after clean up. is acceptable (figure 63-8).Polish out acceptable damage to a 0.250 in.(6.35 mm) minimum fillet and blend radii. b. Inspect area B (figure 63-7) for

corrosion and mechanical damage. Lightcorrosion and scratches are acceptableprovided damage does not exceed 0.002 in.

NOTE (0.0508 mm) nor affect more than 25% oftotal surface area after cleanup. Rework

Surface finish in reworked areas damaged areas by hand using 400 gritshall be 63 RMS or better. abrasive cloth or paper (C-423).

e. Inspect surface E. Nicks and dents NOTEwhich do not exceed 0.005 in. (0.127 mm) indepth nor are located within 90° apart areacceptable. Remove raised material with surface finish after rework shall befine India stone (C-464), until flush with 63 RMS or better.surrounding surface.

c. Inspect area C for corrosion, pitting,f. Inspect coupling by the magnetic wear, and mechanical damage. Light

particle method. No cracks are permitted. corrosion is permissible providing it does notexceed 0.002 in. (0.0508 mm) in depth nor

14. Inspect outer coupling (1, figure 63-3) as affect more than 40% of surface area afterfollows (figure 63-7). cleanup.

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BHT-212-CR&O

1 2

0.1440 IN.(3.6576 mm)

DIAMETER PIN

GRIND PIN TO0.115 IN. (2.921 mm)

NOMENCLATURE MIN. MAXINCHES MilliMeters INCHES MilliMeters A

1. Outer coupling - internal teeth Between pins 4.7657 121.04878 4.7703 121.16562/(Use 0.1728 IN. (4.38912 mm)diameter pins)

2. Inner coupling - sphericalteeth Overpins 5.1680 131.2672 5.1841 131.67614(Use 0.1440 IN. (3.6576 mm)diameter pins)

3. Inner coupling - internal teeth Between pins 2.8427 72.20458 2.8464 72.29856A(Use 0.1440 IN. (3.6576 mm)diameter pins)

4. Shaft - spline Over pins 3.2909 83.58886 3.2952 83.69808(Use 0.1920 IN. (4.8768 mm)diameter pins)

NOTES

A Use pins with one side ground flat to provide clearance between pins and root of splines teeth.

A Maximum allowable depth of wear 0.0055 inch (0.1397 mm) (measure from unworn face of tooth).212-R-63-5

Figure 63-5. Main driveshaft wear limits

63-00-00Page 20

BHT-212-CR&O- --- - GEAR TEETH

AREA A

AREA D AREA C

SPLINEAREA B

- SURFACE E

INSPECTION DIMENSIONSAREA CHARACTERISTIC METHOD MIN MAX

A GEAR TOOTH WEAR MEASURE OVER 0.1440 IN. 5.1680IN. 5.1841 IN.(3.6576 mm) DIA PINS. (131.2672 mm) (131.67614 mm)

A INDENTATIONS, PITTING VISUAL/FEEL SEE TEXTSCRATCHES & SCORING

B SPLINE WEAR MEASURE BETWEEN 0.1440 2.8427 IN. 2.8464 IN.IN. (3.6576 mm) DIA PINS (72.20458 mm) (72.29856 mm)(SEE TEXT)

A,B CORROSION VISUAL SEE TEXT

A,B CHIP. BROKEN OR VISUAL NONE ALLOWEDMISSING TEETHMECHANICAL DAMAGE

C,D CORROSION PITTING OR VISUAL/MEASURE SEE TEXTMECHANICAL DAMAGE

E MECHANICAL DAMAGE VISUAL SEE TEXT

UN- CORROSION PITTING OR VISUAL NONE ALLOWEDDESIGNATED MECHANICAL DAMAGEAREAS

ALL CRACKS MAGNETIC PARTICLE NONE ALLOWED212-R-63-6

Figure 63-6. Inner coupling inspection

63-00-00Page 21

BHT-212-CR&O

D

E

OUTBOARDLAND

WEAR LIMITS DIMENSIONSCHARACTERISTIC INSPECTION METHOD MIN. MAX.

INTERNAL SPLINE TEETH MEASURE BETWEEN 0.1728 IN. 4.7657 IN. 4.7703 IN.(4.38912 mm) DIAMETER PINS (121.04878 mm) (121.16562 mm)

NOTES

1. Refer to text for damage and repair limits.

2 Maximum allowable depth of wear is 0.0055 inch (0.1397 mm) (measure from unworn face of tooth).

212-R-63-7

Figure 63-7. Outer coupling inspection

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BHT-212-CR&O

POSITION METALSTRAIGHT EDGE

FEELER GAGE MAXIMUM PERPENDICULAR0.0055 IN. (0.1397 mm) - TO FACE OF TOOTH

BEING INSPECTED

OUTER WEAR AREACOUPLING

SEE DETAIL A

DETAIL A

PITTING

PEENING

CONTACT AREA

DETAIL B DETAIL C

Detail B shows maximum allowable pitting of Detail C - this condition is acceptable on notcontact area. Reject for pitting of this type more than 15 consecutive teeth of 35 teethdetectable by 0.020 inch (0.508 mm) radius total. Maximum acceptable depth of peening orprobe. wear in 0.0005 inch (0.0127 mm).

212-R-63-8

Figure 63-8. Outer coupling spline teeth

63-00-00Rev.3 Page 23

BHT-212-CR&O

;s....s.s..s.s out acceptable damage using 0.125 in. (3.175jCAUTION J mm) minimum fillet radii. Maintain surface

*.*************** finish at 63 RMS or better. Damage occurringmore than once in any 2.0 in. (50.8 mm) or

COUPLING SHALL BE MASKED TO more than eight places around circumferencePREVENT BEAD IMPINGEMENT is cause for rejection of coupling. RemoveON ANY SPLINE TOOTH SURFACE any acceptable raised material aroundAND CURVIC TOOTH SURFACE circumference by hand using a fine IndiaAND TO PREVENT REMOVAL OF stone (C-464). Maintain surface finish at 63CADMIUM PLATING OUTSIDE RMS or better.REPAIR AREA.

i. Inspect area E for corrosion andd. Remove corrosion from area C by mechanical damage. No corrosion or

glass-bead blasting affected surface in a dry mechanical damage is allowed.process.

j. Inspect washer seat areas surroundinge. Inspect edges of retaining ring groove each bolt hole. Corrosion not exceeding

to ensure edge radius or corner break does 0.002 in. (0.0508 mm) in depth is acceptablenot exceed 0.010 in. (0.254 mm) after rework. providing if removed.Light scratches 0.010 in. (0.254 mm) or lessin depth are acceptable across narrow land k. Inspect fillet area at the couplingoutboard of retaining groove. Remove raised cylinder intersection for indentations at boltmaterial from around acceptable scratches hole locations. Any such indications areusing a fine India stone (C-464). unacceptable and are cause for rejection of

coupling.f. Inspect area D for corrosion and

mechanical damage. Light fretting corrosion . Repair acceptable corrosion damageis acceptable provided it does not exceed around bolt holes in accordance with step g.0.002 in. (0.0508 mm) in depth nor affects abovemore than 50% of surface area between anytwo threaded holes.

m. Inspect area F for corrosion andmechanical damage. Allowable mechanicaldamage in area F is limited to nicks, dents,

CAUTION and scratches at flange outer diameter which************** do not exceed 0.010 in. (0.254 mm) in depth

nor more than 0.5 in. (12.7 mm) in width afterCOUPLING SHALL BE MASKED TO repairs. Polish out acceptable damage usingPREVENT BEAD IMPINGEMENT 0.125 in. (3.175 mm) minimum fillet radii.ON ANY SPLINE TOOTH OR Maintain surface finish at 63 RMS or better.CURVIC TOOTH SURFACE AND Damage occurring more than once in any 2.0TO PREVENT REMOVAL OF in. (50.8 mm), or more than eight placesCADMIUM PLATING OUTSIDE OF around circumference is cause for rejection ofREPAIR AREA. coupling. Remove any acceptable raised

material around circumference by hand usingg. Remove acceptable corrosion from a fine India stone (C-464). Maintain surface

area D by glass-bead blasting the affected finish at 63 RMS or better.surface in a dry process.

n. Visually inspect curvic coupling (areah. Allowable mechanical damage in area G) for spalled, chipped, pitted, dented, or

D is limited to nicks, dents, and scratches at corroded teeth. Only light corrosion orflange outer diameter which do not exceed corrosion staining which can be removed by0.010 in. (0.254 mm) in depth nor more than hand using abrasive pad (C-407) is0.5 in. (12.7 mm) in width after repairs. Polish acceptable.

63-00-00Page 24

BHT-212-CR&O

o. Inspect area H for corrosion and 1. Replace all parts failing magnetic particlemechanical damage. No damage is inspection.permitted.

2. Replace all parts having damagedp. Inspect bolt holes for corrosion. threads.

Corrosion pitting which does not exceed0.010 in. (0.254 mm) in depth or affect more 3. Replace couplings (1 and 8, figure 63-3) ifthan 20% of wall area after cleanup is evidence of overheating is found.acceptable.

4. Replace boot (3) if cracked, torn,q. Inspect threaded holes for damage. No wrinkled, or excessive wear with shroud is

damage allowed. noted.

r. Inspect entire coupling for cracks using 5. Dress off burrs on retainer plate (14) withmagnetic particle inspection. No cracks aluminum oxide cloth (C-406) to ensureallowed. proper packing seat.

6. Replace packings (2 and 13).ICAUTION 7. Replace retaining ring (15), springretainer (9), spring (12), and locking spring(11) if damaged, deformed, or corrosion pitted

DO NOT ALLOW P LATING beyond acceptable limits.SOLUTION TO CONTACT ANYSPLINE TOOTH SURFACE. DOSPLINE TOOTH SURFACE. DO 8. Replace parts exceeding wear limitsN O T A P P L Y ANY (figure 63-8).SUPPLEMENTARY CHROMATETREATMENT. 9. Dress small nicks or burrs on spline teeth

with fine India stone (C-464).s. After repair, treat plated surfaces with

brush cadmium plating solution (C-108). 10. Polish out acceptable defects ondriveshaft (6, figure 63-2). Do not exceed

63-10. Repair. main driveshaft damage limits (table 63-1)(paragraph 63-8, step 10). Touch up repairedareas with brush cadmium plating solution (C-

MATERIALS REQUIRED 108). Apply one coat of epoxy/zinc coating(C-208) to inner area of driveshaft (figure 63-10).NUMBER NOMENCLATURE 10

C-108 Brush Cadmium NOTEPlating Solution

Minimum radius used in polishingC-208 Epoxy/Zinc Coating the outside diameter of theC-305 Aliphatic Naphtha. .Surface finish in reworked areasC-317 Adhesive must be 32 RMS or better.

Maximum permissible length ofC-406 Aluminum Oxide Cloth rework is 1.5 in. (38.1 mm) and

maximum permissible totalC-423 Abrasive Cloth or cumulative length of rework is 4.0

Paper sq. in. (2580.64 sq mm).

C-464 India StoneC-464e___________________________ 11. Install data plate as follows:

63-00-00Page 25

BHT-212-CR&O

DRIVESHAFT NUT

212-R-63-9204-040-1 84N212-040-686 F

Figure 63-9. Main driveshaft corrosion areas

NOTE data plate serves as a spacer and controlsbondline thickness.

Bond two data plates on driveshaft,180° apart, for balance purposes. e. Position data plate on shaft. Use a

fixture or rubber bands to maintaina. Stamp correct information on one data approximately 10 psi (68.95 kPa) pressure on

plate. Data plate on opposite side to be data plate.unmarked and installed face down.

f. Cure bond at room temperature for 24b. Position data plate on shaft and form to hours. Alternate curing may be accomplished

have contact with shaft over entire bonding by heating area 175 to 190°F (79 to 88°C) forsurface. 60 minutes.

c. Clean data plate and shaft in area 12. After rework, shaft shall be rebalancedwhere data plate will be bonded by abrading t within 0.10 in.oz. at each end of shaft withlightly with 400 grit abrasive cloth or paper shaft mounted on outside diameter of external(C-423). Remove residue with a clean cloth spline teeth and rotating at 1500 to 2000 rpm.moistened with aliphatic naphtha (C-305). (Figure 63-11 depicts area from which

material may be removed for balanced. Mix adhesive (C-317) 33 parts B to 100 purposes.)

parts A. Mix thoroughly. (Pot life is 30 to 50minutes after mixing.) Apply a thin coat of 13. Replace temperature indicator TEMP-adhesive to data plate and shaft in area PLATES if necessary. Refer to paragraph 63-where data plate will be bonded. Place a four 4F.mil thread in adhesive on data plate. Twopieces of thread positioned lengthwise on

63-00-00Page 26 Rev. 3

BHT-212-CR&O

NOTE

Apply epoxy/zinc coating (C-208) to inner area of driveshaft as indicated. 212-R-6310

Figure 63-10. Main driveshaft painting requirements

63-11. Assembly. 1A. Couplings with a 212-040-176-101 boot,position outer coupling (1, figure 63-3) on

MATERIALS REQUIRED boot (3) with new packing (2) installed ingroove. Position retainer (3A) and align holesin coupling, boot, and retainer. Install bolts (5)

NUMBER NOMENCLATURE with washers (4).

C-015 Lubricant (Tube Pack) 1B. Torque bolts 50 to 70 in. Ibs (5.649 to7.908 Nm). Secure bolt heads together with

C-405 Lockwire lockwire (C-405). Position coupling with bootdown on work bench.

SPECIAL TOOLS REQUIRED NOTE

Two tubes of lubricant (tube pack)NUMBER NOMENCLATURE (C-015) are necessary for lubricating

driveshaft couplings on 212-040-L-122 Extension Bar 005-003 and -007 driveshafts. Three

T101306 Splined Wrench tubes of lubricant (tube pack) (C-015) are required for lubricating

T101588 Wrench driveshaft couplings on 212-040-005-103 driveshaft.

1. Couplings with a 212-040-176-007 boot, 2. Apply lubricant inside boot as follows:position outer coupling (1, figure 63-3) onboot (3) with new packing (2) installed in a. Squeeze one-fourth tube of lubricantgroove. Align holes in coupling and boot and (tube pack) (C-015) into boot (3) of 212-040-install bolts (5) with washers (4). 005-003 or -007 main driveshaft. Spread

lubricant to coat inner surface of boot.

63-00-00Rev.3 Page 27

BHT-212-CR&O

0.050 IN. (1.27 mm) RADIUS MINIMUMREMOVE FLANGE MATERIAL FORBALANCE REQUIREMENTS

4.060 IN.1103.124 mm) DIA.

~/ \MAXIMUM ALLOWABLEFLANGE REMOVAL

ALTERNATE METHOD OFFLANGE MATERIAL REMOVAL -3-

Figure 63-11. Material removal area for driveshaft balancing

b. Squeeze one-half tube of lubricant(tube pack) (C-015) into boot (3) and inner CAUTIONcoupling (8) of 212-040-005-103 main .driveshaft. Handpack lubricant evenly overcoupling (8) and behind dam in boot (3). BEFORE TORQUING NUT,

ENSURE TEETH OF INNERc. Carefully install inner coupling (8) into COUPLING (8) ARE FULLY

outer coupling (1). ENGAGED IN SPLINES OF OUTERCOUPLING (1).

NOTE 5. Insert T101306 splined wrench in nut (10)and install T101588 wrench on outer coupling

It is recommended that serial (1). Insert L-122 extension bar throughnumbers of couplings be matched as T101588 and engage splined wrenchan aid to reassemble couplings in T101306. Hold T101588 wrench and torqueoriginal position. nut (10) 100 to 200 ft.lbs. (135.58 to 271.16

Nm). Remove tools. Install locking spring3. Coat inner diameter of shaft (6) with a (11) in nut (10). Ensure tang of spring is fullylight film of lubricant (tube pack) (C-015). engaged in hole in nut and slot in driveshaftCoat threads of nut (10) and mating surfaces (6). Verify boot is free of wrinkles. If wrinklesof nut flange, coupling (8), spring retainer (9), are found, loosen and retorque nut (10).and spring (12) with lubricant (tube pack) (C-015). 6. Apply lubricant to inside couplings as

follows:4. Place shaft in suitable support. Installcouplings (1 and 8) on shaft (6). Position a. Spread remaining three-fourths tube ofspring retainer (9) in end of shaft and install lubricant (tube pack) (C-015) into outernut (10) finger tight.

63-00-00Page 28

BHT-212-CR&O

coupling (1) of 212-040-005-003 or -007 main caused by mis-indexing of coupling teeth;driveshaft. Spread lubricant evenly over tears are usually caused during torquing ofcoupling splines. nut (10) because inner and outer coupling

teeth were not properly engaged.

b. Spread one tube of lubricant (tubepack) (C-015) into outer coupling (1) of 212- 11. Deleted.040-005-103 main driveshaft. Spreadlubricant evenly over coupling splines. 63-12. MAIN DRIVESHAFT (212-040-005-

011).7. Seat spring (12) in boss of spring retainer(9). Apply light coat of lubricant on packing(13) and install new packing on retainer plate 63-13. LUBRICATION.(14). Carefully press retainer plate in positionin end of coupling (1).

NOTENOTE

This procedure is to be used forAfter installation of new packing lubrication of main driveshaft when(13), ensure no rubber slivers are specified by Lubrication Chart.present indicating packing (13) wasdamaged during installation. Refer to paragraph 63-3 for

lubrication of 212-040-005-003, -8. Install retainer ring (15) in groove of outer 007, and -103 driveshaft.coupling. Inspect ring for proper seating ingroove.

63-13A. Disassembly.

9. Accomplish steps 1. through 8. onopposite coupling (7). 1. Place driveshaft (14, figure 63-13) in a

suitable support. Remove retainer ring (1),retainer plate (3) with packing (2), and spring

10. Inspect boots (3) for damage which may (4) from coupling assembly. Discard packinghave occurred during assembly. Wrinkles are (2).

63-00-00Rev. 3 Page 29

BHT-212-CR&O

CAUTION CAUTION i

DO NOT DISTURB HOUSING (7), DO NOT WASH ASSEMBLEDPACKING (8), SEAL (10), AND DRIVESHAFT IN SOLVENT. WASHRING (11) WHEN OUTER ONLY REMOVED COUPLING (5)COUPLING (5) IS REMOVED FROM WHICH CAN BE COMPLETELYRING (11). DRIED BEFORE REASSEMBLY.

2. Remove bolts (13) and washers (12). 1. Clean removed outer coupling (5) by IRemove coupling (5) from housing (7), ring wiping with clean, dry, lint-free cloths, or by(11), and inner coupling (9). Remove packing washing in solvent (C-304) and completely(6) and discard. drying with filtered, compressed air.

2A. Inspect grease for being very viscous 2. Clean inner coupling (9) by wiping with I(thick) and having a strong pungent odor. clean dry cloths.Refer to paragraph 63-13C, step 1d.

63-13C. Inspection.63-13B. Cleaning.

MATERIALS REQUIRED

MATERIALS REQUIREDNUMBER NOMENCLATURE

NUMBER NOMENCLATURE C-464 India Stone

C-304 Solvent C-500 Crocus Cloth

l

63-00-00Page 30 Rev. 3 Figure 63-12. Deleted

BHT-212-CR&O

NOTE d. Inspect grease from couplings for beingvery viscous (thick) and having a strong

Overtemperature indicator dots on pungent odor. If grease is found to be viscoustemperature indicator TEMP- (thick) and having a strong pungent odor,PLATES are of a white or light gray replace outer coupling and inner coupling.color and turn black when exposedto an overtemperature condition. NOTEChemical contamination can alsocause the indicating dots to turn If TEMP-PLATES are to be replaced,black. replace TEMP-PLATES after

completing entire inspectionprocedure and couplings have been

1. Inspect outer coupling (5, figure 63-13) determined serviceable and prior totemperature indicator TEMP-PLATES (16) for lubricating couplings.evidence of overtemperature indication. Ifovertemperature indication is noted, perform 2. Inspect outer coupling (5) temperaturecoupling overtemperature inspection as indicator TEMP-PLATES (16) forfollows: deterioration, debonding or discoloration of

epoxy coating that prevents interpretation ofindicating dots. If deterioration, debonding, or

a. Inspect outer coupling cadmium plating discoloration of epoxy is found, replacefor being discolored (circumferential tan or TEMP-PLATES in accordance with paragraphlight brown band) or blistered. If cadmium 63-4E.plate discoloration or blistering is found,replace outer coupling and inner coupling. 3. Inspect couplings (5 and 9) for defective,

burned or pitted teeth. Use a white card or.b. Inspect gear teeth other suitable material to reflect light. If

b. Inspect gear teeth of outer coupling defects are found on inner coupling, outerand inner coupling for being discolored coupling will also be damaged (figure 63-7).(brown or blue) in the normally bright contactpatterns. If discoloration is found, replace 4. Inspect packing groove in housing (7,outer coupling and inner coupling. figure 63-13) and surface in outer coupling

c. Inspect outer coupling and innercoupling under 5x to 10x magnification forteeth exhibiting signs of metal smearing ortearing in the contact patterns. If smearing ortearing is found, replace outer coupling andinner coupling.

63-00-00Rev. 3 Page 30A/30B

BHT-212-CR&O

(5), contacted by packing, for nicks or burrs. 3. Spread remaining three-fourths tube ofRemove any such defects with fine India lubricant (tube pack) (C-015) into outerstone (C-464) or a crocus cloth (C-500). coupling (5). Spread grease evenly overCarefully remove any foreign material. If nicks coupling splines.deep enough to permit passage of grease are

4. Coat spring (4) with a thin film of lubricantfound, replace defective part. Inspect areacontacting retaining ring (1) for excessive (tube pack) (C-015) and set (15) spring (4) inboss of retainer behind nut (15) in shaft.

. Apply light coat of lubricant on new packing(2). Install packing on retainer plate (3).

5. Visually inspect seal (10) and wear sleeve Carefully press retainer plate (3) in position infor wear and corrosion. end of outer coupling (5).

5. Install spiral retainer ring (1) in groove of6. Inspect inside of driveshaft for corrosion. outer coupling (5). Inspect ring for properIf corrosion is evident, refer to paragraphs 63- seating in groove.17 and 63-18.

6. Accomplish lubrication for other end of7. Visually inspect threaded parts for driveshaft (14) by repeating paragraphs 63-13damage. through 63-13D.

8. If TEMP-PLATES (16) are to be replaced, 63-13E. OVERHAUL.Install replacement TEMP-PLATES at thistime, after inspection and prior to lubricating 63-14. Disassembly.couplings. Refer to paragraph 63-4F forreplacement procedure. SPECIAL TOOLS REQUIRED

63-13D. Lubrication and assembly. NUMBER NOMENCLATURE

L-122 Extension barMATERIALS REQUIRED

T101306 Splined wrench

NUMBER NOMENCLATURE T101588 Wrench

C-015 Lubricant (Tube Pack)1. Place driveshaft in a suitable support.Remove retainer ring (1, figure 63-14),

1. Coat new packing (6, figure 63-13) with retainer plate (3) with packing (2) and springlubricant (tube pack) (C-015) and install in (4) from coupling assembly. Discard packing.groove of housing (7). Place outer coupling Remove locking spring (5) from nut (6).(5) on inner coupling (9) and move to point 2. Insert T101306 splined wrench in nut (6)where approximately 0.75 in. (19.05 mm) of and install T101588 wrench on coupling (11).splines are exposed on flange end of outer Insert L-122 extension bar through T101588coupling (5). Use one-fourth tube of lubricant wrench and engage T101306 splined wrench.(tube pack) (C-015) to uniformly cover splinesof outer coupling (5) (shaft side of coupling).

2. Ensure packing (6) is in groove ofhousing (7), and packing (8) is on outside ofseal (10) against ring (11). Assemble housing(7), ring (11), and outer coupling (5) with bolts(13) and washers (12).

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BHT-212-CR&O

4TH GROOVE13

12

DETAIL A 5

SEE TABLE 63-1

1. Retainer ring 9. Inner coupling2. Packing 10. Seal3. Retainer plate 11. Ring4. Spring 12. Washer5. Outer coupling 13. Bolt6. Packing 14. Driveshaft7. Housing 15. Nut8. Packing 16. Temperature indicator

TEMP-PLATES

212-R-63-13

Figure 63-13. Main driveshaft (212-040-005-011) lubrication

63-00-00Page 32 Rev. 3

BHT-212-CR&O

Hold T101588 wrench and remove nut (6). required, accomplish NormalRemove tools. Inspection (paragraph 63-18).

3. Remove couplings (10 and 11) from 63-17. Conditional Inspection.driveshaft (18).

1. Visually inspect driveshaft for externalNOTE damage.

Record serial numbers to facilitate 2. Visually inspect male and femalereassembly of couplings in original couplings for chipped or cracked teeth or forposition. galling caused by excessive misalignment.

3. With couplings (10 and 11, figure 63-14)4. Remove bolts (8) and washers (7). removed from both ends of shaft, mount shaftSeparate coupling (11) from housing (13) and on centers and check runout. Runout shall notring (16). Remove seal (15) from sleeve (17). exceed 0.020 in. (0.508 mm) TIR at mid-pointRemove and discard packings (12 and 14). of shaft nor 0.010 in. (0.254 mm) TIR when

checked 7.0 in. (177.8 mm) from either end.4A. Inspect grease for being very viscous(thick) and having a strong pungent odor.Refer to paragraph 63-18 for overtemperature NOTEinspection. Any evidence of yielding (exceeding

limits of step 3. above) renders5. Repeat steps 1. through 4. for entire component unserviceable anddisassembly of opposite coupling. nonreparable.

~63-15. Cleaning~. ~4. If no evidence of conditions of step 1.63-15. Cleaning. through 3. are found, accomplish Normal

Inspection, paragraph 63-18.MATERIALS REQUIRED

63-18. Normal Inspection.NUMBER NOMENCLATURE

C-304 Solvent MATERIALS REQUIREDC-304 Solvent

NUMBER NOMENCLATURE1. Clean driveshaft parts with solvent (C-304). C-464 India Stone

C-500 Crocus Cloth2. Dry parts with dry, filtered, compressed C-50air.

NOTE63-16. Inspection.

Overtemperature indicator dots ontemperature indicator TEMP-

NOTE PLATES are of a white or light graycolor and turn black when exposed

If records or physical appearance of to an overtemperature condition.main driveshaft indicate assembly Chemical contamination can alsohas been subjected to an accident cause the indicating dots to turnor incident outside realm of normal black.usage, perform ConditionalInspection (paragraph 63-17). IfConditional Inspection is not

63-00-00Rev. 3 Page 32A/32B

BHT-212-CR&O

1. Inspect outer coupling (11, figure 63-14) pungent odor. If grease is found to be viscousindicator TEMP-PLATES (19) for evidence of (thick) and having a strong pungent odor,ove r t e m pe r a t u re i nd i c a t i o n. I f replace outer coupling and inner coupling.overtemperature indication is noted, performcoupling overtemperature inspection as NOTEfollows:

If TEMP-PLATES are to be replaced,replace TEMP-PLATES after

a. Inspect outer coupling cadmium plating completing entire inspectionfor being discolored (circumferential tan or procedure and couplings have beenlight brown band) or blistered. If cadmium determined serviceable and prior toplate discoloration or blistering is found, lubricating couplings.replace outer coupling and inner coupling.

1A. Inspect outer coupling (11) temperatureindicator TEMP-PLATES (19) for

b. Inspect gear teeth of outer coupling deterioration, debonding or discoloration ofand inner coupling for being discolored epoxy coating that prevents interpretation of(brown or blue) in the normally bright contact indicating dots. If deterioration, debonding, orpatterns. If discoloration is found, replace discoloration of epoxy is found, replaceouter coupling and inner coupling. TEMP-PLATES in accordance with paragraph

63-4F.

c. Inspect outer coupling and inner 2. Inspect couplings (10 and 11) forcoupling under 5x to 10x magnification for defective, excessively worn, dented, burned,teeth exhibiting signs of metal smearing or or pitted teeth. Use a white card or othertearing in the contact patterns. If smearing or suitable material to reflect light on couplingtearing is found, replace outer coupling andinner coupling.

d. Inspect grease from couplings for beingvery viscous (thick) and having a strong

63-00-00Rev.3 Page 33

BHT-212-CR&O

6

2 4

13

12

SEETABLE63-1

DETAIL A

1. Retainer 10. Inner coupling

2. Packing 11. Outer coupling3. Retainer plate 12. Packing4. Spring 13. Housing5. Locking spring 14. Packing6. Nut 15. Seal

7. Washer 16. Ring8. Bolt 17. Sleeve9. Retainer 18. Driveshaft

19. Temperature indicatorTEMP-PLATES

212-R-63-14

Figure 63-14. Main driveshaft (212-040-005-011)

63-00-00Page 34 Rev.3

BHT-212-CR&O

teeth (figure 63-7). If defects are found on 8. Inspect ring (16) for nicks, burrs, andinner coupling, outer coupling will also be excessive wear on seal (15) contact surface.damaged.

9. Inspect sleeve (17) for nicks, burrs,3. Inspect packing groove in housing (13) corrosion, and wear.and surface of outer coupling (11), contactedby packing, for nicks or burrs. Remove 10. Inspect seal (15) for cracks, nicks, anddefects with fine India stone (C-464) or lip deformation. Seal lips should contactcrocus cloth (C-500). Carefully remove any sleeve (17) when installed.foreign material. If nicks deep enough topermit passage of grease are found, replace 11. Inspect parts dimensionally and replacedefective part. parts which do not fall within inspection limits

(figure 63-15).

4. Inspect housing (13) for excessive wearin the seal (15) contact area and for corrosion NOTEdamage.

Wear limits are provided to show5. Inspect spring retainer (9) for corrosion required fit between mating parts. Itdamage. Pits to a maximum of 0.010 in. is not intended all dimensions be(0.254 mm) are acceptable. Remove checked as a prescribed overhaulcorrosion with a wire brush. procedure. However, parts showing

evidence of wear or physical6. Visually inspect threaded parts for damage shall be checkeddamage and corrosion. dimensionally.

7. Inspect following parts by magnetic 12. Visually inspect outside diameter of7. Inspect following parts by magnetic andparticle (Code M) or fluorescent penetrant veshaft (18) or nicks, scratches, and(Code F) method as applicable (BHT-ALL- pitting (table 63-2).SPM). Demagnetize parts after magneticinspection.

Figure, Nomenclature CodeIndex No.

63-14, 11 Outer coupling M63-14, 18 Driveshaft M63-14, 10 Inner coupling M63-14, 6 Nut M63-14, 13 Housing F63-14, 16 Ring F63-14, 17 Sleeve F63-14, 3 Retainer plate F

Table 63-2. Main driveshaft (212-040-005-011) damage limits

DAMAGE REPAIR

Nicks and scratches running Not exceeding 0.004 in. (0.1016 mm) in depth are permittedparallel to, or within 15° of without polishing out.parallel, to shaftaxis.

63-00-00Rev. 4 Page 35

BHT-212-CR&O

2

DETAIL A

GRIND PINTO 0.115 IN.(2.92 mm)

1.70 IN. (43.18 mm)DIAMETER PIN

DETAIL B

4 MIN. MAXINCHES MILLIMETERS INCHES MILLIMETERS

1. Outer coupling - internal teeth Between pins 4.7657 121.04878 4.7703 121.16562(Use 0.1728 IN. (4.38912 mm)diameter pins)

2. Inner coupling - spherical teeth Over pins 5.1549 130.93446 5.1841 131.67614(Use 0.1440 IN. (3.6576 mm)diameter pins) (See detail A)

3. Sleeve OD 3.561 90.4494 3.563 90.5002

4. Inner coupling - internal spline Between pins 2.8427 27.20458 2.8464 72.29856(Use 0.1440 IN. (3.6576 mm)diameter pins) (See detail B) A

5. Shaft - spline Over pins 3.2909 83.58886 3.2952 83.69808(Use 0.1920 IN. (4.8768 mm)diameter pins)

NOTES

Maximum allowable depth of wear 0.010 inch (0.254 mm) with no sharp edges or scratches inseal area. Part may be polished to clean up.

Use pins with one side ground flat to provide clearance between pins and root of spline tooth.

Maximum allowable depth of wear 0.0055 inch (0.1397 mm) (measure from unworn face oftooth). 212-R-63-15

Figure 63-15. Main driveshaft wear limits (212-040-005-011)

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BHT-212-CR&O

Table 63-2. Main driveshaft (212-040-005-011) damage limits (Cont)

DAMAGE REPAIR

Not exceeding 0.008 in. (0.2032 mm) in depth or 1.5 in. (38.1mm) in length are permissible if polished out, provided totalpolished area does not exceed 10% of circumference at anypoint.

Nicks and scratches not Not exceeding 0.004 in. (0.1016 mm) in depth are permissiblerunning within 15° of on up to 100% of circumference of shaft if polished out.shaft axis shall be polishedout.

Not exceeding 0.008 in. (0.2032 mm) in depth or 1.5 in. (38.1mm)in length are permissible provided total polished area doesnot exceed 10% of circumference at any point.

Corrosion pitting. Not exceeding 0.008 in. (0.2032 mm) in depth is permissibleprovided it is polished out. Maximum length of rework at anypoint shall not exceed 1.5 in. (38.1 mm) nor cover more than10% of circumference at any point. The maximum permissibletotal reworked area shall not exceed 4.0 sq.in. (2580.8 sq mm).

NOTE c. In area C, last two threads, pits areacceptable to a maximum depth of 0.030 in.

Contact Bell Helicopter Textron, (0.762 mm).Product Support Department ifdriveshaft has corrosion damage 14. Visually inspect nut (6) for corrosionexceeding limits of table 63-2. damage. Pitting to a maximum depth of

0.030 in. (0.762 mm) in area D is acceptable.13. Visually inspect inside diameter ofdriveshaft (18) for corrosion.

63-19. Repair.a. In area A, figure 63-16, pits to a

maximum depth of 0.005 in. (0.127 mm) are MATERIALS REQUIREDacceptable without polishing out. Pits greaterthan 0.005 in. (0.127 mm) in depth shall bepolished out. Maximum acceptable depth of NUMBER NOMENCLATURE

within these limits shall completely clean up Plating Solutionpits. Minimum radius in reworked area shallating onbe 0.50 in. (12.7 mm) or greater and surface C-208 Epoxy/Zinc Coatingfinish shall be 63 RMS or better.

C-305 Aiiphatic Naphthab. In area B, pits to a maximum depth of

0.010 in. (0.254 mm) are acceptable without C-317 Adhesivepolishing out. Pits deeper than 0.010 in. C-406 Aluminum Oxide Cloth(0.254 mm) shall be polished out. Minimumwall thickness, after rework, is 0.060 in. C-423 Abrasive Cloth or(1.524 mm). Rework within this limit shall Papercompletely cleanup pits. Minimum radius inreworked area is 0.090 in. (2.286 mm) and C-464 India Stonesurface finish shall be 63 RMS or better.

63-00-00Page 37

BHT-212-CR&O

1. Replace all parts failing magnetic particle 9. Replace sleeve (17, figure 63-14) havinginspection. scratches or corrosion on sealing surface or

corrosion on inside diameter.2. Replace all parts having damagedthreads. 10. Polish out acceptable defects on

driveshaft (18). Do not exceed main3. Replace couplings (10 and 11, figure 63- driveshaft damage limits (table 63-2 or14) if evidence of overheating is found. paragraph 63-17 step 13). Touch upparagraph 63-17, step 13). Touch up

repaired areas with brush cadmium plating4. Dress off burrs on retainer plate (3) with repaired cadmiumaluminum oxide cloth (C-406) to ensure soluton (C-108). Apply one coat of epoxya proper ackind seat (C-208) zinc coating (C-208) to inside of driveshaft

proper packing seat. (figure 63-17).

5. Replace packings (2, 12, and 14).

NOTE6. Replace retainer (1), retainer (9), spring(4), and locking spring (5) if damaged, Minimum radius used in polishingdeformed, or corrosion pitted beyond outside diameter of driveshaft shallacceptable limits. be 0.5 in. (12.7 mm). Surface finish

in reworked areas shall be 32 RMS7. Replace parts exceeding wear limits or better. Maximum permissible(figure 63-15). length of rework is 1.5 in. (38.1 mm)

and maximum permissible total8. Dress small nicks or burrs on spline teethcumulative length of rework is 4.0cumulative length of rework is 4.0with fine India stone (C-464). sq. in. (25.8 sq cm).sq. in. (25.8 sq cm).

11. Install data plate as follows:

212-R-63-16DRIVESHAFT NUT 204-040-184N

212-040-686F

Figure 63-16. Main driveshaft corrosion areas

63-00-00Page 38

BHT-212-CR&O

NOTE 63-20. Assembly.

Bond two data plates on driveshaft,180% apart, for balance purposes. MATERIALS REQUIRED

a. Stamp correct information on one data NUMBER NOMENCLATUREplate before installation. Data plate onopposite side to be unmarked and installed C-015 Lubricant (Tube Pack)face down.

C-405 Lockwireb. Position data plate on shaft and form to

have contact with shaft over entire bondingsurface. SPECIAL TOOLS REQUIRED

c. Clean data plate and shaft in areawhere data plate will be bonded by abrading NUMBER NOMENCLATURElightly with 400 abrasive cloth or paper (C-423). Remove residue with a clean clothmoistened with aliphatic naphtha (C-305). T101306 Splined wrench

d. Thoroughly mix adhesive (C-317), 33 T101588 Wrenchparts B to 100 parts A. (Pot life is 30 to 50minutes after mixing.) Apply a thin coat ofadhesive to data plate and shaft in area 1. Place outer coupling (11, figure 63-14) onwhere data plate will be bonded. Place a four bench with teeth side down.mil thread in adhesive on data plate. Twopieces of thread positioned lengthwise ondata plate serve as a spacer and control CAUTIONbondline thickness.

e. Position data plate on shaft. Use afixture or rubber bands to maintain PACKING (12, FIGURE 63-14) ANDapproximately ten psi (68.95 kPa) pressure on PACKING (14) ARE LOOK ALIKEdata plates. ITEMS, BUT PACKING (14) IS

MUCH THICKER. DO NOTf. Cure bond at room temperature for 24 REVERSE OR SUBSTITUTE IN

hours. Alternate curing may be accomplished ASSEMBLY.by heating area 175 to 190°F (79 to 88°C) for60 minutes. NOTE

12. After rework, shaft shall be rebalanced When SK 4703 seal is used 205-to within 0.10 in.oz. (0.0007 Nm) at each end40-188-3 ring and 205-040-189-3of shaft with shaft mounted on outside 040-188-3 ring and 205-040-189-3of shaft with shaft mounted on outside housing shall be used.diameter of external spline teeth and rotatingat 1500 to 2000 rpm. (See figure 63-18 forarea in which material may be removed for 2. Place packing (12) in groove of housingbalancing.) (13). Position packing (14) and seal (15) in

ring (16). Place assembled parts on outer13. Replace temperature indicator TEMP- coupling (11), align bolt holes, install washersPLATES if necessary. Refer to paragraph 63- (7) and bolts (8). Torque bolts 50 to 70 in.lbs.4F. (5.65 to 7.9 Nm). Ensure seal (15) is not

pinched and is free to float between housing(13) and ring (16).

3. Secure bolts (8) together in pairs withlockwire (C-405).

63-00-00Rev.3 Page 39

BHT-212-CR&O

NOTES

/Apply epoxy/zinc coating (C-208) to inside area of driveshaft as indicated. 212-R-63-17

Figure 63-17. Main driveshaft painting requirements

4. Lubricate inside diameter of sleeve (17) 10. Coat inside diameter of shaft (18) with awith thin film of lubricant (tube pack) (C-015). light film of lubricant (tube pack) (C-015).

Coat threads and flange of nut (6), coupling5. Place inner coupling (10) on bench with (10), spring retainer (9), and spring (4) withteeth side down. Place sleeve (17) on top of lubricant (tube pack) (C-015).inner coupling with external bevel of sleeveup. Place seal installation tool (figure 63-19) 11. Position assembled coupling and innerin sleeve with tapered end of tool up. coupling (10) on driveshaft (18). Place

retainer (9) in end of shaft and install nut (6)6. Lubricate lip of seal (15, figure 63-14), fingertight.seal installation tool, and outside of sleeve(17) with lubricant (tube pack) (C-015). 12. Assemble coupling on other end of shaft

in accordance with steps 1. through 11.7. Work assembled outer coupling downover seal installation tool until seal (15) is 13. Insert T101306 splined wrench in nut (6)

positioned in center of sleeve (17). and install T101588 wrench on outer coupling

8. Remove seal installation tool and inner (11). Insert L-122 extension bar throughcoupling (10) from assembled outer coupling. T101588 wrench and engage splnedCheck inside of outer coupling to ensure lips T101306 wrench Hold T101588 wrenchof seal (15) are positioned correctly and not torquenu (6) 100 to 200 ft.lbs (135.6 torolled under. 271.1 Nm). Remove tools. Install locking

spring (5) in nut (6). Ensure tang of locking

9. Squeeze one-fourth tube of lubricant spring (5) is fully engaged in hole in nut (6)(tube pack) (C-015) into outer coupling. and slot in driveshaft (18).

14. Spread the remaining three-fourths tubeof lubricant (tube pack) (C-015) into outer

63-00-00Page 40

BHT-212-CR&O

0.050 IN. (1.27 mm) RADIUS MINIMUMREMOVE FLANGE MATERIAL FORBALANCE REQUIREMENTS

4.060 IN.(103.124mm) DIA.

MAXIMUM ALLOWABLEFLANGE REMOVAL

ALTERNATE METHOD OFFLANGE MATERIAL REMOVAL 212-R-63-18

Figure 63-18. Material removal area for driveshaft balancing

coupling (11). Spread grease evenly over 16. Install retainer ring (1) in groove of outercoupling splines. coupling. Inspect ring for proper seating in

groove.15. Seat spring (4) in boss of retainer (9).Apply light coat of lubricant on new packing 17. Accomplish steps 13. through 16. on(2), install packing on retainer plate (3). opposite coupling.Carefully press retainer plate in position inend of coupling (11).

63-00-00Page 41

BHT-212-CR&O

32 RHR 3.550 IN.FINISHED (90.17 mm) DIA.SURFACE

BREAK SHARP EDGES

1.75 IN.(44.45 mm)

_3.430 TO 3.435 IN.0.20 IN.(0.508 mm) (87.122 TO 87.249 mm) DIA.(0.508 mm)

MATERIAL - ALUMINUM OR MICA

205040-1002

212-R-63-19

Figure 63-19. Main driveshaft seal installation tool

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BHT-212-CR&0

~ADAPTER

63-21. ADAPTER (ENGINE-TO- of 1.6632 in. (42.2452 mm). Use two 0.1080DRIVESHAFT). in. (2.7432 mm) diameter pins flatted on one

side to 0.1040 in. (2.6416 mm).

63-22. MAINTENANCE. 3. Inspect engine output drive splines asfollows:

The following procedures are to be used toqualify engine-to-driveshaft adapter for further a. Inspect engine output drive splines forservice. evidence of corrosion fretting (presence of red

dust).63-23. Disassembly.

b. Measure output splines for a minimumdimension of 1.9565 in. (49.6951 mm) over

SPECIAL TOOLS REQUIRED pins. Use 0.1080 in. (2.7432 mm) diameterpins.

NUMBER NOMENCLATURE63-25. Assembly.

T101588 Wrench Set

MATERIALS REQUIRED1. Bend tang of washer (2, figure 63-20) outof adapter retaining nut (1). Refer to BHT-ALL-SPM for specification and

source.t 2. Remove adapter retaining nut (1) using

T101588 wrench set. NUMBER NOMENCLATURE

C-001 GreaseNOTE


Before removal of adapter assembly,check for minimum torque of nut (1). 1. Position driveshaft adapter (3) onIf retaining nut (1) rotates before combining gearbox output shaft (4).attaining mimimum torque of 125 ft.Ibs. (169.475 Nm) (check torque in 2. Install new lockwashers (2). Ensurelocking direction), inspect adapter mating face of lockwasher (2) to adapter is(3) splines (paragraph 63-24). dry (no lubricant allowed).Inspection is not required if nut (1)does not rotate prior to attaining 125 3. Lubricate threads and mating face of nutft. Ibs. (169.475 Nm). (1) to lockwasher (2) using grease (C-001) or

bearing grease (C-007).3. Remove lockwasher (2) and driveshaft bearing grease (-007).adapter (3). 4. Install retaining nut (1) hand tight. Using

suitable marker, mark an index line on outer63-24. Inspection. lockwasher tang and adapter. This will enable

verification lockwasher does not rotate during1. Inspect adapter (3) splines for evidence torquing operation.of corrosion fretting (evidenced by presenceof red dust). 5. Torque nut (1) to 250 to 270 ft. Ibs.

(338.95 to 366.066 Nm) for initial torque.2. Measure internal splines of adapter (3) Loosen nut (1) and then torque 125 to 200 ft.for a maximum dimension between two pins lbs. (169.475 to 271.16 Nm).

63-00-00Rev. 4 Page 43

BHT-212-CR&O

6. Inspect lockwasher (2) to ensure tang 7. Bend tang of lockwasher (2) into a slot ofindexed in step 4. has not rotated. If retaining nut (1).inspection reveals washer has rotated, steps2. through 5. shall be repeated. Newlockwasher is also required.

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BHT-212-CR&O

Figure 63-20. Main driveshaft adapter

63-00-00Page 45/46

BHT-212-CR&O

MAIN ROTOR MAST

63-26. MAIN ROTOR MAST. 6. Press seal (6) from retainer plate (11).Keep shim (12) with retainer plate (11).

63-27. OVERHAUL PROCEDURES. 7. Remove screws (19), lockwasher (17),and oil slinger (22), if installed, from upper

63-28. Disassembly. bearing retaining nut (16).

. At lower end of mast, remove two cotterpins (21) from race retaining nut. UseT101456 wrench to remove lower bearing

NUMBER NOMENCLATURE retaining nut (20).

T100965 Power wrench 9. Use soft drift punch and carefully tapT1 00968 Anchor plate inner race (18) from lower end of mast.

T101303 Socket 10. Reinstall lower bearing retaining nut (20)fingertight to protect mast threads.

T101304 Adapter11. Position T101304 adapter over mast

T101456 Wrench drive splines. Position T101303 socket onupper bearing retaining nut (16). UseT100965 power wrench with T100968 anchor

NOTE plate to break nut torque. Remove tools andAirworthiness upper bearing retaining nut (16).Review Mandatory Airworthiness

Limitations Schedule (BHT-212-MM). 12. Fabricate liner and bearing removalworkaid (figure 63-22). Use workaid to

If main rotor mast is being remove liner (14, figure 63-21) and bearingdisassembled for replacement of (13) as follows:part(s), instead of overhaul,disassemble only to extent a. Install bearing puller plate (1, figure 63-necessary.necessary. 22) on mast, from top of mast, with collar

. down against inner race of bearing.1. Support mast on suitable stand.

2. Remove mast nut (1, figure 63-21) and b. Position bearing holding plate (11),2. Remove mast nut (1, figure 63-21) and from bottom of mast, over bearing and liner.caplug (2). Reinstall mast nut (1) to protect from bottom of mast, over bearing and liner.mast threads. Install bolts and nuts. Tighten until snug.

3. Remove screws (4) attaching shield (5) to c. Place plug (5) on lower end of mastupper bearing retainer plate (11). Remove and install puller (8).shield.

d. Engage legs (4) of puller (8) in slots of4. Remove screw (8) attaching oil jet (9). bearing puller plate (1) and tighten threadedRemove oil jet and packing (10). bolt (10) fingertight.

5. Remove four countersunk screws (15) e. Use suitable wrench to tighten bolt untiland carefully lift retainer plate (11) with seal upper bearing assembly (13, figure 63-21) is(6) from mast. removed from seat.

f. Remove tools from mast.

63-00-00Page 47

BHT-212-CR&O

13. Remove lower bearing retainer nut (20). 2. Support mast on centers and rotate mastwith dial indicator pointer on surfaces A, B,

14. Press bearing outer race from liner (14). and C. Runout shall not exceed values givenin figure 63-23.

63-29. Cleaning. 3. Splines (1, 2, and 3, figure 63-24) mustbe in line, radially, within one-half degree.

MATERIALS REQUIRED

4. Inspect liner (14, figure 63-21) forNUMBER NOMENCLATURE deformation (figure 63-25). Surfaces B and C

C-304 Solvent shall be square with diameter D within 0.001in. (0.0254 mm) TIR. There shall be noevidence of coning or yielding.

1. Clean main rotor mast parts with solvent(C-304). 5. Inspect mast (3, figure 63-21) and liner

(14) by magnetic particle method (BHT-ALL-2. Dry with low pressure, filtered, SPM).compressed air.

6. Failure of mast assembly to conform to3. Use sharp plastic scraper to remove inspection criteria of steps 1. through 5. issealant from retainer plate (11, figure 63-21). cause for rejection.Do not scratch retainer plate.

7. Accomplish Normal Inspection (paragraph63-32), if mast assembly conforms toconditional inspection criteria.

63-30. Inspection.

8. Refer to Airworthiness Limitations (BHT-NOTE 212-MM) for finite life of mast bearing. Inspect

mast bearing, 212-040-136, in accordanceIf records and/or physical with procedures in paragraph 63-32.appearance of main rotor mastindicate assembly has beensubjected to an accident or incident 63-32. Normal Inspection.outside realm of normal usage,perform Conditional Inspection MATERIALS REQUIRED(paragraph 63-31). If main rotormast does not require ConditionalInspection, proceed with Normal NUMBER NOMENCLATUREInspection(paragraph 63-32). C-407 Abrasive Pad

63-31. Conditional inspection.1. Visually inspect mast assembly for wearor damage.1. Visually inspect mast for damage.

Particular attention should be given to areawhich would be contacted by main rotor hub 2. Inspect race (19, figure 63-21) visually forstatic stops. There should be no evidence of spalling, scoring, pitting, brinelling, flaking, oryielding or deformation, corrosion damage.

63-00-00Page 48

BHT-212-CR&O

12

PEEL SHIM FOR0.00 1 TO 0.004 IN

Figure 63-21. Main rotor mast

63-00-00Page 49

BHT-212-CR&O

CL4.75 IN. (120.65 mm)

T Y P

4.733 IN. (120.2182 mm) DIA. BOLTA - +0.001 TO 0.000 IN. 12

CLEAR WELD TO(0.0254 TO 0.0 mm)

TO FULLY CONTACT 0.32 IN. PULLERPULLER PLATE (8.128mm) 1 PLATE

0.03 IN. (0.762 mm) X 45 ° MAX 5.00 N.(127 mm)

1311 BEARING

BEARINGHOLDINGPLATE

PULLERLEGS

4

26.625 IN.(676.275 mm)

2.960 IN. (75.184mm) DIA.+0.000 TO -0.005 IN.(0.0 TO 0.0127 mm)

1.875 IN.(47.62 mm)DIA-

3.00IN. TYP

PLUG

(CARBHONE) 0.24 N. (6.09mm)

TYP

0.50 IN. (12.7 mm)

9

TAP 1/2 (12.7 mm)-13 TYPDRILL 5/8 IN. (15.875 mm) DIA. 8

C BOLT (THREAD PULLER CAS SHOWN)

212-R-63-22

Figure 63-22. Main rotor mast bearing workaid (sheet 1 of 3)

63-00-00Page 50

BHT-212-CR&O

PULLER

Figure 63-22. Main rotor mast bearing workaid (sheet 2)

63-00-00Page 51

BHT-212-CR&O

SF

VIEW C-CLOOKING UP

NOMENCLATURE REQ'D MATERIAL SIZE

1 Puller plate 1 Al. plates 1 1/2 x 6 1/4 x 12 1/4 IN.(38.1 x 158.75 x 311.15 mm)

2 Weld assembly 2 Weld Assy of Det's 3 & 4

3 Rod 1 C.R.S. 1/2 Dia. x 2 1/8 IN. Lg.(12.7 x 53.975 mm)

4 Puller legs 1 C.R.S. 1/2 Dia x 26 3/4 IN. Lg.(12.7 x 679.45 mm)

5 Plug 1 H.R.S. 4 Dia x 2 5/8 IN. Lg.(101.6 x 66.675 mm)

6 Plug 1 H.R.S. 2 Dia x 2 1/8 IN. Lg.(50.8 x 53.975 mm)

7 Plate 1 H.R.S. 3/4 x 2 x 7 1/8 IN.(19.05 x 50.8 x 180.475 mm)

8 Puller 1 Weld Assy of Det's 6 & 7

9 Pin 2 STD 1/4 Dia x 1 1/2 IN. Lg.(6.35 x 38.1 mm)

10 Bolt 1 STD 1/2 - 13 x 4 IN. Lg.(12.7- 13 x 101.6 mm)

11 Bearing holding plate 1 A1. A1. 3/4 x 9 x 9 IN.(19.05 x 228.6 x 228.6 mm)

12 Bolt 2 STD 1/4 - 20 x 3 1/4 IN.(6.35 - 20 x 79.375 mm)

13 Nut 2 STD 1/4 - 20 IN.(6.35 x 20 mm)

NOTES

1. Break all sharp edges.

2. Match so as to be symmetrical about centerline for balanced pull.

3. Cadmium plate all steel parts. 212-R-63-22-3

Figure 63-22. Main rotor mast bearing workaid (sheet 3)

63-00-00Page 52

BHT-212-CR&0

cuts, the result will likely be prematureCAUTION bearing failure and is cause for replacement.

d. Bearing races showing signs ofDO NOT HANDLE BEARING BALLSDO NOT HANDLE BEARING BALLS corrosion in ball path are still consideredAND RACES WITH BARE HANDS usable if corrosion is limited to stains whichBODY ACID CAUSING ETCHING exhibit no visible depth when viewed with aBODY ACID CAUSING ETCHINGR E S U L T I N G E A R LY 4X glass. Corrosion outside loaded ball pathCOMPONENT FAILURE. OIL is acceptable if limited to less than 10% ofBEARINGS AFTER INSPECTION total bearing surface and cannot be felt with aAND PLACE IN A CLEAN PLASTIC probe having an end radius of 0.020 in.BAG 0 R W RA P W I TH (0.508 mm). Remove acceptable corrosionPROTECTIVE PAPER. with abrasive pad (C-407). Polishing of balls

or load area of races is prohibited.3. Inspect mast (3, figure 63-21) visually foryielding or deformation in area contacted bymain rotor hub static stops. CAUTION

4. Inspect mast for nicks, dents, scratches,or corrosion damage (figure 63-24). Inspect DO NOT HANDLE BEARING BALLSfor nicks and scratches with particular AND RACES WITH BARE HANDSattention to radius and area just above upper DUE TO THE POSSIBILITY OFbearing and tapered section below upper BODY ACID CAUSING ETCHINGbearing. RESULTING IN EARLY

COMPONENT FAILURE. OIL5. Inspect bearing, 212-040-136, as follows: BEARINGS AFTER INSPECTION

AND PLACE IN A CLEAN PLASTICa. Inspect bearing (13, figure 63-21) for BAG OR WRAP WITH

evidence of debris damage (indentations) in PROTECTIVE PAPERinner and outer races.

e. Brinelling damage (indentations inNOTE races corresponding to ball spacing) is cause

for replacement.Debris damage will eventually resultin bearing failure and is cause forreplacement. NOTE

b. Inspect inner and outer races for False brinelling is visually evidencedevidence of microspalling in loaded ball path. by minute scratches along bore axisMicrospalling is cause for replacement. of races and usually is caused by

vibrations during shipment. Unlessthis brinelling shows signs of

NOTE noticeable depth, which can be feltwith a surface roughness probe

Microspalling will appear as small having a 0.030 in. (0.762 mm)pits or blisters in the ball path. Use a radius, it is not cause for4X glass to observe this area for replacement.microspalling. Microspalling is aprogressive failure mode and willeventually result in premature failure 6. Inspect retainer plate (11, figure 63-21)of race. for corrosion, scratches, nicks, or damage to

retaining stud holes, especially in area of sealc. Inspect balls of bearing for cuts which seat. Any evidence of pitting is cause for

may indicate excessive angle. If balls exhibit rejection.

63-00-00Rev. 4 Page 53

BHT-212-CR&0

7. Inspect oil jet for damage or deformation MATERIALS REQUIRED (CONT)and cracks. Inspect oil passage in retainerplate (11) for clogging.

NUMBER NOMENCLATURE

8. Inspect parts for any indication of C-203 Lacquerexcessive wear. Dimensionally check, asrequired (figure 63-23). C-204 Primer

9. Inspect shield (5, figure 63-21) and C-206 Thinnerlockwasher (17) for deformation, mechanical C-221 Phosphatize Materialdamage, and corrosion.

C-304 Solvent10. Inspect nuts (1, 16, and 20) fordamaged threads. C-406 Aluminum Oxide Cloth

11. Perform fluorescent penetrant C-407 Abrasive Padinspection on retainer plate (11) (BHT-ALL- C-500 Crocus ClothSPM).

C-411 Steel Wool12. Perform magnetic particle inspection onthe following parts. Demagnetize parts after C-423 Abrasive Cloth ormagnetic particle inspection (BHT-ALL-SPM). Paper

Figure and Nomenclature C-435 Paint RemoverIndex No.

C-464 India Stone

63-21, 1 Mast nut C-470 Glass Beads63-21, 3 Mast63-21, 14 Liner63-21, 16 Retaining nut63-21, 17 Lockwasher CAUTION

63-21, 20 Retaining nut63-21, 22 Slinger MAST MAY BE REWORKED ONE

TIME ONLY. CHECK FOR WORD"REWORKED" VIBRO-ETCHED ONLOWER BEARING FLANGE. IF

63-33. Repair. MAST IS ALREADY MARKED, IT ISNOT SUITABLE FOR REWORK.

MATERIALS REQUIRED 1. Dress mast splines with fine India stoneRefer to BHT-ALL-SPM for specification and (C-464) to blend out burrs or small nicks andsource. scratches.

NUMBER NOMENCLATURE 2. Polish out nicks, dents, scratches, orcorrosion (figure 63-23). Use fine to medium

C-108 Brush Cadmium aluminum oxide cloth (C-406) or fine andPlating Solution final polish to a scratch-free finish with crocus

cloth (C-500).C-112 Cadmium Chromate

Conversion Coating

C-202 Primer

63-00-00Page 54 Rev. 4

BHT-212-CR&O

MIN. MAX

ITEM NOMENCLATURE INCHES MILLIMETERS INCHES MILLIMETERS

1 Liner - thrust bearing ID 6.6919 169.97426 6.6929 169.999662 Mast - bearing seat OD 4.3307 109.99978 4.3315 110.0201

3 Liner - roller bearing ID 4.9987 126.96698 5.0003 127.007624 Bearing - roller OD 4.9984 126.95936 4.9990 126.9746

ID 3.4995 88.8873 3.5001 88.902545 Mast - bearing seat OD 3.5003 88.90762 3.5012 88.930486 Splines - drive Over pins 4.2913 108.99902 4.2962 109.12348

(Use 0.1920 in. (4.8768 mm)dia. pins) Over pins 4.0760 103.5304 4.0961 104.04094

7 Splines - rotor(Use 0.1920 in. (4.8768 mm)dia. pins)

NOTE

TIR run-out check not required at normal overhaul, but is required if crash damage, overtorque, overspeed or

hard landing is recorded, suspected or evident.

Run-out limits using lathe, mast supported on mast centers:

Surface = A B C

Max. TIR = 0.0025 IN. 0.006 IN. 0.0045 IN.(0.0635 mm) (0.1524mm) (0.1143 mm) 212R6323

212-R-63-23

Figure 63-23. Main rotor mast wear limits

63-00-00Page 55

BHT-212-CR&O

c. Make area to be plated the cathode.CAUTION Pour a small amount of brush cadmium

.T**** ***********. plating solution (C-108) into a dish or beakerand saturate wrapped anode with solution.

ONLY STEEL WOOL (C-411) MAY Brush cadmium plate by applying saturatedBE USED TO REMOVE anode to area to be plated in circular or figureCORROSION FROM AREA A, eight motions while applying and adjustingFIGURE 63-24. NO OTHER voltage required of stylus and anode beingMETHOD IS PERMISSIBLE. used. Continue until a uniform plate and

complete coverage is obtained to produce a3. Strip organic finish from internal diameter minimum plating thickness of 0.0005 in.of mast using No. 30 glass beads (C-470) or (0.0127 mm). Thoroughly rinse plated areaplastic media method. with water and cheesecloth or clean rag. Dry

thoroughly.

NOTE 6. After brush cadmium plating, applyAny internal corrosion removed in chromate finish as follows:accordance with limits shown onfigure 63-24 shall be accomplished a. Apply cadmium chromate conversionby honing. Honed area shall be coating (C-112) to external surfaces byblended into surrounding area using swabbing. Allow material to remain ona minimum radius of 0.25 in. (6.35 surface for 30 seconds.mm).

b. Apply cadmium chromate conversion4. Remove internal corrosion on mast as coating (C-112) to entire internal surface byrequired by honing. Reject mast if not within immersion or swabbing. Allow material toallowable rework limits (figure 63-24). remain on surface 10 to 20 seconds.

5. Use brush cadmium plating solution (C- c. Thoroughly rinse with water and dry108) to plate internal diameter and required immediately.areas as follows:

a. Use portable plating unit (or NOTEequivalent), with voltage control, capable of Cleanup limited to external surfaceproducing output of 0 to 15 amps at 0 to 20 corrosion, which can be removedvolts. with steel wool, does not require

mast be marked "REWORKED".

~~~NOTE 7. Mark mast, if required, on lower bearingBaking is not required after brush flange with the word "REWORKED", using acadmium plating solution (C-108) is vibrating stylus.applied.

b. Mask off areas surrounding area to be CAUTIONplated utilizing any good commercial plating ,»***tape. Remove oils, grease, or othercontamination from surface to be plated by DO NOT USE ZINC CHROMATEwiping with cheesecloth or clean rags wetted PRIMER ON MAST AREASwith solvent (C-304). If light oxide is present CONTACTED BY TRANSMISSIONon the surface, lightly abrade with 320 grit or LUBRICATION OIL.lighter abrasive cloth or paper (C-423) prior tosolvent cleaning. 8. After cleanup, all external surfaces of

mast, except data plate, threads, splines, andsurface below area E (figure 63-24) of

63-00-00Page 56

BHT-212-CR&O

10.6 TO 10.8 IN.(269.24TO 274.32 mm) 7.30 TO 7.50 IN.

5.50 TO 5.70 IN. (185.42 TO 190.50mm)

(139.7 TO 144.78 mm)

E -A-- B--C--D-A2 3 EDGE OF -- 1.42 IN. (36.068 mm)

3 SHOT PEEN

F G--G H34.0 IN. (863.6 mm)36.0 IN. (914.4 mm)

MAST CORROSION AND MECHANICAL DAMAGE LIMITS

OUTSIDE DIAMETER

MAXIMUM ALLOWABLE DEPTH OF REWORK

AREA A - Superficial corrosion. Only that which can be removed bysteel wool.AREA B - 0.002 in. (0.0508 mm).AREA C - 0.015 in. (0.381 mm).AREA D - 0.020 in. (0.508 mm).AREA E - 0.010 in. (0.254 mm). Local cleanup.

INSIDE DIAMETER

AREA F - See table below:

NOTE

Table for maximum allowable inside diameter in area F for various outer diameters, atstations measured in inches and millimeters from the top of mast.

If Outer Diameter Measures 3.545 IN. 3.550 IN. 3.555 IN.(90.043 mm) (90.17 mm) (90.297 mm)

Maximum l.D. (Station 0 to 10) 2.980 IN. 2.988 IN. 2.996 IN.(75.692 mm) (75.8952 mm) (76.0984 mm)

Maximum I.D. (Station 10 to 20) 2.976 IN. 2.982 IN. 2.988 IN.(75.5904 mm) (75.7428 mm) (75.8952 mm)

Maximum I.D. (Station 20 to 34) 2.970 IN. 2.976 IN. 2.982 IN.(75.438 mm) (75.5904 mm) (75.7428 mm)

212-R-63-24-1

Figure 63-24. Main rotor mast damage limits (sheet 1 of 2)

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BHT-212-CR&O

AREA G - 2.970 in. (75.438 mm) maximum I.D.

AREA H - 0.005 in. (0.127 mm) - Or to a maximum l.D. of 2.980 in. (75.692 mm). Provided cleanup isaccomplished by honing or similar method, so that material removal is uniform.

AREA J - The mast may be reworked, one time only, unless the rework involves only surface corrosion removal.After cleanup, mark the word REWORKED on the flange at J, using a vibrating stylus. (If cleanup waslimited to the removal of surface corrosion, that required only steel wool for removal, then it is notnecessary to mark the mast Reworked.)

AREA K - 0.002 in. (0.0508 mm) O.D.

NOTE

Damage must be completely removed; within allowable cleanup depth, for mast to beacceptable. Finish reworked areas to 32 RMS. 212-R-63-24-2

Figure 63-24. Main rotor mast damage limits (sheet 2)

external surface shall have surface protective 9. Apply surface coating to internal diametercoating applied as follows: of mast as follows:

a. Remove all external surface finish a. Install tapered plug (nonmetallic) inusing paint remover (C-435) or thinner (C- mast lower end. Flow primer (C-202) into206); then clean with commercial soap, water bore while rotating mast (spraying isrinse thoroughly, and dry with clean, lint-free permissible). Ensure coverage of all internalcloth. surfaces.

b. Mask data plate, threads, splines and b. Position mast upright, remove plug andsurface below area E (figure 63-24) with drain excess primer. Allow remaining primerplating tape. to air dry.

c. Apply phosphatize material (C-221) inaccordance with manufacturers instructions. 63-34. Assembly.

MATERIALS REQUIREDd. Spray or brush one coat of primer (C- MATERIALS REQUIRED204) and two coats of aluminized color No.17178, acrylic lacquer (C-203) on unmasked NUMBER NOMENCLATUREexternal surfaces of mast.

C-010 Lubricating Oil

e. Remove plating tape and use nylon C-101 Corrosion Preventiveweb abrasive pad (C-407) to remove any Compoundprimer or phosphate, if present, from surfaceswhich were masked. C-308 Adhesive

63-00-00Page 58

BHT-212-CR&O

DIA E SURFACE C

SURFACE A

DIA D

SURFACE F SURFACE B

DETAIL A

SURFACE A, B Corrosion and mechanical damage is permitted to a depth of 0.005 inchAND DIAMETER E (0.127 mm) provided no more than 40 percent of the area in any one inch square

(645.2 sq mm) nor more than 40 percent of the total area is affected.

SURFACE C AND Superficial corrosion. Only that which can be removed by steel wool.DIAMETER D

Mechanical damage is permitted to a depth of 0.002 inch (0.508 mm) providedthe damage is polished to a minimum blend radius of 0.25 inch (6.35 mm) and allraised material is removed. Rework shall be controlled to maintain squareness ofsurface C to diametered D within 0.001 inch (0.0254 mm) T.I.R.

SURFACE F Corrosion and mechanical damage is permitted to a depth of 0.020 inch (0.508mm) provided the damage is polished to a minimum blend radius of 0.25 inch(6.35 mm)

NOTE

Damage shall be completely removed, within allowable cleanup depth, for liner to be acceptable.Finish reworked areas to 32 RMS.

212-R-63-25

Figure 63-25. Main rotor mast liner damage limits

63-00-00Page 59

BHT-212-CR&O

MATERIALS REQUIRED (CONT) lower bearing inner race (18) withlubricating oil (C-010) beforeassembly.

NUMBER NOMENCLATURE

C-405 Lockwire 1. Coat inner surface of liner (14) withtransmission oil and press outer race of upperbearing (13) into liner (14).

SPECIAL TOOLS REQUIRED2. Determine thickness of shim (12) requiredbetween outer race and lip of retainer plate

NUMBER NOMENCLATURE (11) to provide 0.001 to 0.004 in. (0.0254 to0.1016 mm) pinch fit when assembled as

T100965 Power wrench followsfollows:T100968 Anchor plate

a. With a depth gauge, measureT101303 Socket dimension from mounting face of liner to top

of bearing outer race (dimension A, figure 63-T101304 Adapter 26).

T101456 Wrenchb. Measure dimension from mounting face

of retainer plate to bottom of lip which willextend into liner when assembled (dimension

~~~NOTE B, figure 63-26).To avoid corrosion damage, avoidhandling unoiled bearings. Coat c. Subtract dimension B from dimension Aupper bearing (13, figure 63-21) and and add 0.001 to 0.004 in. (0.0254 to 0.1016

mm)for pinch fit. Peel shim to required

RETAINER PLATE

SHIM

BEARING OUTER RACE

LINER 212-R-63-26

Figure 63-26. Mast upper bearing shimming measurement

63-00-00Page 60

BHT-212-CR&O

thickness and keep with retainer plate for 7. Position T101304 adapter over mast driveassembly. splines and T101303 socket on upper bearing

retaining nut (16). Using T100965 power3. With mast suitably supported, coat mast wrench kit, with T100968 anchor plate, tightenbearing journal and threads with transmission nut to low side of required 2000 to 2500 ft.lbs.oil. (2711.6 to 3389.5 Nm). Remove tools.

4. If not previously accomplished, fabricatebearing installation workaid (figure 63-27). NOTE

During seating and torquing5. Use workaid to install upper bearing procedure, rotate bearing outer raceassembly (13, figure 63-21 and figure 63-27). to check for freedom of operation.

a. Place bearing on mast and push 8. Place lockwasher (17) and oil slinger (22),against seat with slight pressure. if equipped, over mast drive splines and

secure to upper bearing retaining nut (16)b. Install threaded cap with stud over with screws (19). Secure screw heads to each

lower end of mast. other with lockwire (C-405).

c. Position pressing tool (1, figure 63-27)over mast and seat against inner race of NOTEbearing with three spring-loaded boltscontacting liner on outer race. If screw holes do not align, repeat

step 7. to tighten nut as necessaryd. Install washers and nuts on stud of within torque limits.

threaded cap.9. Carefully apply adhesive (C-308), on allsurfaces where seal (6) will seat into retainerplate (11). Press seal, with lip up, into place.

CAUTION Clean off excess adhesive. Ensure four drain

ALIGN MATCH MARKS OFBEARING INNER RACES (SMALL 10. Install shield (5) and secure to top of"0" ON OUTBOARD SIDE OF retainer plate (11) with two screws (4).INNER RACES) AND KEEPALIGNED U NTIL BEARIN G IS 11. Place previously prepared shim (12) inSEATED. ROTATE OUTER RACE liner (14) on outer race of upper bearing.TO DETERMINE IF BEARING IS Coat lip of oil seal and seal surface on mastBINDING. with transmission oil. To avoid damaging seal

on mast splines, carefully install retainer platee. Hand restrain bearing while seating (11) on mast. Secure bearing liner (14) to

bearing in place by tightening nut on stud of retainer plate (11) with four countersunkthreaded cap with a suitable wrench. screws.

f. Remove nut and washers from stud of 12. Coat top threads of mast with corrosionthreaded cap. Remove balance of workaid preventive compound (C-101) and installdetail parts. plastic cap plug (2) and mast nut (1) on mast.

6. Lubricate retaining nut (16, figure 63-21) 13. Remove lower bearing retaining nut (20)with transmission oil and install hand tight and carefully tap lower bearing inner racewith splined flange down. Install lower (18) onto seat at lower end of mast. Reinstallbearing retaining nut (20) to protect mast retaining nut (20) with T101456 wrench..threads. Torque nut 250 to 300 ft.lbs. (338.95 to

406.74 Nm), aligning two nut slots with holes

63-00-00Page 61

BHT-212-CR&O

CHAMFER UP ON

(VIBRO ETCHED ON RACE)DETAIL A

5

WELD

1. Pressing tool24.0 IN. 2. Plate(609.6 mm) 3. Tube

4. Collar5. Nut

3 6. Washer7. Spring8. Bolt9. Plate

10. Nut4.13IN. 11. Washers(104.902 mm) ID 12. Bolt

4.0 IN. MAST(101.6 mm) KNURL OUTSIDE SURFACE

; 0.375 IN.3.50 IN.(88.9 mm)

0.75 IN.

PER MIL-S-7742 (19.05mm)

0.50 IN.(12.7 mm) HOLE

212-R-63-27-1204-040-366V

Figure 63-27. Mast liner and bearing installation workaid (sheet 1 of 2)

63-00-00Page 62

BHT-212-CR&O

0.250 ± 0.001 IN. 6.60 IN. (167.64 mm)(6.35 ± 0.0254 mm) DIA. BOLT CENTERTYPICAL LT CNTE 0.05 IN. X 45 °

(1.27 mm) 0.250IN.

(101.6 mm)

ITEM REQ'D MATERIAL

1 1 Welded assembly of items 2, 3 and 4

2 1 Al. plate 1/2 X 4-1/2 IN.(12.7 X 114.3 mm) dia.

3 1 Al. tube 4-1/2 dia. X 0.237 X 19-3/4 IN. Ig.(114.3 dia. X 6.0198 X 501.65 mm Ig.)

4 1 Al. cube or rod 8 X 8 X 4-18 IN. NOTES(203.2 X 203.2 X 104.775 mm)

5 3 NAS679A4 Nut A Bolt threaded full length.

6 9 AN960-416 Washer 2. Break all sharp edges.

7 3 MS24585 Helical spring

8 3 AN4-30 Bolt

9 1 Corrosion resistance steel plate 4 IN. x 7/8 IN.(101.6 X 22.225 mm) welded assemblyof 9 and 12

10 1 AN315-8 Nut

11 2 1/2 IN. (12.7 mm) Washer

12 1 AN8-33A BoltA 212-R-63-27-2

Figure 63-27. Mast liner and bearing installation workaid (sheet 2)

63-00-00Page 63

BHT-212-CR&0

at opposite sides of mast. Insert two cotter oil. Install No. 8 oil jet, and secure in placepins (21) with splits horizontal, from inside with screw (6) (figure 63-21). Secure screwmast. Bend both ends of each cotter pin with lockwire (C-405).down and in against mast end, to lie below orflush with outer surface of nut. 15. Install cap assembly (7).

14. Install new packing (10) on No. 8 oil jet 16. Check upper mast bearing for free(9) and coat jet and packing with transmission rotation.

63-00-00Page 64

BHT-212-CR&O

TRANSMISSION

63-35. TRANSMISSION. disassemble only to extentnecessary.

NOTE

Transmission 212-040-001-059, -141 CAUTIONand sub. incorporate a fourth quillport in main case, two additionalchip detectors (one in top case and BEFORE PROCEEDING WITHone in main case), a lift link fitting DI S A S S E M B L Y OFmounted on support case, and a TRANSMISSION, CHECKcollector attached to main input HISTORICAL RECORDS ANDdriven gear quill and top case. PHYSICAL APPEARANCE FOR

INDICATION OF ACCIDENT ORINCIDENT OUTSIDE OF NORMAL

63-36. OVERHAUL INSTRUCTIONS. USAGE. IF SUCH EVIDENCE ISPRESENT, REFER TO

Unless otherwise noted in text or illustrations, CONDITIONAL INSPECTION,the following overhaul instructions apply to all PARAGRAPH 63-39.dash number transmissions installed in Model212 helicopters. DO NOT USE ANY METALLIC

DRIFTS FOR DISASSEMBLY ORREASSEMBLY OF COMPONENTS,

*63-37. Disassembly. SUCH AS BEARINGS, RACEWAYS,SLEEVES, ETC.

SPECIAL TOOLS REQUIRED1. Remove oil hoses (17 and 34, figure 63-28) supporting clamps (18), elbow (28), and

NUMBER NOMENCLATURE nut (29).

T100929 Jackscrew set2. Remove electrical cable harness as

T101308 Jackscrew set follows:

T101338 Jackscrew set a. Disconnect connector fromT101586 Pusher set transmission oil pressure transmitter (2, figure

63-29).204-040-001-3 Backlash toolGIF-1, Detail 54 b. Disconnect connector from

transmission oil pressure switch (1).204-040-001-17 Backlash tool

PAT- Disconnect wires from ground stud (4).

212-040-001-19 Backlash toolGIF-1 d. Disconnect wire thermoswitch (3).

e. Remove connector from transmission

NOTE oil temperature bulb (5).

If transmission is being f. Remove cable clamp at bracket (6).disassembled for replacement ofpart(s) instead of overhaul, g. Remove P-41 plug (7) from connector.

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BHT-212-CR&0

h. Remove cable clamp at bracket (8). T101338 and tighten evenly to pull quill fromcase. Remove packing (88).

i. Remove P-35 connector (9) from rotortachometer generator (10). 9. Refer to paragraph 63-84 for overhaul of

hydraulic pump drive quill.j. Remove cable clamps (11 and 12).

10. Remove tube assembly (8, figure 63-31),k. Remove wire from chip detector (13). elbow (9), nut (10) and packing (11). Remove

tube assembly (47), elbow (46), nut (45), andI. Remove electrical cable (14) from packing (44).

transmission.11. Remove oil pressure valve assembly

m. Remove upper mast chip detector (75) from manifold (92). Remove packingconnector (15, figure 63-30). (74) from valve assembly.

n. Remove planetary chip detector 12. Remove screws and seals from ends ofconnector (16). oil jets (14, 34, 40 or 41, 51 or 52, 76 and

88). Remove oil jets and remove packingso. Remove brackets and clamps (17) from from oil jets. Discard packings.

transmission.13. Remove two elbows (6), nuts (5) and

3. Remove tubes (14 and 22, figure 63-28), packings (4) from auxiliary oil jets.supporting clamp (24), elbow (13), nut (12),packing (11), union (30), and packing (31). 14. Remove manifold (29). Remove spacer

(22). Remove union (30) and packing from4. Remove neck and scupper assembly (1). manifoldSupporting bracket (7) will be removed in asubsequent step. Remove filler cap adapter 15. Remove manifold (92) and gasket (93).

and gasket (21). from manifold.

6. Remove tube (23), elbow (27), and nut 16. Remove tube (68). Remove packings(28). Remove packing from elbow (27). (67 and 69) from tube.Remove cap (19), bolt (18), and elbow (17).Remove packings from bolt and elbow.

17. Remove main input quill (60 or 61) from

7. Remove cover (93, figure 63-32). Cut7. Remove cover (93, figure 63-32). Cut aft side of main case. Cut sealant aroundsealant around flange with sharp plastic flange wth sharp plastic scraper. Removescraper. Remove bolts (96) and washers (94 nutsand washers (56,57, and 58) and

bracket (59). Install T101308 jackscrew setand 95). Use T101338 jackscrew set to pull bracket (59). InsallT101308jackscrew setcover from case. Tighten jackscrews evenly and tighten evenly to pull quill from case.cover from case. Tighten jackscrews evenly

pull cover (93)from case Remve ackn Remove oil tube (64 or 65) and packings (62to pull cover (93) from case. Remove packing(92). Also remove fourth quill port cover in or 63) Remove s (66) from quill.

Discard packings.same manner.

8. Remove hydraulic pump drive quill (87) 18. Refer to paragraph 63-60 for overhaul offrom front side of main case. If cover (85) is main input quill.installed, remove nuts, washers, cover (85),and gasket (86). Cut sealant around quill with 19. Remove top case (4, figure 63-32). Cutsharp plastic scraper. Remove bolts which sealant at mating flange of top case and ringsecure quill (87) to case. Install jackscrews gear with a sharp plastic scraper, also cut

sealant at lower side of ring gear at matingpoint with input quill and main case. Remove

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1. Neck and scupper 19. Screw2. Filler cap 20. Washer3. Adapter 21. Nut4. Aluminum washer 22. Tube5. Bolt 23. Screw6. Steel washer 24. Clamp7. Bracket 25. Bracket8. Aluminum washer 26. Washer9. Steel washer 27. Nut

10. Nut 28. Elbow11. Packing 29. Nut and packing12. Nut 30. Union13. Elbow 31. Packing14. Tube 32. Nut15. Adapter 33. Washer16. B-nut 34. Hose17. Hose 35. B-nut18. Clamp 212-R-63-28

Figure 63-28. Transmission external components

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BHT-212-CR&O

1. Oil pressure switch 8. Bracket2. Oil pressure transmitter 9. P-35 connector3. Thermoswitch 10. Tachometer generator4. Ground stud 11. Clamp5. Oil temperature bulb 12. Clamp6. Bracket 13. Chip detector7. P-41 plug 14. Electrical cable 212-R-63-29

Figure 63-29. Transmission electrical (prior to 212-040-001-059)Figure 63-29. Transmission electrical(pri orto 212-040-001-059)

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BHT-212-CR&O

5. Oil temperature bulb 11. Clamp and brackets (71 are installed at thesemplocations on upper face of ring gear case.

1. Oil pressure switch 7. P-41 plug 13. Chip detector2. Oil pressure transmitter 8. Bracket 14. Electrical cable3. Thermoswitch 9. P-35 connector 15. Upper mast chip detector4. Ground stud 10. Tachometer generator 16. Planetary chip detector5. Oil temperature bulb 11. Clamp 17. Bracket and clamp6. Bracket and clamp 12. Clamp 212-R-63-30

Figure 63-30. Transmission electrical (212-040-001-059 and sub.)

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BHT-212-CR&O

FWD 20

56 .6. 46. Nut

1.4. Packing5. Nut 526. Elbow 46. Elbow7. Screw 47. Tube

9. Elbow10. Nut11. Packing

13. Packing 65 53. Dyna-sea1(86579)14. Jet No. 5 63 54. Screw15. Dyna-seal (86579) 55. Screw16. Screw 31. Manifold 56. Nut17. Elbowandtwo packings 32. Packing 57. Washer, steel

18. Bolt 33. Packing 58. Washer, aluminum

19. Cap 34. Jet No. 2 59. Bracket

20 Breather vent 35. Dyna-seal (86579) ain input quill (P/N 212-040-363)

21. Gasket 36. Screw(two) 61. Main input quill (P/N 212-040-263-101)

22. Spacer 37. Screw 62. Packing23. Tube 38. Screw 63. Packing(2)24. Identification plate 39. Dyna-seal (86579) 64. Tube

25. Data plate 40. Jet No. 65. Tube (P/N 214-040-780)

26. Nut 41. Jet No. 1 (P/N 212-040-261) 66. Packing (2)27. Elbow and packing 42. Packing28. Nut 43. Packing NOTE29. Manifold 44. Packing30. Union and packing 45. Nut Used on P/N 212-040-001-059, -141 and subsequent transmissions

212-R-63-31-1

Figure 63-31. Transmission jets, manifolds, and main input quill (sheet 1 of 2)6

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BHT-212-CR&O

68. Tube 84. Washer69. Packing 85. Bolt70. Thermoswitch 86. Screw71. Packing 87. Dyna-seal (86579)_6 9172. Packing 88. Jet No. 373. Packing 89. Packing

74. Packing 90. Packing75. Oil pressure valve 91. Packing76t No.7 92. Manifold

77. Dyna-seal (86579) 93. Gasket78. Screw (2) 94. Packing

79. Washer 95. Packing

80. Bracket 96. Packing81. Washer 97. Thermobulb

67. Packing 83. Bracket68. Tube 84. Washer

82. Packing 85. Bolt70. Thermoswitch 86. Screw71. Packing 87. Dyna-seal (86579)72. Packing 88. Jet No. 373. Packing 89. Packing74. Packing 90. Packing75. Oil pressure valve 91. Packing

21 2-R-63-31 -276Figure 63-31.Transmission jets, manifolds, anifold main input quill (sheet 2)77. Dyna-seal (86579) 93. Gasket78. Screw (2) 94. Packing79. Washer 95. Packing80. Bracket 96. Packing81. Washer 97. Thermobulb82. Bolt

212-R-63-31-2

Figure 63-31. Transmission jets, manifolds, and main input quill (sheet 2)

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4 13

1.Used in P/N 212-040-001-059, -141 4

10. Liner 20. Liner 30. Jet housing 40. Bolt1 Used in P/N 212-040-001-059, -141 46and subsequent transmissions.1. Controls spring bracket 4 37

2. Screw3. Washer 44

5. Packing6. Retainer ring 47. Upper planetary8. Mast driving adapter 18. Packing 28. Aluminum washer 38. Steel washer9. Upper bearing 19. Aluminum washer 29. Aluminum washer 39. Nut

10. Liner 20. Liner 30. Jet housing 40. Bolt11. Upper sun gear 21. Lower bearing 31. Gasket 41. Washer12. Retainer ring 22. Bearing liner 32. Steelwasher 42. Gasket13. Oildeflector 23. Lower sun gear 33. Steelwasher 43. Jet housing14. Lower planetary 24. Packing 34. Nut 44. Aluminum washer15. Bolt 25. Oiltube 35. Cotter pin 45. Aluminum washer16. Steelwasher 26. Bolt 36. Ring gear 46. Steel washer17. Chip detector 1 27. Steelwasher 37. Packing 47. Bolt 212-R-63-31-1

Figure 63-32. Transmission and quills (sheet 1 of 3)

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BHT-212-CR&O

58

948

49 50

64

48. Main input driven gear quill

49. Packing51. Steel washer

55. Main case (P/N 212-040-053 shown)Aluminum washer56. Chip detector

57. Packing58. Cotter pin

60. Steel washer 77 Nut61. Offset accessory drive quill 78. Accessory drive sump62. Retainer ring 79. Aluminum washer 7963. Mast guide ring 80. Steel washer64. Lower mast bearing 81. Nut65. Packing 81. 078 8066. Plug 82. Lift link fitting

(used on support case67. WasherP/N 212-040-054-013) 81

69. Support case(P/N 212-040-054-001. -005)

70. Aluminum washer71. Steel washer72. Nut73. Tail rotor drive quill adapter Used in P/N 212-040-001-059, -141 and subsequent

transmissions. 212-R-63-32-2

Figure 63-32. Transmission and quills (sheet 2)

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DETAIL VIEW B

83 91

DETAIL VIEW A

83. Nut 90. Steel washer84. Washer 91. Bolt85. Cover 92. Packing86. Gasket 93. Cover87. Hydraulic pump drive quill 94. Aluminum washer88. Packing 95. Steel washer89. Aluminum washer 96. Bolt

212-R-63-32-3

Figure 63-32. Transmission and quills (sheet 3)

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sixteen bolts (15), washers (16) and washers set and tighten evenly to pull quill from case.(19) which attach top case to ring gear (36) Remove packing (49) from quill.0y and also remove controls spring bracket (1).Remove three screws (2) and use T100929 28. Refer to paragraph 63-60 for overhaul ofjackscrew set to pull top case from ring gear. main input quill.Tighten jackscrews evenly to pull case fromring gear. Remove oil tube (25) and packings 29. Remove nuts (50), washers (51), and(24). Remove packing (5) from top case.(24). Remove packing (5) from top case. washers (52) which secure main case (55) to

support case (69). Cut sealant with sharp20. Refer to paragraph 63-45 for overhaul of plastic scraper. Use T101308 jackscrew settop case. and tighten evenly to separate main case

from support case. Remove packing (54)21. Lift upper planetary assembly (7) with from case.mast driving adapter (8), upper bearing (9)and liner (10) out of ring gear as a unit. 30. Refer to paragraph 63-45 for overhaul ofRemove retainer ring (6) and separate mast main case.driving adapter (8), bearing (9) and liner (10).Remove upper sun gear (11). RemoveRemove upper sun gear (1 1). Remove 31. If component has been subjected toretainer ring (12) and oil deflector (13).retainer ring (12) and oil deflector (13). accident or incident, visually inspect gears for

cracked or chipped teeth. Visually inspect22. Refer to paragraph 63-53 for overhaul of dowels between main case and support caseupper planetary. for shearing. If cracked or chipped gear teeth

in the main rotor drive train are found and/or23. Remove bolts (40) and washers (41) more than one dowel is sheared (indicative ofwhich attach ring gear (36) to main case and torsional overload), entire component shall beremove neck and scupper support bracket (7, considered nonairworthy and nonreparable.figure 63-28). Cut sealant with sharp plasticscraper and tap ring gear lightly with plastic 32. Remove nuts (59) and washers (60) andor rawhide mallet to separate it from main remove offset accessory drive quill (61) fromcase. Remove packing (37, figure 63-32) top of support case (69). Remove tail rotorfrom ring gear. drive quill adapter (73). Remove retainer ring

(62), mast guide ring (63), lower mast bearing24. Remove three jet housings (30 and 39, (64), and packing (65). Remove setscrewfigure 63-32) from ring gear. Remove gaskets (68) with washer (67) and push plug (66)(31 and 42) from jet housings. upward out of case. Discard packing.

25. Lift lower planetary (14) out of 33. Refer to paragraph 63-90 for overhaul oftransmission. Remove and separate liner offset accessory drive quill.(20), lower bearing (21), and bearing liner(22). Remove lower sun gear (23). 34. Rotate stand support and transmission

ninety degrees to horizontal position.26. Refer to paragraph 63-53 for overhaul oflower planetary. 35. Remove nuts (81, figure 63-32) and

washers (79 and 80). Tap accessory driveNOTE and sump (78) with plastic (or other non-

metallic) mallet to remove from support case.Ensure manifold (figure 63-33) is Remove gasket (74).removed prior to removing maininput gear quill (48, figure 63-32). 36. Refer to paragraph 63-96 for overhaul of

accessory drive and sump.27. Remove main input gear quill (48) fromtop of main case. Use T100929 jackscrew 37. Remove support case (69) from stand.

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TUBE

HOUSING

TUBE ASSY -

-- TUBE

, Xt/-MANIFOLD

DETAIL VIEW C

212-R-63-33

Figure 63-33. Transmission manifold

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63-38. Cleaning. NOTE

i Precautionary measures shall beMATERIALS REQUIRED exercised at all times to prevent

corrosion. Fingerprint residue,NUMBER NOMENCLATURE reactive with moisture in the air, will

cause accelerated corrosion inC-105 Corrosion Preventive affected areas.

C-304 Solvent (1) Wash all ferrous parts in solvent (C-

C-334 1.1.1-Trichloroethane 304) and drain dry.

C-436 Paint Remover (2) Gently agitate parts in corrosionpreventive (C-105) and drain dry.

1. Apply following procedures to cleantransmission parts and to treat parts to (3) Apply protective coat ofprevent corrosion. transmission oil to all parts.

a. Clean all parts with solvent (C-304). NOTEUse nonmetallic, soft-bristle brush to dislodgestubborn deposits. All parts (other than Parts treated per steps (1), (2), andbearings) may be cleaned with 1.1.1- (3) may be left covered in indoortrichloroethane (C-334) if desired. Dry parts storage for approximately 150 hourswith clean, lint-free cloths or filtered, without being affected by corrosion.compressed air. Do not allow bearings tospin when drying with compressed air. Coatbearings with corrosion preventive (C-105) 63-39. Conditional inspection.immediately after cleaning. Do not handleunoiled bearings with bare hands. NOTE

b. Inspect cases and sleeves for corrosion If records or physical appearance ofdamage to threaded holes for studs before transmission indicate assembly hascleaning. No structural damage to threads is been subjected to an accident oracceptable. incident outside realm of normal

usage, perform the followingc. Remove sealant from cases and Conditional Inspection. If

sleeves with plastic scraper. transmission does not requireConditional Inspection, accomplish

d. Clean all parts (except bearings) by Normal Inspection (paragarph 63-40)vapor degreasing with 1.1.1-trichloroethane(C-334). 1. Visually inspect for external damage.

Particular attention should be given to thee. Remove paint from all painted parts main support case for cracks or yielding.

except manifolds (29 and 92, figure 63-31)and jet housing (30, figure 63-32). Use paintremover (C-436). Rinse parts with water and a. Check assembly for freedom anddry with filtered, compressed air. smoothness of rotation of bearings.

f. Treat parts to prevent corrosion after b. Visually inspect gears for cracked orcleaning in accordance with following chipped teeth. If cracked or chipped gearprocedures: teeth are found in the tail rotor drive train, the

following gears and pinion, 212-040-150, 212-040-151, 212-040-201 and 212-040-202, shallbe replaced and cases dimensionally checked

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BHT-212-CR&0

for bore alignment. Check free wheeling damage, cracked or broken retainers, andclutch for brinelling. excessive wear.

2. Inspect gears for cracks by magnetic 5. Inspect planetary support liners (10, 20,particle method (BHT-ALL-SPM). and 22, figure 63-32) for excessive wear.

3. If inspection reveals main rotor drive 6. Inspect manifolds (29 and 92, figure 63-train has experienced excessive torsional 31) and jet housings (30 and 43, figure 63-32)loads, indicated by cracked or distorted cases for corrosion damage, excessive wear, oror gears, entire component should be damaged threads.considered unserviceable and nonreparable.A cracked, broken, or yielded arm or lift link 7. Inspect all oil jets for cracks or bends.lug on main support case may result from a Inspect using magnetic particle method (BHT-hard landing and does not necessarily ALL-SPM). Demagnetize parts after magneticindicate excessive torsional loads. If there is inspection. A single indication of a straightno evidence main rotor drive train has been line crack across inner end of oil jets is aoverloaded torsionally and transmission smudge line typical of the method ofmeets this conditional inspection requirement, manufacturing. Inspect for cracks andaccomplish Normal Inspection, paragraph 63- bending in area of slots.40.

8. Inspect hoses (17 and 34, figure 63-28)4. Refer to paragraph 63-48 for conditional and related fittings for damage andinspection of transmission case. deterioration.

63-40. Normal Inspection. 9. Inspect oil tubes (14 and 22) for cracks63-40. Normal Inspection. and damage.

NOTE 10. Inspect neck and scupper (1) and oilfiller cap (2) for damage. Inspect bracket (7)

If records or physical appearance of for cracks and damage.transmission indicate assembly hasbeen subjected to an accident or 11. Inspect tubes (8, 23, 47, 64 and 68,incident outside realm of normal figure 63-31) and (25, figure 63-32) andusage, perform a Conditional related fittings for cracks and damage.Inspection (paragraph 63-39). If Inspect breather vent (20, figure 63-31) fortransmission does not require damage. Inspect valve assembly (75) thermoConditional Inspection, accomplish switch (70) and thermobulb (97) for damage.Normal Inspection as follows:

12. Inspect all parts visually for damage1. Inspect ring gear (36, figure 63-32), and excessive wear. Inspect gears andupper sun gear (11), and lower sun gear (23) splines for chipped, broken, or worn teeth.for chipped, dented, spalled, scuffed, and Check bearings for smooth operation and forpitted teeth. indications of failure or excessive wear. If

metal particles were found in the transmission2. Inspect mast driving adapter (8) for at disassembly or if there is evidence of metalcorrosion, excessive wear, and damaged particles going through the gear meshes,spline teeth. carefully examine gear teeth and bearings for

dents and cuts. Inspect cases and sleeves for3. Inspect planetary support upper and corrosion damage, excessive wear, and looselower bearings (9 and 21) for roughness, or damaged bearing liners.spalling, scoring, pitting, brinelling, corrosiondamage, cracked or broken retainers, and 13. Inspect following parts by magneticexcessive wear. particle (Code M) or fluorescent penetrant

(Code F) method as applicable (BHT-ALL-4. Inspect lower mast bearings (64) for SPM). Demagnetize parts after magneticspalling, scoring, pitting, brinelling, corrosion inspection.

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BHT-212-CR&0

NOTEFigure, Nomenclature CodeIndex No. All parts reworked or repaired shall

be reinspected prior to use or63-32, 4 Top case F63-32, 8 Mast driving adapter M63-32, 10 Liner M 1. Replace all seals, gaskets, preformed63-32, 11 Upper sun gear M packings, cork plugs, and cotter pins on63-32, 20 Liner M reassembly.63-32, 23 Lower sun gear M63-32, 36 Ring gear M 2. Replace parts which are cracked, broken,63-32, 55 Main case F warped, distorted, or have malformed threads.63-32, 69 Support case F

3. Replace all parts which exceed allowabletolerances given in applicable limits charts.

14. Inspect parts dimensionally as required 4. Replace badly corroded, nicked, pitted,(figure 63-34). scratched, or dented parts which cannot be

repaired in accordance with repair proceduresset forth in this manual.

NOTE

5. Duplex bearings are marked with serialLimits charts are provided to show numbers. Replace in matched pairs.the required fit between matingparts. It is not intended all 6. Assemble roller bearing inner and outerdimensions listed on limits charts be races with matched or same serial numbers.checked as a prescribed overhaulprocedure. However, parts exhibitingprocedure. However, parts exhibiting 7. Serial number on ground shim plate shallevidence of wear or physicalevidence of wear or physical conform to serial number on sleeve or case.damage shall be checkeddimensionally. 8. Bearing spacers are finished ground

together and serial numbered for replacement.,„~63-41 -. Repair.as a matched set.

63-41. Repair.

9. Repair manifold (92, figure 63-31) asMATERIALS REQUIRED follows:

Refer to BHT-ALL-SPM for specification andsource. a. Inspect helicoil threads on manifold. If

helicoil threads are stripped or damaged,

NUMBER NOMENCLATURE rework as outlined in steps b. through f.

C-100 Chemical Film Material b. Remove old helicoil and tap drill hole0.252 to 0.263 in. (6.4008 to 6.6802 mm)

C-103 Chormic Acid diameter to 0.335 in. (8.509 mm) maximumdepth. Countersink 90° 0.312 to 0.342 in.

C-108 B r u s h C admiu m (7.9248 to 8.6868 mm) diameter.Plating Solution

C-116 Chromic Acid c. Tap 5/16-18 UNC-3B to 0.280 in.(7.112 mm) full thread depth.

C-201 Primerd. Treat reworked surfaces with C-103.

C-204 Primer

C-464 India Stone e. Make an insert from a H2R-205SC-7Rosan (Insert U-Tap). Machine overall

63-00-00Rev. 4 Page 79

BHT-212-CR&0

10

14

MIN. MAXINCHES MILLIMETERS INCHES MILLIMETERS

1 Ring Gear Teeth Between pins 13.683 347.5482 13.6931 347.80474(Use 0.2160 IN. (5.4864 mm)diameter pins)

2 Adapter Spline Over pins 6.4223 163.12642 6.4269 163.24326(Use 0.2160 IN. (5.4864 mm)diameter pins)

3 Adapter Spline Between pins 3.8429 97.60966 3.8458 97.68332(Use 0.1440 IN. (3.6576 mm)diameter pins)

4 Sun Gear Teeth Over pins 6.9964 177.70556 7.0120 178.1048(Use 0.2160 IN. (5.4864 mm)diameter pins)

5 Sun Gear Spline Over pins 7.0039 177.89906 7.0120 178.1048(Use 0.2160 IN. (5.4864 mm)diameter pins)

6 Outer Liner ID 5.5113 139.98702 5.5124 140.014967 Bearing OD 5.5112 139.98448 5.5118 139.99972

ID 4.3302 109.98702 4.3308 110.002328 Adapter OD 4.3298 109.97692 4.3309 110.004869 Inner Liner OD 4.3298 109.97692 4.3309 110.0048610 OuterLiner ID 5.5113 134.98702 5.5124 140.0149611 Sun Gear Spline Between pins 4.3400 110.236 4.3441 110.34014

(Use 0.1440 IN. (3.6576 mm)diameter pins)

12 Sun Gear Teeth Over pins 7.0059 177.94986 7.0120 178.1048(Use 0.2160 IN. (5.4864 mm)diameter pins)

13 Liner ID 4.9987 126.96698 5.0003 127.0076214 Bearing OD 4.9984 126.95436 4.9990 126 9746

212-H-63-34

Figure 63-34. Transmission wear limits

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BHT-212-CR&O

length to 0.250 in. (6.35 mm) by removing chipping, scoring, scratches, dents, reworkmaterials from end where external threads are procedures, etc. (BHT-212-MM).cut back. Brush cadmium plate rework areausing brush cadmium plating solution (C-108) a. Aluminum Parts: Touch up with brush(BHT-212-MM). chemical film material (C-100).

NOTE b. Magnesium parts: Remove all traces ofcorrosion by immersion in chromic acid (C-

Top four threads of insert are 116). Touch up parts with chromic acid (C-expanded to provide interference fit. 103) or treat entire part with magnesium alloy

chemical film treatment (BHT-ALL-SPM).

f. Install insert made in step e. using hex Cadmium pated steel parts: Treatwrench to install insert. Apply primer (C-201) reworked areas with brush cadmium platingor primer (C-204) to external threads of insert solution (C-108). (BHT-212-MM).and install while primer is still wet. Insert tobe driven 0.030 in. (0.762 mm) below surface. 13. Refer to paragraph 63-50 for repair of

top, main, and support cases.10. Replace all bearings exhibiting evidenceof spalling, scoring, pitting, brinelling, flaking, 14. Refer to paragraph 63-100 for repair ofor corrosion damage on rolling elements or accessory drive sump and case.races, or which have cracked or brokenretainers, or do not roll smoothly. Replaceroller bearings exhibiting evidence of spalling, 15 Refer toscoring, pitting, brinelling, or large corrosionpitting damage on rolling elements or races,* or which have cracked or broken retainers. 16. Refer to paragraph 63-107 for repair ofMinor nicks, cuts, or scratches are acceptable accessory case quills.on rollers provided such defects are too smallto be felt with a probe having and end radius 17 Replace parts which are not withinof 0.030 in. (0.762 mm) and provided total allowable wear limits.affected area does not exceed 10% of contactarea at any point. Minor circumferential 63-42. Assembly.scoring is acceptable on rollers and racesprovided such scoring cannot be felt with aprobe having end radius of 0.030 in. (0.762 MATERIALS REQUIREDmm) and affected area does not exceed 10%of contact area at any point (figure 63-35). NUMBER NOMENCLATURE

11. Replace bevel gears which are spalled C-201 Primeror scuffed or have improper wear patterns.Replace spur gears which are spalled or C-304 Solventscuffed beyond limits shown (figure 63-36). If C-308 Adhesivemetal particles are found in transmissionduring disassembly, or if there is evidence of C-405 Lockwiremetal particles going through gear meshes,carefully examine gear teeth for indentionsand cuts. Repair minor nicks, scratches, and NOTburrs on splines and gear teeth by dressingwith fine India stone (C-464) in accordance Refer to paragraph 63-52 for properwith inspection requirements. dimensions of original or

replacement shim plates for main12. Refinish parts on which finish has been case.damaged or removed by wear, corrosion,

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BHT-212-CR&O

ACCEPTABLE

UNACCEPTABLE

212-R-63-35C0000

Figure 63-35. Roller bearing wear pattern

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BHT-212-CR&O

Refer to paragraph 63-101 for main case down into position and ensureproper dimensions of original or packing (54) is properly seated and notreplacement shim plates for damaged. Install washer (52), washer (50),accessory case. and nut (51) on each stud (including studs on

lower side of support case (69). Omit oneRefer to paragraph 63-71 for proper aluminum washer and install bracket (25,dimensions of original or figure 63-28) on stud directly below manifoldreplacement shim plates for mounting pad. Torque nuts 230 to 250 in.lbs.transmission quills and paragraph (25.9854 to 28.2450 Nm).63-113 for accessory quills.

7. Heat upper section of main case (55,NAS1197 washers shall be replaced figure 63-32) with a heat lamp. Positionwith AN960JD washers. packing (49) on main input gear quill (48).

Coat packing and mating surface of quill with1. Clean all parts, as required, with solvent transmission oil and install quill in main case.(C-304) and drain. All parts coated with Ensure gear shaft engages roller bearing andcorrosion preventive fingerprint remover shall spline in offset accessory drive withoutbe cleaned. Apply a protective coat of damage, also ensure FWD arrow on quilltransmission oil after parts have drained. case is properly oriented with main case.Avoid handling unoiled parts. Coat all (Forward is side opposite main input quillpackings and mating surfaces with port.)transmission oil before installing.

8. Position 204-040-001-17 PAT 1 backlash2. Mount support case (69, figure 63-32) in tool on main input gear quill (48, figure 63-32)buildup stand and inspect visually for particles and secure with four bolts through quill andof magnesium which might become detached. main case. Tighten clamp on backlash tool toRemove any such particles and clean case prevent shaft from turning in main input gearthoroughly. quill.

3. Invert case in build-up stand and install 9. Install main input quill as follows:plug (66) and packing (65). Align hole andinstall setscrew (68) and washer (67). Ensure a. Fabricate workaid (figure 63-37).setscrew tightens fully against head before Reaching through main input quill mountingthreaded end bottoms on plug. Secure port, insert chain and plug into roller bearingsetscrew to case rib with lockwire (C-405). for quill. (Purpose of workaid is to holdReturn case to upright position. bearing rollers out against outer race while

installing main input quill.) Extend chain out4. Install lower mast bearing (64) in liner at of rotor brake quill port so workaid can becenter of support case. Install mast guide ring pulled out after quill engages roller bearing.(63) on bearing and secure with retainer ring(62). b. Heat main input quill port with a heat

lamp. Position two packings (63, figure 63-5. Heat case at port for offset accessory 31) on tube (64) or packings (63) on tubedrive (61) with heat lamp. Coat mating (65). Coat packings with transmission oil andsurfaces of accessory drive sleeve and case insert tube into main case. Position twowith transmission oil. Install offset accessory packings (66) on main input quill (60) forwarddrive. If it is necessary to tap on assembly to and aft grooves; leave middle groove open forseat it, do not tap on gear. Install six nuts oil circulation. Coat packing and quill with(59) and washers (60) to secure assembly to transmission oil.case. Secure nuts (59) with cotter pins (58).

c. Remove three setscrews from studs6. Install packing (54, figure 63-32) on main around quill opening. Install T101586-5 studscase (55). Coat packing with transmission oil (from pusher set) in setscrew holes andand install case on support case (69). Tap tighten finger tight. Install main input quill on

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Lower Sun GearHeavy wear along the tip ofthe tooth. Unacceptablecondition. Any spalling,scuffing or pitting that can befelt with a probe having a0.020 Inch (0.508 mm) radiusis unacceptable.

Upper Sun GearTypical acceptable wear pattern.

Upper Sun GearHeavy wear along the tip of

condition. Any spalling,scuffing or pitting that can befelt with a probe having a0.020 Inch (0.508 mm) radiusIs unacceptable.

212-R-63-36COOOO

Figure 63-36. Transmission sun gear wear pattern

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T101586-5 studs far enough to install three position. Place a steel washer (57) onT101586-3 spacers and hex nuts. Ensure all remaining six studs. Install nuts (56) andpackings and tube (64 or 65) are in place. torque 160 to 190 in.lbs. (18.0778 to 21.4662Exercise care to avoid damage to gear teeth Nm).and bearings as quill is installed.

10. Install hydraulic pump drive quill (87,d. When main input quill race is started figure 63-32). Heat transmission main case in

into roller bearing, remove workaid plug area of quill port with heat lamp. Install newthrough rotor brake quill port. packing (88) on quill (87). Coat packing and

sleeve with transmission oil and insert quillinto transmission with oil hole in quill sleeve

cover (93) with a heat lamp. Install newe. Tighten hex nuts equally to seat main packing (92) on cover (93). Lightly coat

input quill into main case. Remove pusher packing with transmission oil and install coverset. Install setscrews in studs at 3, 7, and 11 (93) on transmission. Align cover holes witho'clock positions. threaded holes in transmission. Install steel

washer (95) next to bolt head and aluminumf. Place an aluminum washer (58) on each washer (94) on bolt (96). Brush bolt threads

stud. Install bracket (59) on stud at 5 o'clock

HARD RUBBER DISC. APPROX. 2 1/8 IN.(53.975 mm) IN DIAMETER AND AT LEAST1/4 IN. (6.35 mm) THICK.

COTTER PIN

LIGHT CHAIN, APPROX.6 IN. (152.4 mm) LONG.

APPROX. 2 FT. (0.6096 mm) OF SEMI-RIGID WIRE - 0.041 IN. (1.0414 mm)DIAMETER OR HEAVIER.

RED WARNING FLAG, STENCILED.REMOVE BEFORE CLOSING TRANSMISSION.

212-R-63-37

Figure 63-37. Main input quill workaid

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with unreduced primer (C-201) and install bolt c. Remove dial indicator, dial indicatorwhile primer is wet. support, and backlash tool from main input

quill. Leave backlash tool (installed on main12. Check backlash on main input quill. input gear quill in step 8.) in place. Reinstall

lockspring, retainer, and retainer ring on quill.

ICAUTION 13. Check backlash on hydraulic pump drive

DO NOT ALTER SHIM PLATE ONMAIN CASE OR QUILL SLEEVE TO CAUTIONO B T A I N BACKLASH. IFBACKLASH IS NOT WITHINLIMITS, PARTS ARE IMPROPERLY DO NOT ALTER SHIM PLATES ONA S S E M B L E D OR A R E MAIN CASE OR QUILL SLEEVE TODIMENSIONALLY INCORRECT OBTAIN BACKLASH. IF(PARAGRAPHS 63-52 AND 63-71). BACKLASH IS NOT WITHIN

LIMITS, PARTS ARE IMPROPERLYa. Remove retainer ring, retainer and lock A S S E M B L E D O R A R E

spring on main input quill. Install 212-040- DIMENSIONALLY INCORRECT001-19 GIF-1 backlash tool on main input (PARAGRAPHS 63-52 AND 63-89).quill. Install dial indicator support on one ofmain input drive quill studs (figure 63-38). a. Install 204-040-001-3 GIF-1, backlashInstall dial indicator on support and position to tool, detail 54, on hydraulic pump drive quill.contact marked spot on backlash tool. Install dial indicator support on one of

hydraulic pump drive quill studs (figure 63-b. Take backlash reading at three places 38). Install dial indicator on support and

approximately 120° apart around gear and position to contact dowel pin in backlash tool.record. Backlash for 212-040-263 input quillto be 0.012 to 0.019 in. (0.3048 to 0.4826 b. Take backlash reading at three placesmm). Backlash for 212-040-363 input quill to approximately 120 ° apart around gear andbe 0.005 to 0.012 in. (0.127 to 0.3048 mm). record. Backlash shall be within 0.005 to

0.012 in. (0.127 to 0.3048 mm) for 212-040-001, all dash numbers except -059 and -141

NOTE transmissions, and 0.012 to 0.020 in. (0.3048

If 212-040-001-19 GIF-1 backlash to 0.508 mm) for 212-040-001-059 and -141tool is unavailable, backlash may be transmissions.determined by an alternate method.Take backlash readings at three NOTEplaces approximately 120° apartaround gear and at a distance If 204-040-001-3 GIF-1, detail 54,(radius) of 2.070 in. (52.578 mm) backlash tool is unavailable,from gear center. Backlash shall be backlash may be determined by anwithin limits noted in step b. alternate method. Take backlash

readings at three placesapproximately 120° apart around

CAUTION gear and at a distance (radius) of1.774 in. (45.0596 mm) from gearcenter. Backlash shall be as noted

ENSURE LOCK SPRING IS FULLY in step b.SEATED IN GROOVE WHENREINSTALLED ON QUILL. c. Remove dial indicator, dial indicator

support, and backlash tool from hydraulicpump drive quill. Remove backlash tool

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APPROXIMATELY7 1/4IN. (184.15mm)

APPROXIMATELY1 3/4 IN. (44.45 mm)

GRIND FLAT TO OPEN HOLE TOTHIS SURFACE 13/32 IN.

(10.31875 mm)

1. Make from AN44-80 or AN45-80 eyebolt.2. Heat and bend as shown. 212-R-63-38

Figure 63-38. Input quill backlash indicator support workaid

(installed in step 8.) from main input gear oil, before jet is installed. Install screw (55),quill. seal (53), and screw (54). Secure screws (54

and 55) together with lockwire (C-405).14. Install manifold (92, figure 63-31).Ensure gasket (93) and two packings (94 and 16. Position lower sun gear (23, figure 63-95) are properly positioned. Install bolt (82) 32) on main input gear quill shaft with longerwith washer (81) and bracket (80). Install inner shoulder down. Assemble lower bearingpackings (89, 90, and 91) on oil jet (88). Coat (21), outer liner (20), and bearing liner (22)all packings with transmission oil. Install oil jet with thrust side of outer race of bearing up,in manifold and secure with bolt (85), washer i.e. with face of bearing down. Place(84), and bracket (83). Install screw (86) and assembly on gear shaft above lower sun gear.seal (87). Install packings (72, 73, and 91) on Inspect parts for correct positioning (figureoil jet (76) and position jet in manifold. Secure 63-34).with screw (78) and washer (79). Install screw(78) and seal (77) in end of jet. Install oil 17. Install lower planetary assembly (14)pressure valve (75) with packing (71). Install with pinion engaged with lower sun gear.thermo bulb (97) with gasket (96). Use Splines of lower planetary should rest onlockwire (C-405) to secure fasteners and flange of outer liner (20).components as follows: Two screws (78) andbolt (82) together, bolt (85) and screw (86) 18. Position oil deflector ring (13) on uppertogether, and thermoswitch (70), valve (75), sun gear (11) in position (figure 63-34) andand thermobulb (97) together. install retainer ring (12, figure 63-32). Ensure

retainer ring is fully seated in recess. Position15. Install jet (51 or 52, figure 63-31). upper sun gear (11) into splines in lowerEnsure packings (48, 49, and 50) are properly planetary (14) with notches in lower end ofpositioned and are coated with transmission sun gear engaged with tangs on liner (20).

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CAUTION | 31) on tube (68). Coat packings with**************** transmission oil and insert tube into manifold

(92).DO NOT ALLOW SEALANT TOENTER JET PORT OF HOUSING. 22. Lightly coat packing (37, figure 63-32)

with transmission oil. Install packing on maininput gear quill (48). Install ring gear (36) on

NOTE main input gear quill with tooling hole directlyover main input quill. Align oil tube (installed

Position jets through jet housings in preceding step) with jet housing (30). Tapand ring gear to ensure correct ring gear into place. Position bracket (7,alignment during installation of each figure 63-28) as illustrated and install fourjet housing. bolts (5) to secure bracket to transmission.

Install steel washer (6) under bolt head.19. Position ring gear (36) on work bench Install aluminum washer (not illustrated) nextwith wider gear teeth of ring gear up. Apply to bracket (7). Install aluminum washer (8)adhesive (C-308) 0.10 to 0.20 in. (2.54 to (next to case) steel washer (9), and nut (10).5.08 mm) thick to faying surfaces of housing Install remaining sixteen bolts (5) with steel(30) and gasket (31) Install jet housing (30) washer (6) under heads, aluminum washers

with gasket (31). in first set of holes (8) (next to case), steel washers (9), and nutswith gasket (31) in first set of holes (10). (Omit steel washer under heads atcounterclockwise from tooling hole. (Tooling locations of brackets as shown in figure 63-29hole is located on bottom flange or on bottom or 63-30). Transmissions 212-040-001-059, -and top.) Install bolt (26) with steel washer 141 and subsequent, torque nuts (10) 230 to(27) under head, with heads outboard. Install 250 inch pounds (25.986 to 28.246 Nm).aluminum washer (28) and thin aluminum Other transmissions use standard torque.washer (29), as required, next to jet housingand one steel and one thin steel washer (32 23. Install oil filler neck and scupper (1) withand 33) under nuts (34). Torque 50 to 70 four aluminum washers (4) between scupperin.lbs. (5.649 to 7.9086 Nm). Allow assembly and bracket and with four steel washers (33)to set for 15 minutes and retorque. Install and four nuts (32) underneath.cotter pins (35).

24. Assemble bearing (9, figure 63-32),................ outer liner (10), and mast driving adapter (8)

ICAUTION with back or thrust side of bearing outer race****.********** down. Insert assembly up through upper

planetary (7) and secure with retainer ring (6).

DO NOT ALLOW SEALANT TO Ensure retainer ring is fully seated.

ENTER JET PORT OF HOUSING.ENTER JET PORT OF HOUSING. 25. Install upper planetary assembly (7) intoring gear case with pinion teeth engaged in

20. Apply adhesive (C-308) 0.10 to 0.20 in. ring gear and upper sun gear (11). Engage(2.54 to 5.08 mm) thick to faying surfaces of projections on liner (10) with notches in linerhousing (43) and gasket (42). Install two (20). Upper bearing (9) and lower bearingremaining jet housings (43) with gaskets (42). (21) should now be back-to-back.Install bolts (47) with steel washer (46) underhead with heads outboard. Install standard 26. Spray inside of transmission withaluminum washer (45) and thin aluminum transmission oil.washer, as required, next to jet housing.Install standard steel washer (32) and thinsteel washer (33) under nuts (34). Torquenuts 50 to 70 in.lbs. (5.649 to 7.9086 Nm).Allow assembly to set for 15 minutes andretorque. Install cotter pins (35).

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BHT-212-CR&O

27. Install packing (5) on top case (4). position top case on transmission with oil tube. Position two packings (24) on oil tube (25). (25) aligned. Tap top case lightly to seatLightly coat packings with transmission oil. against ring gear. Position controls springInsert oil tube into jet housing (30) and

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BHT-212-CR&O

bracket (1) as shown. Install sixteen bolts washer (79) next to sump, a steel washer(15) with heads up, thin steel washer (16) (80), and nut (81) on each of thirteen studsunder heads, aluminum washer (19) next to with one exception: Omit aluminum washertop case, thin steel washer (38) next to ring and install bracket (75) on stud directly abovegear and nuts (39). Omit two thin steel magnetic chip detector in sump. Rotatewashers where bracket (1) is installed. (Omit transmission to vertical position.aluminum washers where 205-040-131-1brackets are installed (figure 63-29 or 63-30). 29. Install oil jets and external components.Install three screws (2) and aluminumwashers (3) in jackscrew holes in top case. a. Install breather vent (20, figure 63-31)Secure screws with lockwire (C-405). Ensure and gasket (21).planetary assemblies are properly installed intransmission by measuring the distance from b. Position spacer (22) and manifold (29)top surface of transmission top case to mast on transmission, secure with an aluminumdriving adapter (figure 63-39). The minimum washer, steel washer and nut (26) on eachacceptable dimension is 2.570 in. (65.278 stud. Install elbow (17), bolt (18) and twomm). Install cover and lift plate in top case. packings. Install cap (19) on bolt (18). Install

elbow and packing (27), nut (28) and tube(23). Install union (30) in manifold (29) with

28. Install accessory and tail rotor drive and packing and install cap or union. Installsump assembly: Rotate transmission to protective cover in boss at lower side ofhorizontal position in stand. Install tail rotor manifold (29).drive quill adapter (73, figure 63-34) in baseof transmission and position drive and sump c. Position packings (42 and 43) on oil jetassembly (78) on support case with gasket number one (40 or 41) and position in(74) in place, splined adapter engaged, and transmission. Install screws (37 and 38) andwith tail rotor drive quill and main input quillon same side. Secure sump with an aluminum

TOP CASE2.570 IN.(65.278 mml MIN. DIM.

TRANSMISSION 212-R-63-39

Figure 63-39. Mast installation dimensional check

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seal (39). Secure screws with lockwire (C- (4) Attach clamp to cable (14) and405). install on bracket (8).

d. Position packing (32 and 33) on oil jet (5) Install P-41 connector (7) onnumber two (34) and install in transmission. connector.Secure with two screws (36) and seal (35).Secure screws with lockwire (C-405). (6) Attach clamp to cable (14) and

install on bracket (6).e. Install elbow (46) with packing (44) and

nut (45). Install auxiliary oil jet (2) with (7) Install P-37 connector onpacking (1) and secure with screw (3). Install transmission oil temperature bulb (5).elbow (6) with packing (4) and nut (5).Secure screw (3) with lockwire (C-405)thermoswitch (3).around elbow. Install tube (47). Installopposite auxiliary jet and tube (8) in samemanner. (9) Install wires to ground stud (4).

f. Position packings (12 and 13) on jet No. (10) Attach cable (14) to brackets and5 (14). Coat packings with approved oil. clamps (17).Install jet in jet housing (30, figure 63-32).Install screws (16 and 7, figure 63-31) and (11) Install wires on chip detectors (15dyna-seal (15). Secure screws with lockwire and 16), if installed.(C-405).

(12) Reconnect P-36 connector tog. Install chip detectors on 212-040-001- transmission oil pressure switch (1).

059 and -141 transmissions.(13) Install P-39 connector to

(1) Place packing (57, figure 63-32) on transmission oil pressure transmitter (2).chip detector (56) and install chip detector.Secure chip detector with lockwire (C-405). i. Install elbow (13, figure 63-28) with

packing and nut (12). Install adapter (15).(2) Place packing (18) on chip detector Install tube (14).

(17) and install chip detector.j. Install union (30) with packing (31).

h. Install electrical cable as follows: Install tube (22). Route tube to sump scupperand secure with clamp to bracket (75, figure63-32).

NOTE

Only use M83248-1 packing on chip k. Install elbow (28, figure 63-28) with nutdetector. and packing (29). Install hose (17) and two

clamps (18).

See figure 63-29 or 63-30, as I. Install hose (34).applicable.

m. Replace identification and data plates(1) Install wire on chip detector (13). (24 and 25, figure 63-31), as required.

(2) Install cable in clamps (11 and 12) 30. Seal and paint transmission (paragraphand attach to brackets. 63-43)

(3) Connect P-35 connector (9, figure 31. Perform run-in and test (paragraph 63-63-29) to rotor tachometer generator (10). 44).

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63-43. Sealing and painting. 5. Clean areas of transmission that are tobe painted with clean cheesecloth wetted with

MATERIALS REQUIRED alphatic naphtha (C-305). Wipe dry with cleancheese cloth before naphtha evaporates.

Refer to BHT-ALL-SPM for specification andsource. 6. Apply one coat of primer (C-246) 5 to 8

mil thickness.NUMBER NOMENCLATURE

C-100 Chemical Film Material NOTE

C-103 Chromic Acid Apply coating (C-245) coat not less

C-246 Primer applied.

C-305 Aliphatic Naphtha 7. Spray on first coat of coating (C-245) to4 to 6 mil thickness. Allow to dry for thirty

308 Adhesive minutes to one hour and apply second coat.C-309 Methyl-Ethyl-Ketone

(MEK) NOTE

C-311 AdhesiveIf second coat of coating (C-245)

C-328 Sealing Compound cannot be applied within time limitsnoted in step 8., second coat maybe delayed for up to seventy-two

NOTE hours, but surface to be paintedshall be cleaned with a tack rag prior

If transmission is to be run-in on a to applying second coat.run-in stand, skip painting andsealing until after run-in inspection 8. Allow last coat of coating (C-245) to dry(paragraph 63-44). for forty-eight hours and remove masking

tape.1. Apply sealing compound (C-328) andadhesive (C-308) prior to painting 9. Install SERVICE TRANSMISSION decal

I transmission (figure 63-40). on main support case below and to left of oilfiller cap to indicate type of oil to be used.

2. Install protective covers at the followinglocations: 10. Identify transmission by part number on

top case. Use stamp ink or stencil.a. Tachometer generator mounting

flange. 11. Install hoses and lines removed in step3.

b. Hydraulic pump mounting flangeadjacent to tachometer generator.

63-44. Run-in and test.c. Hydraulic pump mounting flange on

main case. It is recommended transmission, afteroverhaul, be test run and inspected in

3. Mask transmission for primer and paint. accordance with Bell Helicopter Textron BHT-Remove external lines and hoses to facilitate PUB 77-003, Run-in and Test Manualpainting. Cap or plug all openings. furnished with run-in test stand. In event a

run-in stand is not available, the functional4. Touch up exposed magnesium surfaces test specified in BHT-212-MM may bewith chemical film material (C-100) or accomplished as minimum acceptablecorrosion preventive compound (C-103). alternate test.

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BHT-212-CR&O

SEE VIEW B

SEE VIEW C

VIEW CVIEW A VIEW BVIEW B

NOTES

Clean surfaces with MEK (C-309). Mix sealant (C-328) in accordance with instructions oncontainer. Apply sealant (C-328) to both faying surfaces, assemble parts prior to sealantcuring.

Clean area to be sealed with MEK (C-309). Mix adhesive (C-311) in accordance withinstructions on container. Apply adhesive (C-311) prior to painting transmission, smoothsealant prior to curing.

212-R-63-40-1

Figure 63-40. Transmission sealant application (sheet 1 of 2)

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ITEM APPLICATION POINT REMARKS

1 Top Case and Mast Bearing Retaining Plate When mast assembly is installed,apply Sealant per notes 1 and 2.

2 Input Quill Flange Apply Sealant per notes 1 and 3.

3 Cover Apply Sealant per notes 1 and 3.

4 Tail Rotor Drive Quill Flange Apply Sealant per notes 1 and 3.

5 Tail Rotor Drive Quill Bearing Retaining Nut Apply Sealant per notes 1 and 3.

6 Hydraulic Drive Quill Flange Apply Sealant per notes 1 and 3.

7 Hydraulic Pump Drive Quill Flange Apply Sealant per notes 1 and 3.

8 Main Case to Driven Quill Flanges Apply Sealant per notes 1 and 3.

9 Driven Quill to Ring Gear Mating Surface Apply Sealant per notes 1 and 2.

10 Driven Quill to Ring Gear Flanges Apply Sealant per notes 1 and 3.

11 Top Case to Ring Gear Mating Surface Apply Sealant per notes 1 and 2.

12 Top Case to Ring Gear Flanges Apply Sealant per notes 1 and 3.

13 Scupper to Oil Cap Adapter Mating Area and Transmission Apply Sealant per notes 1 and 3.Support case to Oil Line

14 Adaptor at lower end of Oil Line Jet Housing to Top Case Apply Sealant per notes 1 and 3.Oil Tube (both ends of tube)

15 Manifold to jet Housing Oil Tube (both ends of tube) Apply Sealant per notes 1 and 3.

16 Open Stud Holes on Base of Sump Case Apply Sealant per notes 1 and 3.

NOTES

1. Apply sealant to mating flange surfaces of mast bearing retaining plate and top case - to top case and ringgear - and to ring gear and driven quill at final assembly after 2.8 hour run-in. Apply sealant at otherindicated application points after preservation run and prior to painting transmission.

2. Clean mating surfaces with methyl-ethyl-ketone and wipe surface dry with a clean cloth before the solventevaporates. Mix the two-part MIL-S-8784, class B-2, sealant in accordance with instructions on container.The sealant must be used before the pot life time expires. (Do not attempt to assemble mating flanges withcured sealant in place. If sealant cures before assembly, clean cured sealant from parts with a sharp plasticscraper.) Run a small bead of sealant on both mating surfaces and smooth with a wooden spatula. A smallbead or squeeze-out of sealant will be visible at each side after parts are assembled when the correct amountof sealant is used.

3. Clean area of flanges, open stud holes, air bleed holes in bosses and other mating areas where sealant is to beapplied with methyl-ethyl-keytone and wipe dry with a clean cloth before solvent evaporates. Mix thetwo-part MIL-S-8802, class B-4, sealant (C-308) in accordance with directions on container. The sealantmust be used before pot life time expires. Run a small bead of sealant in area to be sealed off. Use andextrusion gun. If necessary, smooth sealant before it cures with a wooden tongue depressor wetted withmethyl-ethyl-ketone or with finger wetted with water.

212-R-63-40-2

Figure 63-40. Transmission sealant application (sheet 2)

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63-45. TRANSMISSION CASES. 63-47. Cleaning.

SPECIAL TOOLS REQUIRED MATERIALS REQUIRED

NUMBER NOMENCLATURE NUMBER NOMENCLATURE

T101586 Pusher set C-105 Corrosion Preventive

C-304 Solvent

NOTE C-334 1.1.1 -Trichloroethane

C-436 Paint RemoverThis paragraph outlines overhaul ofthe top case, main case, andsupport case. Refer to paragraph 1. Clean all parts with solvent (C-304). Use63-96 for accessory drive sump and soft bristle brush to dislodge stubborncase overhaul. deposits. All parts except bearings may be

cleaned with 1.1.1-trichloroethane (C-334) byvapor degreasing, if desired.

63-46. Disassembly.2. Dry parts with clean, lint-free cloths or

1. Remove retainer ring (4, figure 63-41) dry, filtered, compressed air. Do not allowand bearing (3) from main case. bearings to spin while drying.

3. Coat bearings with corrosion preventive2. Remove retainer ring (20) and bearing (C-105) immediately after cleaning.(21).

3. Remove screws (5, 15, and 25) and shim CAUTIONplates (7, 16, and 24). Remove screws (33)and shim plate (32) from 212-040-053 case.Identify shim plates for reinstallation in same DO NOT HANDLE UNOILEDposition on same case. BEARINGS WITH BARE HANDS.

4. Inspect cases for corrosion damage to4. Remove bushings (4, figure 63-46) from threaded studs and stud holes beforethreaded studs and stud holes beforesupport case.cleaning. No structural damage to threads orholes is acceptable.

NOTE5. Remove sealant with plastic scraper.

Remove bushing (3) only if damagedor loose. 6. Use paint remover (C-436) to remove

paint from all painted parts except manifolds(29 and 92, figure 63-31) and jet housing (30,5. Remove nuts (3, figure 63-47), washers figure 63-32). Rinse parts with water and dry

(4), and lift link fitting (5) from support case. with filtered, compressed air.

NOTE

Top case and support caseassemblies include studs and insertswhich do not require furtherdisassembly unless damaged.

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63-48. Conditional Inspection. has been subjected to an accidentor incident outside realm of normal

NOTE usage, perform ConditionalInspection (paragraph 63-48). If

If records or physical appearance of transmission case does not requiretransmission case indicate assembly Conditional Inspection, accomplishhas been subjected to an accident Normal Inspection in accordanceor incident outside realm of normal with the following steps.usage, perform ConditionalInspection in accordance with the 1. Inspect top case for corrosion damagefollowing steps. If transmission case and loose or damaged studs and inserts.does not require ConditionalInspection, accomplish Normal NOTEInspection (paragraph 63-48).

Rework main case if cracks are1. Visually inspect top, main and support found in taper pin area.cases for external damage. Particularattention should be given to main support 2. Inspect main case for corrosion damagecase for cracks or yielding. and loose or damaged studs and inserts.

Inspect for excessive wear and loose or2. If there are no visual indications of damaged bearing liners. Inspect all washeryielding or cracks in support case, check case seats for secure installation.dimensionally for yielding. Check dimensionfrom surface G, figure 63-42, to lower face of 3. Inspect support case for corrosionlateral mount bushing in each ear. damage and loose or damaged studs andAcceptable limits are 2.270 to 2.260 in. inserts. Inspect for excessive wear and loose(57.658 to 57.404 mm) as illustrated; or damaged bearing liner. Inspect lift link lugshowever, this dimension may be exceeded by on lower side of case around bushing and in0.010 in. (0.254 mm) above 2.270 (57.658 bushing bores for indications of cracks ormm) or 0.010 in. (0.254 mm) below 2.260 in. yielding and loose or damaged bushing (3,(57.404 mm) provided four bushing mounting figure 63-46).faces (lower) are parallel and flat within 0.003in. (0.0762 mm) TIR of each other and 4. Perform fluorescent penetrant inspectionparallel within 0.003 in. (0.0762 mm) TIR with of top case, main case, and support casesurface G. (BHT-ALL-SPM).

3. Check main case dimensionally for 5. Inspect shim plates for damagedyielding. Surface T, figure 63-42, shall be flat cadmium plating.within 0.002 in. (0.0508 mm) TIR.

6. Inspect bearings (3 and 21, figure 63-41)4. Check top, main, and support cases for for spalling, scoring, pitting, brinelling,freedom and smoothness of rotation of corrosion, damage, cracks, or brokenbear retainers, and for excessive wear.

5. Accomplish Normal Inspection (paragraph 7. Inspect fitting (5, figure 63-47) as follows:63-49). a. For damage and cracked or worn

clevis.63-49. Normal Inspection.

b. Stud holes for corrosion damage. Nostructural damage allowed.

NOTE

If records or physical appearance oftransmission case indicate assembly

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BHT-212-CR&O

14

25 21 16

4. Retainer ring 13. Lockring 22. Stud 31. Main case5. Screw 14. Insert 23. Stud (212-040-053)6. Washer seat 15. Screw 24. Shim plate 32. Shim plate7. Shim plate 16. Shim plate 25. Screw 33. Screw8. Insert 17. Stud 26. Washer seat9. Lockring 18. Stud 27. Main case (204-040-353) 212-R-63-41

Figure 63-41. Transmission main case

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BHT-212-CR&O

2.260 TO 2.270 IN.(57.658 TO 57.404 mm)

X /IMENSION LINE (LOWER

SURFACE OF STEEL BUSHING)

SUPPORT CASE

212-R-63-42

Figure 63-42. Transmission case inspection

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BHT-212-CR&O

c. Inspect fitting by magnetic particle 3. Repair cases which have damaged ormethod. Demagnetize after magnetic particle loose inserts or studs (BHT-ALL-SPM).inspection.

4. Replace washer seats if loose or missing.d. Inspect diameters L and M to following (Washer seats are normally located under

dimensions (figure 63-48). shim plates and serve as supports forjackscrew seats.)

Dia. L 0.7525 in. (19.1135mm) maximum 5. Top Case: Replace case assemblies

Dia. M 1.0025 in. (25.4685 which have corrosion damage exceeding themm) maximum following limits for the areas shown in figure

63-43.

a. In areas A, C, and C1, maximum depthof pitting is 0.020 in. (0.508 mm). No morethan 80% of area within any 1.0 sq.in. (645.2

MATERIALS REQUIRED sq mm) within area C1, nor more than 40% ofarea within any 1.0 sq.in. (645.2 sq mm)within area A and area C, exclusive of area

NUMBER NOMENCLATURE C1, may be pitted. No more than 25% of totalarea of any surface or diameter (exclusive of

Chromic Acid area C1) may be pitted. Refer to step d. for

C-201 Primer inspection and repair of studs in Area A.

C-204 Primer b. Inside bolt holes, maximum depth ofpitting is 0.020 in. (0.508 mm) (except as

C-308 Adhesive noted below) and no more than 40% of areaof wall of hole may be pitted. Isolated pits to

C-363 Adhesive a maximum depth of 0.060 in. (1.524 mm) are

C-423 Abrasive Cloth or acceptable provided pitting in excess of 0.020Paper in. (0.508 mm) in depth does not exceed 10%

of area of wall of hole, and provided total areapitted does not exceed 40% of area of wall ofhole. Corrosion in areas A, C, or on walls of

NOTE bolt holes shall be cleaned by immersion in a

This paragraph outlines repair and chromic acid bath (BHT-ALL-SPM). Removereplacement instructions for top, all traces of corrosion products in areas A, C,main, and support cases. and on walls of bolt holes.

1. Replace magnesium cases which have c. In area B, maximum depth of pitting iscorrosion damage in critical areas which 0.020 in. (0.508 mm). If there is no pitting on

would affect functional or structural integrity area contacted by washers, corrosion may beof part, or if damage exceeds limits specified removed by acid bath. If area contacted byfor areas shown for each component. washer is pitted, surface shall be machined

off (using mill cutter with same corner radiusas originally used) to a minimum dimension D

NOTE of 0.500 in. (12.7 mm) for aluminum case or0.530 in. (13.462 mm) for magnesium case,

The areas of transmission most provided this will give 100% cleanup.frequently damaged by corrosion areshown on figure 63-43. d. Rework top cases which have corrosion

around studs at mast mounting port as2. Replace cases if bearing liners are loose, follows:or if there is corrosion between liner andcase.

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NOTE 6. Main case: Rework main case if cracksare found in magnesium boss at taper pins

When corrosion has not penetrated (figure 63-43, Area M).past first thread, rework as outlinedin step (1) through (4). a. File out crack, using rotary file.

Minimum fillet radius after rework is 0.125 in.(1) Remove stud in corroded area. (3.175 mm). Maximum allowable depth of

Counter drill stud hole with a 0.327 to 0.334 cleanup is 0.060 in. (1.524 mm), measuredin. (8.3058 to 8.4836 mm) diameter drill to from original cast surface (figure 63-43, areamaximum depth of 0.125 in. (3.175 mm). M). Rework is permissible within these limitsBreak all sharp edges except in area of at all three pin locations.threads.

b. Inspect reworked cases by fluorescent(2) Treat reworked surfaces with penetrant method. There must be no

chromic acid (C-103). indication of cracks after rework (BHT-ALL-SPM).

(3) Install AN126365 through AN126370stud which will provide desired driving torque c. Treat rework areas for corrosion.of 100 to 225 in.lbs. (11.298 to 25.4205 Nm).Use wet primer (C-201) or primer (C-204) on d. Replace main cases with corrosionmating parts. damage exceeding following limits for areas

shown.(4) Fill counter drill holes with adhesive

(C-308) flush with top surface of case. (1) Maximum depth of pitting in area P

is 0.020 in. (0.508 mm) and no more thanNOTE 20% of area within any 1.0 sq. in. (645.2 sq

mm), nor 10% of total surface may be pitted.When corrosion has penetrated past Washers shall still make contact with case forthe first thread, rework as outlined in entire 360° around each bolt for at least 50%steps (5). through (9). as follows: of washer width. No more than 10% of

normal area contacted by washer may be

(5) Remove stud in corroded area. Drill pitted. In area I or J maximum depth ofexisting hole 5/16 (0.31250) in. (7.9375 mm) pitting is 0.020 in. (0.508 mm) and no morediameter through case, counter drill 0.389 to than 40% of area within any 1.0 sq.in. (645.20.397 in. (9.8806 to 10.0838 mm) diameter sq mm) nor 20% of total area of any surfaceand 0.062 in. (1.5748 mm) deep. or diameter may be pitted. Remove corrosion

by chromic acid bath (BHT-ALL-SPM). Inspectarea J carefully prior to any corrosion removal

(6) Tap 3/8-16 UNC-3B modified for evidence of corrosion between inserts andthreads through case. Break all sharp edges case. Any evidence of corrosion is cause forexcept in area of threads. rejection of case.

(7) Treat reworked surfaces with (2) In area G of figure 63-43 and area Achromic acid (C-103). of figure 63-42, pitting to a maximum depth of

0.020 in. (0.508 mm) is acceptable provided(8) Install AN155385 through AN155390 no more than 40% of any 1.0 sq.in. (645.2 sq

stepped stud which will provide desired mm), and 20% of total surface area isdriving torque of 100 to 240 in.lbs. (11.298 to corroded. Case having corrosion on studs, or27.1152 Nm). Apply wet primer (C-201) or adjacent to studs, shall be further inspectedprimer (C-204) to threads. as follows:

(9) Fill counterdrilled holes with (a) Measure and record height ofadhesive (C-308) flush with top of case. stud.

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SECTION K-K VIEW L-L

TOP CASE

AREA

Cl- \\ DEPTH OF CLEANUP - AREA M

MAIN CASE

21 -R-63-43

Figure 63-43. Transmission case corrosion damage limits

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BHT-212-CR&O

(b) Remove stud from corrosion maximum allowable pitting depth on surface,damaged area. If a stud is removed below four places only, between ends of shim platesinput quill bore, also remove filler from top of is 0.060 in. (1.524 mm). Rework to removehole. pitting, staying outside shim and seal area.

Rework area to have 0.5 in. (12.7 mm)(c) If corrosion has affected more minimum radius. Smooth with 400 grit

than one complete thread, replace case. abrasive cloth or paper (C-423).

(d) If corrosion has affected less than (4) Inside mounting flange bolt holes,one complete thread, rework case as follows: maximum depth of pitting is 0.020 in. (0.508

mm) (except as noted below) and no more1 Using a 0.452 to 0.459 in. than 40% of area of wall of hole may be

(11.4808 to 11.6585 mm) diameter drill, pitted. Isolated pits to a maximum depth ofcounter drill stud hole to a maximum depth of 0.060 in. (1.524 mm) are acceptable provided0.156 in. (3.9624 mm). Break all sharp pitting in excess of 0.020 in. (0.508 mm) inedges, except in thread area. depth does not exceed 10% of area of wall of

hole, and provided total area pitted does not2 Treat surfaces, after drilling, with exceed 40% of area of wall of hole. Remove

chromic acid (C-103) or treat entire part with corrosion by chromic acid bath (BHT-ALL-chromic acid bath (BHT-ALL-SPM). SPM).

3 Install a new stud in reworked (5) Treat reworked areas for corrosionhole (BHT-ALL-SPM). protection.

4 If stud below input quill bore was 7. Main case center web:replaced, fill top of stud hole smooth andflush with input quill bore with adhesive (C- NOTE363). Bore shall be resin free.

Inspect main case (figure 63-44) for5 All counterdrilled holes shall be cracks in center web above input

filled with adhesive (C-308) flush with top quill port. If cracks are found whichsurface of case. extend deeper than 0.250 in. (6.35

mm), case is nonreparable. If~~~NOTE cracks are found which do not

exceed 0.250 in. (6.35 mm), proceedIn areas I and J, figure 63-43, and as follows:area A, figure 63-42, the maximumallowable pitting depth on all internal a. Grind out all indications of crack withinchamfers is 0.060 in. (1.524 mm) on limits shown using a rotary file with minimumno more than 20% of diameter. In material removal. If all indications of crackarea I, maximum allowable pitting cannot be removed within prescribed limits,depth on surface, four places only, case is considered to be nonreparable.between ends of shim plates is0.060 in. (1.524 mm). Rework to b. Polish reworked area to remove allremove pitting, staying outside shim sharp edges. Surface finish is to be 63 RMSand seal area. Rework area to have or better.a 0.5 in. (12.7 mm) minimum radius,and shall be smoothed with 400 grit c. Fluoroescent penetrant inspectabrasive cloth or paper (C-423). reworked area to ensure all indications of

crack are removed. Minor imperfections such(3) The maximum allowable pitting as porosity and gas holes are acceptable.

depth on all internal chamfers in area I and J,figure 63-43, is 0.060 in. (1.524 mm) on no d. Treat reworked area with chromic acidmore than 20% of diameter. In area I, (C-103). Prime and paint area to match

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finish, except for a 1.0 in. (25.4 mm) wide NOTEband centered on web which is to be primedonly. The H in part number indicates

bushing is 1/32 in. (0.79375 mm)8. Main support case: larger than first dash number

indicates. The first dash numberindicates size in sixteenths of an

NOTE inch (1.58750 mm).

For support cases with integrally (5) If diameter C exceeds 1.1572 in.cast lift link lugs, proceed as follows. (29.39288 mm) but does not exceed 1.1877For support cases with bolt on lift in. (30.16758 mm), ream 1.1870 to 1.1885 in.link lug, proceed to step b. (30.1498 to 30.1879 mm), and use new 22-

019-63-66-43 bushing. If diameter C exceedsa. Replace lift link bushings (3 and 4, 1.1885 in. (30.1879 mm), replace case (5).

figure 63-46) as follows:

(6) After rework, diameter B shall be(1) Check ID of bushing (3 and 4) to concentric to diameter C or E within 0.002 in.

determine if bushing replacement is (0.0508 mm) and surface finish in reamednecessary. Remove bushing if ID exceeds the hole shall be 40 RMS or better.following:Dia. D 0.7508 in. (19.07032 mm) (7) Treat all reworked areasDia. E 1.0008 in. (25.42032 mm) immediately after rework with corrosion

preventive compound (C-103)(BHT-212-MM).

NOTE (8) Heat case (5) lugs to approximately200°F (93°C) with a heat lamp. Coat mating

All 212-040-054 cases shall be surfaces of bushings and case withreworked at initial overhaul to accept unreduced primer (C-201). Tap bushing in to22H14-47-33-34 bushings (4). seat flange against case.

(2) Ream diameter B, figure 63-45, (9) Ream bushing (4), diameter D,0.9057 to 0.9067 in. (23.00478 to 23.03018 0.7500 to 0.7505 in. (19.05 to 19.0627 mm).mm). Bore shall be concentric with diameterC or E within 0.002 in. (0.0508 mm). Surface (10) Ream bushing (3), diameter E,finish of the reamed hole shall be 40 RMS or 1.0000 to 1.0005 in. (25.4 to 25.4127 mm).better.

(11) After reaming inside diameter of(3) If diameter B exceeds 0.9067 in. bushing, diameter D shall be concentric with

(23.03018 mm), but does not exceed 0.9375 diameter E within 0.001 in. (0.0254 mm) TIR.in. (23.8125 mm), ream 0.9370 to 0.9380 in. Surface finish in reamed hole shall be 40(23.7998 to 23.8252 mm) and use new 22- microinches (1.02 um) or better.015-47-33-34 bushing (4, figure 63-46). Ifdiameter B exceeds 0.9380 in. (23.8252 mm), b. Rework in critical areas shown onreplace case (5). figure 63-45 is limited to blending out minor

scratches which do not exceed 0.010 in.(4) If diameter C exceeds acceptable (0.254 mm) in depth and/or 1.0 in. (25.4 mm)

limits but does not exceed 1.1564 in. in length with following exception: Minor(29.37252 mm), ream 1.1567 to 1.1572 in. damage located on radii in critical areas shall(29.38018 to 29.39288 mm) and use 22H018- be blended out up to maximum depth of 0.03063-66-42 bushing. in. (0.762 mm) and maximum length of 2.0 in.

(50.8 mm).

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MAIN CASE WEB AFFECTED BY CRACKING

MAIN INPUTQUILL PORT(REF) A

(REF) X + 0.250 IN. (6.35 mm) 2

REWORK MUST BERESTRICTED TO WITHINTHIS AREA

NOTES

Measure reference dimension "X"between surface of shim plate andface of web before grinding.

Maximum allowable depth afterrework equals "X" plus 0.250inch (6.35 mm).

Prime only 1 inch (25.4 mm) wideband. Center of web. Do not paint.

SECTION A-A 212-R-63-44

Figure 63-44. Main case center web

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NOTE (c) Treat surfaces after drilling withchromic acid (C-103) or treat entire part with

Rework areas are shown on figure magnesium alloy chemical film treatment63-45. Dimensions given are based (BHT-ALL-SPM).on minimum wall thickness.

(d) Install new stud in reworked holec. Rework in crosshatched areas (figure (BHT-ALL-SPM)

63-45) is limited to blending out nicks,scratches, and dents, which do not exceed (e) All counterdrilled holes shall be0.040 in. (1.016 mm) in depth with following filled with adhesive (C-308). Flush with topexception: Minor damage located on radii in surface of case.crosshatched areas shall be blended out upto a maximum depth of 0.060 in. (1.524 mm).

NOTEd. Rework in shaded areas (figure 63-45)

is limited to blending out nicks, scratches and All areas not specifically detailed indents which do not exceed 0.060 in. (1.524 figure 63-45 shall have damagemm) in depth. Minor damage located on radii blended out to a maximum of 0.010in shaded areas shall be blended out up to a in. (0.254 mm) depth.maximum depth of 0.060 in. (1.524 mm).

f. All case surfaces reworked shall bee. In areas F and G, figure 63-45, pitting finished using 400 grit abrasive cloth or paper

to a maximum depth of 0.020 in. (0.0508 mm) (C-423).is permitted, provided no more than 40% ofany 1.0 sq.in. (645.2 sq mm), and no more g. Treat all reworked areas immediatelythan 20% of total surface area is corroded. after rework with chromic acid (C-103).Areas of corrosion which exceed half thewidth of mounting surface are not permissible. h. Inspect reworked areas by fluorescentCases having corrosion on studs or on case penetrant method (BHT-ALL-SPM).immediately adjacent to studs shall be furtherinspected to determine if rework is possible, Replace fifth mount bushings (1 and 2,as follows:as follows: figure 63-46) as follows:

(1) Measure and record stud height. NOTE

(2) Remove stud from corrosion After rework, diameters G and H,damaged area. figure 63-45, shall be concentric with

each other within 0.002 in. (0.0508(3) If corrosion has affected more than mm). Surface finish of reamed hole

one complete thread, replace case. to be 40 RMS or better.

(4) If corrosion has affected less than a. Check size of diameter G, figure 63-45,one complete thread, rework case as follows: to determine size of replacement bushings.

(a) In area F, use a 0.327 to 0.334 in. (1) If diameter G does not exceed 0.938(8.3058 to 8.4836 mm) diameter drill, counter in. (23.825 mm), use 22-015-51-32-40drill stud hole to a maximum depth of 0.125 bushing (steps c. through i.).in. (3.175 mm). Break all sharp edges,except in area of thread. (2) If diameter G exceeds 0.938 in.

(23.825 mm), but does not exceed 0.9678 in.(b) In area G, use a 0.452 to 0.459 (24.58212 mm), ream 0.9683 to 0.9693 in.

in. (11.4808 to 11.6586 mm) diameter drill, (24.59482 to 24.62022 mm) for 22H015-51-counterdrill stud hole to a maximum depth of 32-40 bushing (2, figure 63-46).0.156 in. (3.9624 mm). Break all sharpedges, except in area of thread.

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NOTE (4) If diameter H, figure 63-44, exceeds0.708 in. (17.9832 mm), replace case (5,The H in part number indicates (17.9832 mm), replace case 5,

bushing is 1/32 inch larger than firstdash number indicates. The firstdash number indicates size in c. Treat all rework areas, after reaming,sixteenths of an inch. with magnesium alloy chemical film treatment

(BHT-ALL-SPM).

(3) If diameter G (figure 63-45) exceeds0.9693 in. (24.59482 mm) but does not d. Heat fifth mount lug to approximatelyexceed 0.999 in. (25.3746 mm), ream 0.9995 200°F (93°C) with a heat lamp.to 1.0005 in. (25.3873 to 25.4127 mm) for 22-016-51-32-40 bushing (2, figure 63-46). e. Coat faying surfaces of bushing and

fifth mount lug with unreduced primer (C-201).(4) If diameter G, figure 63-45, exceeds Tap bushing in to seat flange against case.

1.0005 in. (25.4127 mm), but does not exceed1.0300 in. (26.162 mm), ream 1.0307 to f. Ream bushing (2, figure 63-44),1.0317 in. (26.17978 to 26.20518 mm) for diameter J, figure 63-45, 0.812 to 0.8125 in.22H016-51-32-40 bushing (2, figure 63-46). (20.6248 to 20.6375 mm).

(5) If diameter G, figure 63-45, exceeds g. Ream bushing (1, figure 63-45),1.0317 in. (26.20518 mm), but does not diameter K, figure 63-45, 0.5621 to 0.5625 in.exceed 1.0610 in. (26.9494 mm), ream (14.27734 to 14.2875 mm).1.0620 to 1.0630 in. (26.9748 to 27.0002 mm)for 22-017-51-32-40 bushing (2, figure 63-46). h. Diameters J and K shall be concentric

with each other within 0.001 in. (0.0254 mm).(6) If diameter G, figure 63-45, exceeds Surface finish in reamed hole shall be 40

1.0630 in. (27.0002 mm), replace case (5, RMS or better.figure 63-46).

i. Inspect reworked areas by fluorescentNOTE penetrant method (BHT-ALL-SPM).

Bushings (1, figure 63-46) are to be 10. Repair fitting (5, figure 63-47) inreplaced as a set of two. accordance with figure 63-48.

b. Check size of diameter H, figure 63-45, a. Replace parts not within allowable wearto determine size of replacement bushing. limits.

(1) If diameter H does not exceed 0.688in. (17.4752 mm), use 22-011-35-15-26 63-51. Painting.bushing (1, figure 63-46) (steps c. through i.).

Paint top, main, and support cases(2) If diameter H, figure 63-45, exceeds (paragraph 63-43), as applicable.

0.688 in. (17.4752 mm), but does not exceed0.6965 in. (17.7673 mm), ream 0.697 to 0.698in. (17.7078 to 17.7292 mm) for 22X011-35- 63-52. Assembly.15-26 bushing (1, figure 63-46).

MATERIALS REQUIRED(3) If diameter H, figure 63-45, exceeds

0.6965 in. (17.6911 mm), but does not exceed0.7065 in. (17.9451 mm), ream 0.707 to 0.708 NUMBER NOMENCLATUREin. (17.9578 to 17.9832 mm) for 22Y011-35- C-201 Primer15-26 bushing (1, figure 63-46).

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NOTE required thickness. Apply cadmium plate(BHT-ALL-SPM). Measure required thickness

Top and support cases do not of shim plate after plating.require shimming or assembly of e. Identify new shim plate by etchingcomponent parts, serial number of applicable case on shim

plate. Also etch thickness (in thousandths of

1. Inspect original shim plates on main case. an inch) on shim plate. Use AE No. 21etching ink or equivalent. Neutralize withEnsure cadmium plating on shim plate is etching ink or equivalent. Neutralize withwater and common baking soda after etching.

intact.3. Inspect main case visually to ensure

NOTE washer seat inserts and clinch nuts areproperly installed.

Refer to figure 63-42 for assembly of 4. Install shim plate set (30, figure 63-41) onmain case. top flange of main case and secure with

screws (1).

2. Identify shim plates for installation in a5. Install shim plate (7) for main input quill

specific location and/or determine required on rear port of main case and secure withthickness of shim plates as follows: screws (5).

a. Inspect shim plates and case on which 6. Install shim plate (24) for hydraulic pumpdrive quill on front port of main case and

shim plate is to be installed for an etched drive quill on front port of main case andsecure with screws (25).

serial number. The same serial number shallbe on both parts. If parts cannot be identified 7. Install shim plate (16) for rotor brake driveby serial number, determine required quill, if installed, on left port of main case anddimension of shim. secure with screws (15).

8. Install shim plate (32) on right port ofb. Inspect case for a reference dimension main case (31) and secure with screws.

which shall be metal stamped or vibro-etchedon part adjacent to mounting surface. Record 9. Install input pinion bearing (3) and securethis dimension and location on case. with retainer ring (4). Install input gear shaft

bearing (21) and secure with retainer ring(20).

c. If a shim plate of correct part numberbut without a serial number is available, 10. Install lift link fitting (5, figure 63-47),measure thickness and record. Determine washers (4), and nuts (3). Torque 37 to 42whether shim plate is correct for this ft.lbs. (50.1646 to 56.9436 Nm). Install cotterparticular installation as follows: pins.

I (1) Subtract shim plate thickness toreference dimension found on main case. Theresulting value shall be within requireddimension given in Table 63-3.

d. If required shim plate is missing, repeatsteps b. and c. Grind new blank shim plate to

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BHT-212-CR&O

A REA G

CRITICAL AREAS

i SHADED AREAS

(ENLARGED)

HATCHED AREAS 212-63-45212-R-63-45-1

Figure 63-45. Transmission main support case repair limits (sheet 1 of 2)

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BHT-212-CR&O

A J

SECTION B-B

212-R-63-45-2

Figure 63-45. Transmission main support case repair limits (sheet 2)

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BHT-212-CR&O

Table 63-3. Main case required dimensions

REQUIRED DIMENSIONLOCATION SHIM PLATE PART MIN. MAX.

NUMBER(INCHES) (MM) (INCHES) (MM)

FOR 204-040-353 CASE

Main Case -top 204-040-353-011 6.1240 155.5496 6.1250 155.575Main Case - rear port 204-040-353-013 8.5620 217.4748 8.5625 217.4875Main Case- front port 204-040-353-017 7.4715 189.7761 7.4720 189.7888Main Case - left port 204-040-353-015 7.4715 189.7761 7.4720 189.7888

FOR 212-040-053 CASE

Main Case -top 212-040-053-017 6.1340 155.8036 6.1350 155.829Main Case - rear port 212-040-0533-015 8.6420 219.5068 8.6425 219.5195Main Case -front port 212-040-053-013 7.4715 189.7761 7.4720 189.7888Main Case - left port 212-040-053-013 7.4715 189.7761 7.4720 189.7888Main Case - right port 212-040-053-013 7.4715 189.7761 7.4720 189.7888

NOTE 205-040-308- 0.006 in.007 (0.1524 mm)

Transmission cases which do not oversizehave three studs installed at input 205-040-308- 0.009 in.quill bore to accept T101586 pusher 009 (0.2286 mm)set may be reworked in accordance oversizewith step 11. 205-040-308- -0.012 in.

011 (0.3048 mm)11. Install studs for T101586 pusher set as oversizefollows:

a. Remove standard studs from one, five, c. Coat threads of studs with unreducedand nine o'clock positions. primer (C-201). Start studs into holes in

b. Select a 205-040-308 stud to achieve case.

d. Use a suitable stud driving tool andtorqued. torque studs 175 to 250 in.lbs. (19.7715 to

PART SIZE 28.245 Nm), maintaining a projected height ofNUMBER 1.290 and 1.310 in. (32.766 to 33.274 mm).

205-040-308- -Standard e. Install set screws into internal threaded003 end of studs.205-040-308- -0.003 in.005 (0.0762 mm) 63-53. PLANETARY GEAR

oversize ASSEMBLIES.

NOTE

This paragraph outlines overhaul ofthe planetary ring gear, upper

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BHT-212-CR&O

1. Forward Fifth Mount Bushings 4. Right Lift Link Bushings2. Aft Fifth Mount Bushing 5. Main Support Case3. Left Lift Link Bushing

212-R-63-46

Figure 63-46. Transmission main support case bushing replacement (212-040-054-005)

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BHT-212-CR&O

1. Forward fifth mount bushings 4. Washer2. Aft fifth mount bushing 5. Lift link fitting3. Nut 6. Main support case

212-R-63-47

Figure 63-47. Transmission main support case bushing replacement (212-040-054-013)

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1. Maximum acceptable diameter for diameter L is 0.7525 inch (19.1135 mm). Maximum acceptable diameterfor diameter M is 1.0025 inch (25.4635 mm).

2. Area A

Corrosion pitting up to 0.010 inch (0.254 mm) in depth is acceptable provided no more than 20 percent ofany one square inch (645.2 square mm) and no more than 10 percent of the total surface area is corroded.Washers must make contact with fitting for entire 360 degrees around each bolt for at least 50 percent ofwasher width. No more than 10 percent of normal area contacted by washer may be pitted.

3. Area B

Corrosion pitting up to 0.005 inch (0.127 mm) in depth is acceptable provided no more than 20 percent ofany one square inch (645.2 square mm), and no more than 20 percent of the total surface area is corroded,except area E.

4. Area C

Mechanical damage in either area C, but not on radii, up to 0.010 inch (0.254 mm) in depth and 0.50 inch(12.7 mm) in length, and mechanical damage on the radii up to 0.020 inch (0.508 mm) in depth and 1.0 inch(25.4 mm) in length is acceptable if polished out.

5. Area D

Corrosion pitting up to 0.010 inch (0.254 mm) in depth is acceptable provided no more than 20 percent ofany one square inch (645.2 square mm), and no more than 40 percent of the total surface area is corroded.Minor damage on blend radii shall be blended out to a maximum depth of 0.010 inch (0.254 mm) andmaximum length of one inch (25.4 mm).

6. Area E

Surface corrosion only is permitted. Surface corrosion is that which can be removed with wire brush or steelwool.

r DIA L DIA M AREA E

AREA A AREA A (FARSIDE - 2 PLACES(4 PLACES)

AREA B

LIFT LINK FITTING 212-040-105-001212-R-63-48

Figure 63-48. Lift link fitting damage limits

63-00-00Page 112

BHT-212-CR&O

planetary gear, and lower planetarygear. CAUTION

63-54. Disassembly. USE CARE WHEN REMOVINGPINION FROM SPIDER TO

SPECIAL TOOLS REQUIRED PREVENT DAMAGE TO ROLLERSAND RACE.

NUMBER NOMENCLATUREd. Separate planetary pinion bearing

204-040-009-1 Holding fixture washers (3), planetary pinion roller set (7),PAT-2D pinion bearing retainer (6), pinion bearingT101332 Planetary installing pin race (5) from planetary pinion (4).T101332 Planetary installing pin

T101562 Gauge blockCAUTION

T101565 Washer removal nut CAUTION

T101572 Alignment fixturePLANETARY PINION ROLLERS

T101573 Holding fixture FROM EACH PINION ARE AMATCHED SET AND SHALL NOT

T101574 Shaft guide BE INTERMIXED.

1. Planetary ring gear. e. Remove remaining pinions in samemanner outlined in steps b. through d.

a. If not previously accomplished, removethree jet housings from planetary ring gear 3. Lower planetary.(paragraph 63-37).

a. Mount T101573 holding fixture in a2. Upper planetary. bench vise and position planetary on fixture

figure 63-51, view A. Remove nuts (2).a. Remove pinion bearing shaft nuts (2, Invert planetary on holding fixture, view B.

figure 63-50) using square wrench adapter. Break high torque on bolts (9 or 16), but keeptight to provide assembly rigidity during

b. Press one pinion shaft (1) out of spider removal of shafts (1). After torque is brokenassembly (8) with T101574 shaft guide. on four bolts (9 or 16), remove planetary from

holding fixture.

NOTE b. Thread T101574 shaft guide into shaft

Do not disassemble spider (8). The (1). Press shaft out of planetary. Do notDo not disassemble spider (8). Thespider consists of a plate and web allow pinion to fall out of planetary. Installwhich are assembled prior to final T101332 planetary installing pin into pinionmachining at time of manufacture. inner race (5) and tap pinion gear (4) out of

side opening between plates. Hold thrustc. Position T101332 planetary installing washers (3) in place to keep rollers (7) inc. Position T101332 planetary installing

pin through pinion bearing race (5) and tap retainer (6).pinion out of side opening of spider. Holdplanetary pinion bearing washers (3) in place c. Separate thrust washers (3), rollers (7),to prevent planetary pinion roller set (7) from retainer (6), inner race (5), and T101332falling out of pinion bearing retainer (6). planetary installing pin from pinion gear (4).

63-00-00Page 113

BHT-212-CR&O

MATERIALS REQUIRED (CONT)CAUTION

NUMBER NOMENCLATUREROLLERS (7) ARE A MATCHED C-334 1.1.1-TrichloroethaneSET. DO NOT INTERMIX WITHROLLERS FROM ANOTHER C-436 Paint RemoverPINION GEAR.

d. Remove and disassemble remaining 1. Clean all planetary parts with solvent (C-pinion gears in same manner outlined in steps 304). Use soft bristle brush to dislodgeb. and c. stubborn deposits. All parts except bearings

may be cleaned with 1.1.1-trichloroethane (C-

e. Remove nuts (8) and bolts (9) or nuts 334) by vapor degreasing, if desired.(18) and bolts (16). Separate plate set (12)and spider (13). 2. Dry parts with clean, lint-free cloths or

dry, filtered, compressed air. Do not allow

f. Remove cups (10) and washers (11) bearings to spin while drying.from plate set (12). Use T101565 washerremoval nut to remove washers. Thread nut 3. Remove paint from all painted partson washer and place a drift through washer except manifolds and jet housings with paintand cup of washer and nut so drift is against remover (C-436).inner surface of washer removal nut. Tapdrift with mallet to remove washer. 4. Rinse all parts with water and dry with

filtered compressed air.

g. Remove four retaining rings (14). 5. Coat bearings with corrosion preventive(C-105) immediately after cleaning. Do nothandle unoiled bearings with bare hands.

CAUTION6. Immediately after cleaning bearings,gently agitate bearings in corrosion preventive

INSPECT BEARING (15) FOR (C-105) and allow to drain dry. Apply coat ofPROPER PART NUMBER. IF oil of type used in transmission to bearings.MS14102-9 BEARINING ISINSTALLED, DISCARD. ENSUREBEARING PART NUMBER KWB9 IS NOTEINSTALLED ON INSTALLATION.

Parts treated per steps above may

h. Position spider (13) in base of be left covered in indoor storage foralignment fixture with guide and punch in approximately 150 hours withoutposition to press bearing (15) out of spider being affected by corrosion.(see view C). Press four bearings out ofspider. 7. Inspect parts for corrosion damage to

threaded studs and stud holes beforecleaning. No structural damage to threads or

63-55. Cleaning. holes is acceptable.

MATERIALS REQUIRED 8. Remove sealant from planetary ring gearwith plastic scraper.

NUMBER NOMENCLATURE Inspection63-56. Inspection.C-105 Corrosion Preventive

1. Inspect all parts of upper and lowerC-304 Solvent planetary visually for excessive wear and

63-00-00Page 114

BHT-212-CR&O

SEE DETAIL A

SURFACE G SURFACE H

C I A F A I D

DETAIL A

AREA TYPE OF DAMAGE NOMENCLATURE INSPECTION METHOD LIMIT

A Corrosion/Mechanical Gear Teeth Visual/Measure

B Corrosion/Mechanical External Surfaces Visual/Measure

C Wear Diameter Visual/Measure 14.801 IN.(375.9454 mm) MAX

D Wear Diameter Visual/Measure 14.801 IN.(375.9454 mm) MAX.

E Corrosion Flange Holes Visual/Measure

F Corrosion/Mechanical Interior Surface Visual/Measure

G Corosion/Mechanical Flange Face Visual/Measure

H Corrosion/Mechanical Flange Face Visual/Measure

I Corrosion/Mechanical Interior Surface Visual/Measure

212-R-63-49-1

Figure 63-49. Planetary ring gear (sheet 1 of 2)

63-00-00Page 115

BHT-212-CR&O

NOTES

A Visually inspect gear teeth in Area A for spalled, scuffed, pitted or scratched surfaces or chipped teeth. Anyspalling, scuffing and pitting that can be detected with a probe having a 0.020 inch (0.508 mm) sphericalradius is unacceptable. Polish out minor damage in tops or ends of teeth with fine India stone (C-464). Nocorrosion pitting is permitted on any gear tooth surface. No corrosion or mechanical damage is permitted inthe area between the gear root diameter and the rim inside diameter.

A Light corrosion pitting is acceptable in Area B provided the pitting, after rework is no deeper than 0.005inch (0.127 mm) and covers no more than 40 percent of any one square inch (645.2 square mm) of surfacenor, as an aggregate total, cover more than 10 percent of the total area of any surface.

Mechanical damage in the form of nicks, dents, and scratches is acceptable in Area B provided the damageafter rework is no deeper than 0.005 inch (0.127 mm), nor longer than 0.500 inch (12.7 mm) with 1.50inch (38.1 mm) minimum separation between the reworked areas.

A Corrosion and mechanical damage may extend no closer than 0.100 inch (2.54 mm) from the edge of anyflange hole or jet manifold mounting hole and may cover no more than 15 percent of the area bounded bythe hole diameter and a 0.625 inch (15.875 mm) diameter centered on the hole axis. Polish out corrosionand mechanical damage using a fine India stone (C-464) to a 0.250 inch (6.35 mm) minimum fillet radiiwith a surface finish of 63 RMS or finer. Remove any raised material flush with surrounding surface.

A Light corrosion fretting is acceptable on Surfaces G and H provided the fretting does not extend out,circumferentially from any flange hole center line more than 1.00 inch (25.4 mm) and may be removed bylightly hand polishing with fine steel wool (C-411) or fine nylon web abrasive pad (C-407).

Mechanical damage in the form of nicks, dents, and scratches is acceptable on Surfaces G and H providedthe damage is no deeper than 0.005 inch (0.127 mm), no longer than 0.400 inch (10.16 mm) and with1.50 inch (38.1 mm) minimum separation between damage sites.

Jackscrew scars are acceptable at three locations on Surface H.

Do not polish out mechanical damage and jackscrew scars but remove any raised material flush withsurrounding surface using a fine India stone (C-464).

5 Corrosion pitting is not acceptable in Area I. Discontinuous circular wear bands are acceptable in Area Iprovided the wear and associated light fretting corrosion can be readily removed or blended by lightly handpolishing with fine steel wool (C-41 1), or fine nylon web abrasive pad (C-407).

Diameter C and D wear limits must be satisfied following polishing.

Mechanical damage only in the form of very light axial scratches is acceptable in Area I provided the depthof the scratches does not exceed 0.001 inch (0.0254 mm).

6 Diameters C and D must be measured at four equally spaced locations and the measurement averaged. Theaverage value must be no larger than the replacement limit given.

7 Light corrosion is acceptable in Area F only provided that it can be removed by hand polishing with fine steelwool (C-411) or fine nylon web abrasive pad (C-407).

212-R-63-49-2

Figure 63-49. Planetary ring gear (sheet 2)

63-00-00Page 116

BHT-212-CR&O

-

1. Shaft2. Nut3. Washer4. Pinion5. Race6. Retainer7. Roller Set8. Spider Assembly

AREA OF ALLOWABLE PITTING

VIEW B-B

212-R-63-50

Figure 63-50. Upper planetary

63-00-00Page 117

BHT-212-CR&O

1. Shaft 10. Cup2. Nut 11. Washer 23. Washer 12. Plate set4. Pinion gear 13. Spider5. Innerrace 14. Retaining ring 166. Retainer 15. Bearing7. Roller 16. Bolt8. Nut 17. Spacer9. Bolt 18. Nut

12

NOTES 17

Used on P/N 204-040-784-101lower planetary.

Used on P/N 204-040-784-005 VEE MARKlower planetary.

3

5 0.020 IN. (0.508 mm)

MAX. CHIP

2 VEE MARK

212-R-63-51-1

Figure 63-51. Lower planetary (sheet 1 of 2)

63-00-00Page 118

BHT-212-CR&O

VIEW A - HOLDING FIXTURE (T101573) APPLICATION -POSITION FOR REMOVAL/INSTALLATION OF NUTS (2).

PUNCH

(T101572- 5)

VIEW C - ALIGNMENT FIXTURE (T101572) APPLICATION -POSITION FOR REMOVAL OF BEARING (15).

212-R-63-51-2

Figure 63-51. Lower planetary (sheet 2)

63-00-00Page 119

BHT-212-CR&O

damage. Inspect all threaded parts for (Cont)

damaged threads. Figure and NomenclatureIndex No.

2. Inspect pinion gears for chipped, broken,or worn teeth.

63-51, 5 Inner race

3. Inspect bearing surfaces of rollers, races, 63-51, 8 Nutand pinion gears for spalling, scoring, pitting, 63-51, 9 Boltbrinelling, indentations, or corrosion damage. 63-51, 10 Cup

63-51, 11 Washer63-51, 12 Plate set (See note)

CAUTION 63-51, 13 Spider63-51, 16 Bolt63-51, 17 Spacer

DO NOT HANDLE UNOILED 63-51, 18 NutBEARINGS WITH BARE HANDS.

NOTENOTE

Light scoring is acceptable in centerof races in area contacted by bronze Do not separate carrier plate fromretainer. web of spider (8, figure 63-50)

during magnetic particle inspection.

4. Inspect retainers (6, figure 63-50) and (6,figure 63-51) for damage and for evidence of Plate set (12, figure 63-51) is aimbedded bearing chips or other steel matched set. Individual plates areparticles in tang on retainers. not interchangeable.

5. Inspect upper surface of spider of upper 9. Inspect parts dimensionally and replaceplanetary for corrosion. parts which do not fall within inspection limits

(figures 63-52 and 63-53).6. Inspect planetary ring gear visually forchipped, broken, or worn teeth (figure 63-49). NOTENOTE

7. Inspect ring gear by magnetic particle Wear limits are provided to showinspection (BHT-ALL-SPM). required fit between mating parts. It

is not intended all dimensions be8. Inspect following parts by magnetic checked as a prescribed overhaulparticle method. Demagnetize all parts after procedure. However, parts exhibitinginspection (BHT-ALL-SPM). evidence of wear or physical

damage shall be checkedFigure and Nomenclature dimensionally.Index No.

10. Inspect upper planetary gears wear63-50, 1 Shaft pattern (figure 63-54). Replace gears which63-50, 2 Nut exceed limits.63-50, 4 Pinion63-50, 5 Race63-50, 8 Spider (See note) 11. Inspect lower planetary gears wear63-51, 1 Shaft pattern (figure 63-55). Replace gears which63-51, 4 Pinion exceed limits.

63-00-00Page 120 Rev. 4

BHT-212-CR&0

63-57. Repair. MATERIALS REQUIRED (CONT)

MATERIALS REQUIRED NUMBER NOMENCLATURE

Refer to BHT-ALL-SPM for specification and C-464 India Stonesource.

NUMBER NOMENCLATURE 1. Rework minor chipping at ends ofplanetary ring gear teeth if rework can be

C-105 Corrosion Preventive accomplished within following limits:

C-304 Solvent a. Blend out chipped area with fine Indiastone (C-464) to effect a 0.015 in. (0.381 mm)

C-344 Cleaner

63-00-00Rev. 4 Page 120A/120B

BHT-212-CR&O

radius. Rework area shall not exceed 0.020 only. Avoid getting cleaner in jointin. (0.508 mm) from original end of tooth. between spider halves, pinion shaft

holes, or threaded holes.2. Inspect planetary ring gear by magneticparticle method. No indications of cracks are (5) Dry planetary spider in an ovenpermissible. Demagnetize ring gear (BHT- (150°F maximum), or with clean, dry cloths, or

ALL-SPM). use clean, dry, filtered compressed air.

3. Repair upper planetary as follows: (6) Treat planetary spider for corrosionprevention. Gently agitate part in corrosion

a. Replace all unserviceable parts. preventive (C-105) and drain on rack. Applyprotective coat of approved lubricating oil.

b. Blend out small nicks, burrs, andscratches on splines and gears with fine India 4. Repair lower planetary as follows:stone (C-464) (figure 63-52).

a. Replace all unserviceable parts.c. Inspect upper surface of spider of

upper planetary for corrosion. Pitting isallowable on top plate of upper planetary b. Replace bearings (15, figure 63-51) in(view B-B, figure 63-50) except for area lower planetary spider at each transmissioncontacted by flange of pinion shafts. overhaul.Maximum depth of pitting shall not exceed0.010 in. (0.254 mm) and no more than 20% NOTEof any 1.0 in. square (645.2 sq mm) may beaffected. Old bearings shall be discarded due

to permanent damage duringd. Remove corrosion from upper planetary disassembly.

spider as follows:

c. Blend out any gouges, scratches, and(1) Lightly polish pits with fine emery nicks in spider bearing bore. Replace spider if

cloth and clean and treat to prevent further damage exceeds 0.020 in. (0.508 mm) depthcorrosion, t o p revet damage exceeds 0.020 in. (0.508 mm) depth

and/or if more than 20% of area of bore isdamaged.

(2) Prepare cleaner by thoroughlymixing one volume of cleaner (C-344) andthree volumes of water. 5. Replace parts not within allowable wear

limits.

(3) Surfaces, which are to receivealcoholic phosphoric cleaner, shall be free of 63-58. Assembly.oil, grease, shop soil, and paint. Preclean asrequired with solvent (C-304).

MATERIALS REQUIRED

(4) Apply cleaner by brushing orswabbing. Leave cleaner in contact with metal NUMBER NOMENCLATUREsurface for one to three minutes and rinsethoroughly with clean water. C-304 Solvent

C-405 LockwireNOTE C-423 Abrasive Cloth or

The procedure may be repeated as Paperrequired to remove light rust. Apply C-440 Antiseize Compoundcleaner and rinse to corroded area

63-00-00Rev.3 Page 121

BHT-212-CR&O

PIN DIAMETERPIN DIAMETER

PINION TEETH

SPLINE TEETH

6 5

MIN. MAXITEM NOMENCLATURE INCHES mm INCHES mm

1 Pinion - Gear Teeth Over pins 3.9730 100.9142 3.9793 101.07422(Use 0.2160 IN. (5.4864 mm)diameter pins)

2 Inner Race OD 1.8297 46.47438 1.8303 46.489623 Inner Race ID 1.3750 34.925 1.3758 34.945324 Pinion Gear ID 2.6969 68.50126 2.6976 68.519045 Pinion Shaft OD 1.3752 34.93008 1.3760 34.95046 Spider - Shaft Bore ID 1.3750 34.925 1.3758 34.945327 Spider - Spline Between pins 5.7986 147.28444 5.8143 147.68322

(Use 0.2160 IN. (5.4864 mm)diameter pins) 212-R-63-52

Figure 63-52. Upper planetary wear limits

63-00-00Page 122

BHT-212-CR&O

PIN DIAMETER PIN DIAMETER

SPLINE TEETH PINION TEETH

/

.

11


1 Spider arm ID 1.1245 28.5623 1.1250 28.5752 Cup OD 1.3752 34.93008 1.3760 34.9504

ID 0.5620 14.2748 0.5635 14.31293 Spider spline Between pins 6.3523 161.34842 6.3682 161.75228


4 Spider shaft bore ID 1.3750 34.925 1.3758 34.945325 Pinion shaft OD 1.3752 34.93002 1.3760 34.95046 Pinion gear ID 2.6969 68.50126 2.6972 68.519047 Inner race OD 1.8297 46.47438 1.8303 46.489628 Inner race ID 1.3750 34.925 1.3758 34.945329 Pinion gear teeth Over pins 3.9730 100.9142 3.9793 100.07422


10 Washer ID 1.3750 34.925 1.3765 34.9631ID 0.5690 14.4526 0.5715 14.5161

11 Nut OD 1.3752 34.93008 1.3760 34.950412 Bolt OD 0.5587 14.19098 0.5620 14.274813 Spacer OD 1.3752 34.93008 1.3758 34.94532

ID 0.5650 14.351 0.5663 14.38402

NOTES

Used on 204-040-784-101 planetary assembly.

For 204-040-784-005 planetary assembly.212-R-63-53

Figure 63-53. Lower planetary wear limits

63-00-00Rev. 4 Page 123

BHT-212-CR&O

Pinion, Lower Planetary Assembly.

side.

Pinion, Lower Planetary Assembly.Typical acceptable wear pattern for sun gear

Pinion, Lower Planetary Assembly, Sun GearSide.Pinion is spalled in the flank. Any spalling,scuffing or pitting that can be felt with aprobe having a 0.020 inch (0.508 mm) radiusis unacceptable.

212-R-63-54

Figure 63-54. Lower planetary gear wear pattern

63-00-00Page 124 Rev. 3

BHT-212-CR&O

Pinion, Upper Planetary Assembly.Typical acceptable wear pattern for sun gearside.

Pinion, Upper Planetary Assembly.Typical acceptable wear pattern for ring gearside.

Pinion, Upper Planetary Assembly, Sun GearSide.Pinion is spalled in the flank. Any spalling,scuffing or pitting that can be felt with aprobe having a 0.020 inch (0.508 mm) radiusIs un acceptable.

212-R-63-55

Figure 63-55. Upper planetary gear wear pattern

63-00-00Rev. 3 Page 125

BHT-212-CR&O

SPECIAL TOOLS REQUIRED 040-009-1 PAT-2D holding fixture, alignpinion gear with holes in spider and presspinion shaft (1) into position through pinion.

NUMBER NOMENCLATURE Catch T101332 pin as it is pressed out of

204-040-009-1 Holding fixture pinion. Use caution to prevent damage toPAT-2D shaft or spider assembly. Ensure pinion shaft

(1) is seated. Remove T101574 shaft guideT101332 Planetary installing pin from pinion shaft.

T101562 Gauge block c. Repeat steps a. and b. to installremaining pinions. Install nuts (2) on all eight

T101565 Washer removal nut pinion shafts and torque 60 to 80 ft.lbs.T101572 Alignment fixture (81.348 to 108.464 Nm). Check each pinionAlignment fixture for free rolling in spider. Use a 0.0015 in.T101573 Holding fixture (0.0381 mm) feeler gage to check for

minimum clearance between ends of eachT101574 Shaft guide roller (7) and thrust washers (3). Check at

same points for maximum clearance of 0.003in. (0.0762 mm).

1. Upper planetary.

NOTE

CAUTION If rollers do not turn freely, checkretainer for burrs, and check forchips and foreign material in

DO NOT HANDLE UNOILED PARTS bearing. Recheck partsWITH BARE HANDS. dimensionally if necessary.

d. Secure pinion shafts (1) and nuts (2)a. Assemble planetary pinion (4, figure with lockwire (C-405) (figure 63-56).

63-50), pinion bearing retainer (6), roller set(7), pinion bearing race (5), and washers (3) 2. Lower planetary.on T101332 planetary installing pin. Holdparts together and insert into spider assembly(8). NOTE

Refer to step a. for assembly of 204-NOTE 040-784-005 lower planetary and to

step b. for assembly of 204-040-784-Roller set (7) for one pinion 101 lower planetary.assembly shall be from same

identification mark on end of rollers. CAUTION

Individual rollers (7) are not DO NOT HANDLE UNOILED PARTSinterchangeable and shall not be WITH BARE HANDSmixed between roller sets. Rollersshall be replaced as complete sets. a. Lower planetary (204-040-784-005).Both dash numbers, in completesets, may be used in a planetaryassembly.

b. Install T101574 shaft guide in pinionshaft (1). Position spider assembly (8) in 204-

63-00-00Page 126 Rev.3

BHT-212-CR&O

. MS20995C32 LOCKWIRE

SAFETY WIRE PATTERN FOR LOWER SURFACE.

MS20995C32LOCKWIRE

SAFETY WIRE PATTERN FOR UPPER SURFACE.

212-R-63-56

Figure 63-56. Upper planetary lockwiring

63-00-00Page 127

BHT-212-CR&0

NOTECAUTION

Rollers (7) for one pinion shall befrom same manufacturer. Check

ENSURE BEARING (15) IS PART manufacturers identification mark onNUMBER, KWB9, PRIOR TO end of rollers.INSTALLATION IN SPIDER (13).

Individual rollers (7) are not(1) Obtain four new bearings (15, figure interchangeable and shall not be

63-51) and inspect for sharp edges at outer mixed between roller sets. Rollersdiameter of the chamfer. Polish sharp edge shall be replaced as complete sets.lightly with 400 grit abrasive cloth or paper Both dash numbers, in complete(C-423). Exercise care to avoid damage to sets, may be used in a planetarybearing. Clean bearing with solvent (C-304) assembly.and coat with transmission oil and drain.

(7) Install T101574 shaft guide in shaft(2) Heat spider (13) to 200°F (93°C) (1). Position assembled planetary assembly in

and install in T101572 alignment fixture. 204-040-009-1 PAT-2D holding fixture.Press bearings into position. See figure 63-57 Position assembled pinion gear (4) infor illustration of tool application. Install four planetary assembly. Press shaft (1) throughretaining rings (14, figure 63-51). plates and pinion gear from top and catch

T101332 planetary installing pin as it is(3) Locate V index marks on plate set pushed out through the bottom. Use caution

(12). These marks shall be in line when to prevent damage to shaft or plate set.planetary is assembled (figure 63-51). Select Ensure shaft (1) is seated. Remove T101574four holes in one plate for installation of cups shaft guide from shaft (1). Repeat for(10). Support plate adjacent to hole and press remaining pinions. Verify pinions roll freely.cups into position. Note relative position offlange on plate set (12) and on cup (10) to (8) Apply antiseize compound (C-440)obtain correct installation. Install washers (11) to thread of nuts (2) and install in shafts. Doon cups with press, using a suitable hollow not torque at this time.tool, so force is applied to washer on flatsurface adjacent to thread. (9) Install T101573 holding fixture in a

vise. Position planetary on holding fixture(4) Install four nuts (8) and washers (figure 63-51, view A). Torque nuts (2) 60 to

(11) on lower half of plate set (12) in same 80 ft.lbs. (81.348 to 108.464 Nm) inmanner noted in step c. Ensure nuts and diametrical sequence. Remove planetary fromwashers are installed in correct holes so V on holding fixture and reposition on holdingplates will align on assembly and flanges on fixture (figure 63-51, view B). Torque bolts (9)plate set (12) are outboard as illustrated. 400 to 900 in.lbs. (45.192 to 101.682 Nm) to

obtain a dimension of 1.3770 to 1.3780 in.(5) Position plate set (12) and spider (34.9758 to 35.0012 mm) between plates

(13) together with V marks aligned. Apply adjacent to and on both sides of spider ballantiseize compound (C-440) under heads and joints. Use a T101562 gauge block to checkon threads of bolts (9). Install bolts (9) and dimension.pull up snug but do not torque.

(10) Using a 0.001 in. (0.0254 mm)(6) Assemble pinion gear (4), retainer feeler gage, ensure nuts (2) and shafts (1)

(6), rollers (7), inner race (5), and washers (3) are seated flat against plates.on T101332 planetary installing pin.

NOTE

The 0.001 in. (0.0254 mm) feelergage may slip partially between

63-00-00Page 128 Rev. 4

BHT-212-CR&O

DRIVE(T101572-7)GUIDE(T101572-5)

BASE(T101572-3)

212-R-63-57

Figure 63-57. Lower planetary bearing

flange of nut or shaft at outer edge diameter of chamfer. Polish sharp edgeat some points, but shall not go fully lightly with 400 grit or finer abrasive cloth orunder flange. paper (C-423), if required. Exercise care to

avoid damage to bearing. Clean bearing with

(11) Check pinion gears (4) for free solvent (C-304) and coat with transmissionrotation. Check end clearance between oil. Drain thoroughly.rollers (7) and washers (3). Clearance shallbe 0.001 to 0.003 in. (0.0254 to 0.0762 mm). (2) Heat spider (13) to 200°F (93°C)Check dimension with feeler gage. and install in T101572 alignment fixture.

Press bearings into position (figure 63-57).Install four retaining rings (14, figure 63-51).

(12) Secure nuts (2) and (8) in pairswith lockwire (C-405) (figure 63-58). Secure (3) Locate V index marks on plate setshafts (1) and bolts (9) in same manner. (12). These marks shall be in line when

planetary is assembled (figure 63-51). Selectb. Lower planetary 204-040-784-101. four holes in each plate, keeping V index in

line for installation of spacers (17). Supportplate adjacent to hole and press spacers into

CAUTION position.

(4) Install four nuts (18) and spacers

ENSURE BEARING (15) IS PART (17) on lower half of plate set (12) in sameNUMBER, KWB9, PRIOR TO manner noted in step (3). Ensure nuts andINSTALLATION IN SPIDER (13). spacers are installed in correct holes so V onINSTALLATION IN SPIDER (13). plates will align on assembly and flanges on

plate set (12) are outboard as illustrated.(1) Obtain four new bearings (15, figure

63-51) and inspect for sharp edges at outer

63-00-00Page 129

BHT-212-CR&O

MS20995C32LOCKWIRE-

212-R-63-58

Figure 63-58. Lower planetary lockwiring

(5) Position plate set (12) and spider 204-040-009-1 PAT-2D holding fixture.(13) together with V marks aligned. Apply Position assembled pinion gear (4) inantiseize compound (C-440) under heads and planetary assembly. Press shaft (1) throughon threads of bolts (16). Install bolts (16) and plates and pinion gear from top and catchpull up snug but do not torque. T101332 planetary installing pin as it is

pushed out through bottom. Use caution to(6) Assemble pinion gear (4), retainer prevent damage to shaft or plate set. Ensure

(6), rollers (7), inner race (5), and washers (3) shaft (1) is seated. Remove T101574 shafton T101332 planetary installing pin. guide from shaft (1). Repeat for remaining

pinions. Verify pinions roll freely.

NOTE (8) Apply antiseize compound (C-440)to thread of nuts (2) and install in shafts. Do

Rollers (7) for one pinion shall be not torque at this time.from same manufacturer. Checkmanufacturers identification mark on (9) Install T101573 holding fixture in aend of rollers. vise. Position planetary on holding fixture

(figure 63-51, view B). Torque bolts (16) 35 to IIndividual rollers (7) are not 45 ft.lbs. (47.453 to 61.011 Nm) in diametricalinterchangeable and shall not bemixed between roller sets. Rollersshall be replaced as complete sets. (10) Remove planetary from holdingBoth dash numbers, in complete fixture and reposition on holding fixture (figuresets, may be used in a planetary 63-50, view A). Torque nuts (2) 60 to 80assembly. ft.lbs. (81.348 to 108.464 Nm) in diametrical

sequence. Check with a 0.001 in. (0.254 mm)(7) Install T101574 shaft guide in shaft

(1). Position assembled planetary assembly in

63-00-00Page 130 Rev. 4

BHT-212-CR&O

feeler gage to ensure nuts (2) and shafts (1) (11) Check pinion gears (4) for freeare seated flat against plates. rotation. Check end clearance between

rollers (7) and washers (3). Clearance shallbe 0.001 to 0.003 in. (0.0254 to 0.0762 mm).

NOTE Check dimension with feeler gage.

The 0.001 in. (0.0254 mm) feelergage may slip partially between (12) Secure nuts (2) and (18) in pairsflange of nut or shaft at outer edge with lockwire (C-405) (figure 63-58). Secureat some points, but it shall not go shafts (1) and bolts (16) in same manner.fully under flange.

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TRANSMISSION QUILLS

63-59. TRANSMISSION QUILLS. NOTE

The following paragraphs provide overhaul Bearings (8) must be rigidlyinformation for main input driven gear quill, supported on the inner race aroundno.1 the full circumference so that themain input quill, no.1 hydraulic pump drive the full circumference so that thequill, offset accessory drive quill, accessory outer races are not loaded duringcase input quill, no.2 hydraulic pump and bearing removal. Inadequate supporttachometer drive quill, and rotor brake drive will result in damaged bearings and/quill. or shaft.

5. Remove thirty-two bolts (10) from flange63-60. MAIN INPUT DRIVEN GEAR of shaft (11). Carefully tap or press spiralQUILL. bevel gear (12) off shaft.

63-61. Disassembly. 63-62. Cleaning.



T100965 Power wrench kit C-105 Corrosion Preventive

T100968 Anchor plate C-304 Solvent

T101303 Socket1. Clean quill parts with solvent (C-304).

1. Remove twenty-four bolts and washers (1, Use soft bristle brush to dislodge stubbornfigure 63-59). deposits. All parts except bearings may be

cleaned with solvent (C-304) by vapor2. Carefully tap gear support case (2) off degreasing, if desired.bearings. Remove shims (3 and 4) andidentify for reassembly. Remove collector 2. Dry parts with clean, lint-free cloths or dry(13), if installed. filtered compressed air. Do not allow bearings

to spin while drying.3. Remove screws (5) and lockring (6).Position T101303 socket on nut (7). Install 3. Coat bearings with corrosion preventiveT100968 anchor plate and T100965 power (C-105) immediately after cleaning. Do notwrench on shaft (11) and loosen nut. Remove handle unoiled bearings with bare hands.tools and nut (7).

4. Inspect parts for corrosion damage to4. Support duplex bearings (8) on inner race holes before cleaning. No structural damageand press out of shaft. Identify bearings for to holes is acceptable.reassembly. Bearings are a matched set andmust be retained or replaced in pairs. 5. Remove sealant with plastic scraper.Remove bearing retainer plate (9).

63-63. Inspection.

1. Inspect all parts visually for damage andexcessive wear.

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BHT-212-CR&0

2. Inspect gear support case (2, figure 63- within 0.10 in. (2.54 mm) of edge of a bolt59) for corrosion, and for loose bearing liner hole. The bottom of the holes shall be free ofas follows: burrs, tears, gouges, or compacted chips.

a. The maximum permissible depth of 8. Inspect bevel gear (12) for spalled,pitting, in area E, figure 63-60, is 0.020 inch scuffed, chipped, or dented teeth.(0.508 mm) except as defined in step b.below. No more than 40 percent of area 9. Inspect bevel gear (12) teeth for pittingwithin any one inch square (645.2 sq mm) nor or corrosion damage as follows:20 percent of total area of any surface ordiameter may be pitted. Inspect area F a. Pitting of any magnitude resulting fromcarefully prior to any corrosion removal for surface fatigue during operation is notevidence of corrosion in bolt holes and permissible. This may appear as only a finebetween bearing liner and case. Any evidence line of pin holes near pitch diameter and beof corrosion in bolt holes or between liner and detectable only with a side light source and adetectable only with a side light source and acase is cause for rejection of part. probe point of approximately 0.001 in. (0.0254

mm) radius. A more severe example of this isb. The maximum permissible depth of shown on figure 63-61, detail B. Minor pitting

pitting on lower flange only in area 1/32 inch resulting from corrosion is permissible within(0.79375 mm) below radius to packing groove following limits:in area E, figure 63-60 is 0.030 inch (0.762mm) and is limited to no more than 40 54(1) No more than 0.001 in. (0.0254 mm)percent of area within any one inch squarep and no more than 0.04 in. (1.016 mm)deep and no more than 0.04 in. (1.016 mm)(645.2 sq mm) or 20 percent of total area.Isolated pits in area E are acceptable to amaximum depth of 0.060 inch (1.524 mm)provided total area pitted in excess of 0.030 (2) No more than 0.002 in. (0.0508 mm)inch (0.762 mm) does not exceed 2 percent of deep and no more than 0.04 in. (1.016 mm)area within any one inch square (645.2 sq wide or 010 in. (2.54 mm) long and locatedmm) or 0.50 percent of total area of any on outer (i.e. adjacent to heel) half of face ofsurface or diameter. tooth and above pitch line, or located outside

of wear pattern and outside of root radius.

3. Inspect nut (7, figure 63-59) for damagedthreads. b. Surface roughness detectable by

drawing a probe along tooth in profile4. Inspect duplex bearings (8) for spalling, direction is cause for rejection if pittingscoring, flaking, corrosion, and roughness occurred on mating member.when rotated.

c. Grinding Scratches: Any scratches5. Inspect bearing retainer plate (9) for around which pitting or other damage occursdamaged threads. are not permissible.

6. Inspect shaft (11) for spalling, scoring, d. Nicks, cuts, or dents caused bypitting, flaking, corrosion, and indentations on handling or by foreign material going throughbearing contact surfaces. Inspect splines for mesh during operation are permissiblepitted, chipped, or excessively worn teeth. provided they are no more than 0.003 in.Inspect threads for defects. (0.0762 mm) deep and are no more than 0.02

in. (0.508 mm) across in any direction, and7. Inspect mating surfaces of shaft (11) and cannot be felt with a probe having an endbevel gear (12) for fretting damage. The radius of 0.03 in. (0.762 mm).maximum acceptable depth of fretting (pitting)is 0.0005 in. (0.0127 mm). Pitting of 10. Inspect following parts by magneticmeasurable depth is acceptable only in the particle (Code M) or fluorescent penetrantarea on gear or shaft surface outside of (Code F) as applicable. Demagnetize partsdiameter of bolt holes and is not acceptable after magnetic inspection (BHT-ALL-SPM).

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BHT-212-CR&O

1. Bolts and washers2. Gear support case3. Shim4. Shim5. Screws6. Lockring7. Nut8. Duplex bearings9. Bearing retainer plate

quill.

212-R-63-59

Figure 63-59. Main input driven gear quill

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BHT-212-CR&O

AREA

MAIN INPUT GEAR QUILL CASE

212-R-63-60

Figure 63-60. Main input driven gear quill case corrosion damage areas

NOTE NOTE

Refer to steps 11. and 12. for If ac magnetic particle inspectionspecial inspection procedures for equipment is used, use 60% of dcshaft (11). amperes specified.

a. Thoroughly degrease shaft.Figure, Nomenclature CodeIndex No. b. Place a 2.0 in. (50.8 mm) diameter

63-59, 2 Gear support case F central conductor through the part and place63-59, 7 Nut M the central conductor with part between63-59, 9 Bearing retainer plate M contact plates. Pass 2500 amperes dc63-59, 11 Shaft M voltage through the central conductor.63-59, 12 Spiral bevel gear M

and again pass 2500 amperes dc voltagethrough central conductor. Inspect shaft for

11. Inspect shaft (11, figure 63-59) by indications of defects.magnetic particle method. The shaft shall beinspected by all of the following steps using d. Place the part in coil such that longwet continuous method. Use of fluorescent axis of part is 90° to direction of current flowcoated particles with ultra violet light is through the coil. Magnetize the part usingmandatory. The length of any indication shall 13,000 ampere turns magnetizing force withbe determined by the residual method of dc current. Inspect the part 100% formagnetization. indications.

e. The shaft shall be inspected on bothI.D. and the O.D. after each magnetization.

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DIM A DIM A

DIM B DIMB

PRIMARY CONFIGURATION OF THREADED HOLES OPTIONAL CONFIGURATION OF THREADED HOLES

PART NO. DIM A DIM B PART NO. DIM A DIM B

204-040-701-ALL .510 MAX .616 MAX 204-040-701-ALL .510 MAX .580 MAX

NOTE

Hole depth measurements for gears which were drilledand tapped but have optional true-bored configuration.

212-R-63-60A

Figure 63-60A. Damage limits - spiral bevel gear mounting holes (204-040-701)

63-00-00Rev. 4 Page 136A/136B

BHT-212-CR&O

A. Spiral Bevel Gear, Input Driven Gear Quill.Typical acceptable wear pattern.

B. Spiral Bevel Gear, Input Driven Gear Quill.Gear is spalled on the face of tooth. Anyspalling of this type is unacceptable, and boththe gear and the mating pinion should bereplaced - even though the mating pinion maynot be spalled.

C. Input Pinion.Input drive quil wear pattern showing anonuniform wear pattern with a band of heavywear In the flank. This is maximum acceptablefor this condition.

212-R-63-61C0000

Figure 63-61. Main input driven gear quill wear pattern

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BHT-212-CR&O

f. After completion of inspection, (7) Indications of subsurfacedemagnetize shaft and check with pocket field discontinuities which break a transverse faceindicator or compass to assure shall not exceed 0.031 in. (0.7874 mm) indemagnetization. length or cross section.

12. Evaluate defects noted during magnetic (8) Indications of surface discontinuitiesparticle inspection of shaft (11) as follows which break over corners, run into fillets,(figure 63-62): splines or threads are cause for rejection.

a. Magnetic indications interpreted as (9) Indications caused by a change incracks are cause for rejection regardless of section are acceptable.size or location on part. (10) Strong magnetic indications where

b. Magnetic indications of inclusions, considerable build up is present (indicatingstringers, shuts, or laps are acceptable defect has considerable depth and/or crossprovided they are within all the following section) shall be cause for reectonlimits. regardless of location.

(1) Indications parallel to long axis of 13. Inspect parts dimensionally and replacepart (±150) not exceeding 1/8 in. (3.1750 mm) parts which exceed inspection limits (figurepart (+15°) not exceeding 1/8 in. (3.1750 mm) 63-63).

in length are acceptable in all areas of partexcept as otherwise restricted herein. Not NOTEmore than two 1/8 in. (3.1750 mm) long Wear limits are provided to showinclusions shall be allowed in any 2.0 sq.in. required fit between mating parts. It(1290.4 sq mm) of surface area. Maximum is not intended all dimensions beaccumulative length of all inclusions shall not checked as a prescribed overhaulexceed 1/4 in. (6.350 mm) in any 2.0 sq.in. procedure. However, parts(1290.4 sq mm) of surface area. exhibiting evidence of wear or

(2) Circumferential indications, or physical damage shall be checkedindications more than 15° off long axis of part dimensionally.are acceptable in section BB, figure 63-62, if 63-64. Repair.length of indication does not exceed 1/4 in. MATERIALS REQUIRED(6.350 mm). Not more than two suchindications allowed in any 1.0 sq.in. (645.2 sqmm) of surface area. Maximum accumulative NUMBER NOMENCLATURElength of all indications shall not exceed 1/2 C-464 India Stonein. (12.7 mm) in any 1.0 sq.in. (645.2 sq mm)of surface area. 1. Replace all parts which exceed inspection

(3) Circumferential indications, or limits.indications more than 15° off long axis of part 2. Replace all unserviceable parts.in section A-A are cause for rejection. 3. Dress splines and gear with fine India

(4) Indications on bearing journal in stone (C-464), if small nicks, burrs orsection B-B, figure 63-62, are acceptable if scratches are visible (figure 63-63).length of indications does not exceed 1/16 in. 4. Repair minor damage to bevel gears by(1.58750 mm) and provided indication is 1/8 lightly polishing with fine India stone (C-464)in. (3.1750 mm) or more from end of bearing to remove any material which protrudesjournal. Indications within 1/8 in. (3.1750 above original ground surface.mm) of end of bearing journal surface or at 5 Replace bevel gear support case whichbreak over area are cause for rejection. Not has corrosion damage affecting function ormore than four indications, within above structural integrity (figure 63-61). Removelimits, allowed on each bearing journal. corrosion in area E by acid bath (BHT-ALL-

(5) Indications more than 15° off long SPM).axis, transverse or circumferential, to long 63-65 Assembly.axis are acceptable in spline areas providedthey do not exceed 1/8 in. (3.1750 mm) in MATERIALS REQUIREDlength. Not more than one indication allowedper tooth and not more than six to each spline NUMBER NOMENCLATUREarea. All other indications in spline areas are C-304 Solventcause for rejection. C-405 Lockwire

(6) Indications in threaded section arecause for rejection regardless of size or 1. Clean all parts with solvent (C-304) andlocation in section AA. drain.

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BHT-212-CR&O

A 5.0 IN.(127 mm)

212-R-63-62

Figure 63-62. Main input driven gear quill shaft magnetic inspection areas

evenly to 390 in.lbs. (44.0622 Nm) thenCAUTION individually break bolt torque and retorque to

300 to 325 in.lbs. (33.894 to 36.7185 Nm).Secure bolt heads in pairs with lockwire (C-

DURING ASSEMBLY OF SPIRAL 405) around heads, not over tops.BEVEL GEAR TO SHAFT ENSUREMATING SURFACES ARE DRY. 3. Coat all parts with transmission oil andUSE OF ANY LUBRICANT TO drain.EASE INSTALLATION OF GEARON SHAFT WILL RESULT IN 4. Check duplex bearings (8) to confirmTORQUE LOSS OF ATTACHMENT serial number is same on both bearings. HoldBOLTS AND SUBSEQUENT bearings back to back, measure width ofFRETTING DAMAGE. outer races, and record as dimension C,

figure 63-64.EXERCISE EXTREME CARE WHENASSEMBLING THIS QUILL.

NOTE

AN107607 BOLT IS NO LONGER To determine shim thickness forAUTHORIZED TO ATTACH 204- 204-040-362-013 main input driven040-701 BEVEL GEAR TO 204-040- gear refer to step 5. Refer to step 6.324 SHAFT, USE 214-040-117-5 for 204-040-362-103 main inputBOLT. driven gear.

2. Position spiral bevel gear (12) on shaft 5. Determine thickness of shims (3 and 4,(11) with holes aligned. Tap or press gear on figure 63-59) for 204-040-362-013 main inputflange. Coat threads of bolts (10) with driven quill (figure 63-64 and followingtransmission oil and install. Torque all bolts example):

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BHT-212-CR&O

6 5

10 7


1 Bearings ID 4.7232 119.96928 4.7236 119.97944OD 6.6923 169.98442 6.6929 169.99966

2 Spline (Use 0.1920 IN. Over pins 4.7894 121.65076 4.7938 121.76252(4.8768 mm) diameter pins)

3 Shaft Bearing Seat OD 4.7250 120.015 4.7255 120.02774 Support Case Liner ID 6.6919 169.97426 6.6931 170.004745 Gear ID 7.6000 193.04 7.6008 193.060326 Shaft Gear Seat OD 7.6007 193.05778 7.6015 193.07817 Shaft Bearing Race OD 5.1537 130.90398 5.1545 130.92438 Spline (Use 0.1920 IN. Over pins 4.8948 124.32792 4.8993 124.44222

(4.8768 mm) diameter pins)9 Bearing OD 6.4983 165.05682 6.4990 165.0746

10 Main Case Liner ID 6.4980 165.0492 6.4990 165.0746

P/N 204-040-362-013 SHOWN 212-R-63-63

Figure 63-63. Main input driven gear quill wear limits

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BHT-212-CR&O

NOTE I.INCHES MM

Determine thickness of shim (1)between bearing and liner as Dim. 113.95202outlined in steps a. through c. 4.4863

a. Record the following dimensions. III.

Dim. I above 4.5163 114.71402Dim. C- Measure width of bearing

outer races. Refer to step 4. Dim. II above -4.4863 113.95202

Dim. X - Etched on support case. required thickness Dim. 0.762for shim (3) 0.0300

Dim. Y - Etched on support case.c. Recheck computation of shim

Dim. R - Etched on shaft. thickness.

Dim. T - Etched on bearing retainer NOTEplate.

Determine thickness of shim (2)between case and bearing retainer

Dim. B Given: 3.0610 to 3.0630 in. as outlined steps d. through e.as outlined steps d. through e.(77.7494 to 77.8002 mm).

d. Typical example:

b. Typical example:

IV.INCHES MM

INCHES MMShim determined at III 0.0300 0.762

Dim. B (average) 3.0620 77.7748Dim. C +1.7248 43.80992

Dim. Y +1.4543 36.93922Dim 44.571921.7548Dim 114.71402 1.7548

4.5163V.

II.Dim. T 0.2775 7.0485

Dim. R 1.3095 33.2613Dim. Y 1.4543 36.93922

Dim. C 1.7248 43.80992Pinch required +0.0030 0.0762(0.001 to 0.005 in.)

Dim. X +1.4520 36.8808 (0.0254 0.0127 mm)

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BHT-212-CR&O

IV. I.INCHES MM INCHES MM

Dim. 44.06302 Dim. B (average) 3.0620 77.77481.7348

Dim. Y +1.4543 36.93922VI.

Dim 114.71402Dim. IV above 1.7548 44.57192 4.5163

Dim. V above -1.7348 44.06392 II.

Required thickness Dim. 0.508 Dim. R 1.3095 33.2613for shim (2) 0.0200

Dim. C 1.7248 43.80992

6. Determine thickness of shims (2 and 3) Dim. X +1.4520 36.8808for 204-040-361-103 main input driven quill(figure 63-65 and following example): Dim. 113.95202

4.4863

NOTE I

Determine thickness of shim (3)between bearing and liner as Dim. I above 4.5163 114.71402outlined in steps a. through c.

Dim. II above -4.4863 113.95202a. Record the following dimensions.

Required thickness Dim. 0.762for shim (3) 0.0300

Dim. C- Measure width of bearingouter races. Refer to step 4.

c. Recheck computation of shimDim. X - Etched on support case. thickness.

Dim. Y - Etched on support case. NOTE

Dim. R- Etched on shaft. Determine thickness of shim (2)between case and bearing retainer

Dim. S- 0.0330 in. (0.8382 mm) as outlined in steps d. through e.(Actual measured dim.)

d. Typical example:Dim. T - Etched on bearing retainer

plate.IV.

Dim. B- Given: 3.0610 to 3.0630 in. INCHES MM(77.7494 to 77.8002 mm).

Shim determined at III 0.0300 0.762

b. Typical example: Dim. C +1.7248 43.80992

Dim 44.571921.7548

V.

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BHT-212-CR&O

IV. NOTEINCHES MM

The etched marks placed onDim. T 0.2440 6.1976 bearings by bearing manufacturer to

mark high point of race run out.

Dim. S 0.0330 0.8382 8. Position gear support case (2) on shaft(11). Align vibro etched O on ends of inner

Dim. Y 1.4540 36.9316 races with index marks on shaft. See NOTEfollowing step 2.

Pinch required 0.0030 0.0762(0.001 to 0.005in.)(0.0254to 0.127 mm) If shaft (11) is being replaced, vibra-

etch index mark on new shaft sameDim. 44.0436 as on old shaft.1.7340

9. Press duplex bearings (8) inner races toVI. seat against shoulder of shaft (11). Install

retaining nut (7). Position T101303 socketDim. IV above 1.7548 44.57192 over nut. Assemble T100968 anchor plate and

T100965 power wrench on shaft. TorqueDim. V above -1.7340 44.0436 bearing retaining nut to low side of 150 to 200

ft.lbs. (203.37 to 271.16 Nm). (This is 13.5 toRequired thickness Dim. 0.52832 18 ft.lbs. (18.3033 to 24.4044 Nm) on torquefor shim (2) 0.0208 wrench when using T100965 power wrench

kit.)(Use 0.021in. (0.5334 10. Remove tools as necessary to placemm) shim lockring (6) on nut. Readjust torque, if

necessary, by tightening within torque limitsuntil screw holes line up. Install two screws

e. Recheck computation of shim (5) at opposite sides of shaft and secure eachthickness. with lockwire (C-405) to a hole in edge of

lockring (6).7. Place shim (3, figure 63-59) in liner ofgear support case (2). Install collector (13). 11. Check assembly on surface plate withPress bearings into case back-to-back. Install vernier height gage and dial indicator.twenty-four bolts (1), with washers under Measure dimension B, figure 63-64, at severalheads, through case and shim (4) into points approximately 90° apart.retainer Plate (9). Torque bolt evenly and Measurements shall be between 3.0610 andsecure in pairs with lockwire (C-405) . 3.0630 in. (77.7494 and 77.8002 mm). If

dimension is not obtained, a damaged shim orshim of incorrect thickness may be the cause.

CAUTION Repeat steps 4. through 11. Failure to obtain

and gear wear pattern.

ENSURE BEARINGS AREPROPERLY INSTALLED BACK-TO- 12. Check bearings for free rotation.

BACK. ENSURE SHIMS (3 AND 4)ARE NOT DAMAGED DURINGINSTALLATION OF BOLTS.ENSURE BOLTS (1 AND 10) AREPROPERLY SECURED.

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BHT-212-CR&0

NOTES

1 Shim (shim to obtain dimension B).

2 Shim (shim to obtain 0.001 to 0.005 inch(0.0254 to 0.127 mm) pinch on bearing).

212-R-63-64

Figure 63-64. Main input driven gear quill (204-040-362-013 and -105) shimming

63-00-00Page 144 Rev. 4

BHT-212-CR&O

t tY

3.0610 TO 3.0630 IN.R T ( (77.7494 TO 77.7316 mm)

1. Collector Measure actual thickness2. Shim Shim to obtain 0.001 to 0.005 inch (0.0254 to 0.127 mm)

pinch on bearing3. Shim Shim to obtain dimension B

NOTE

Used on P/N 204-040-362-103 main input driven gear quill.

212-R-63-65

Figure 63-65. Main input driven quill (204-040-362-103) shimming

63-00-00Page 145

BHT-212-CR&O

63-66. MAIN INPUT QUILL (212-040- subjected to an accident or incident363). outside the realm of normal usage,

replace freewheeling clutchSPECIAL TOOLS REQUIRED assembly.

5. Remove nuts (2), washers (3), andNUMBER NOMENCLATURE bearing retainer plate (4). Support sleeve and

press pinion and triplex bearings (5) with shimT101306 Wrench (6) out of sleeve (12).

T101362 Sleeve 6. Support inner races of triplex bearing (5)

T101588 Wrench with T101885 plate. Position plate (4)between pinion (1) and bearing removal tool.

T101885 Plate Press pinion out of bearings. Bearings shallbe retained as a matched set.

NOTE 7. Remove screws (7) and shim plate (8).Tag shim plate for reinstallation on same

For overhaul instructions for main sleeve.input quill, 212-040-263-101, refer toparagraph 63-72. For overhaul of 8. Remove cap (9), union (10), and packingmain input quill, 212-040-263-107, (11). Remove plug (13) and packing (14).refer to paragraph 63-78.

9. Remove seal (24) from sleeve (12).

63-67. Disassembly.63-68. Cleaning.

1. Secure 3/4 in. square bar in visevertically, and position quill on bar with pinion MATERIALS REQUIREDengaged on bar.

2. Remove retainer ring (29, figure 63-66) NUMBER NOMENCLATUREretainer (28) and packing (27). Remove lockspring (26). Remove nut (25) with T101306 C-105 Corrosion Preventivewrench. Lift outer race (16) and internal parts C-304 Solventoff pinion splines. Discard packing (27).

C-334 1.1.1-Trichloroethane3. Remove retainer ring (22) and shield (21).Position outer race (16) on a support withflanged end down. Press inner race (18), 1. Clean all quill parts with solvent (C-304).spacer (17), and bearing (15) out of outer Use a soft bristle brush to dislodge stubbornrace. deposits. All parts except bearings may be

cleaned with 1.1.1-trichloroethane (C-334) by4. Remove bearing (15) and spacer (17) vapor degreasing, if desired.from inner race (18). Remove bearing (20)and freewheeling clutch (19) from outer race. 2. Dry parts with clean, lint-free cloths orReplace clutch (19) at overhaul. dry, filtered, compressed air. Do not allow

bearings to spin while drying.

NOTE 3. Coat bearings with corrosion preventive

If records and/or physical (C-105) immediately after cleaning. Do notappearance of transmission handle unoiled bearings with bare hands.freewheeling clutch assembly (19)indicates assembly has been 4. Inspect quill for corrosion damage to

threaded studs and stud holes before

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BHT-212-CR&O

cleaning. No structural damage to threads or provided they are no more than 0.003 in.holes is acceptable. (0.0762 mm) deep and are no more than

0.020 in. (0.508 mm) across in any direction5. Remove sealant with plastic scraper. and cannot be felt with a probe having end

radius of 0.030 in. (0.762 mm).

63-69. Inspection.3. Inspect nut (25) for damaged threads.

1. Inspect all parts visually for damage and 4excessive wear. 4. Inspect sleeve (12) for corrosion damage,

loose, or damaged liner, loose or damaged

2. Inspect pinion (1, figure 63-66) for studs, or damaged threads.Sleeve flangechipped, dented, spalled, scuffed, and pitted nicks or dents, exceeding 0.030 in. (0.762teeth. Inspect roller bearing surface for mm) depth are cause for rejection of part.spalling, scoring, pitting, brinelling,indentations, and corrosion damage. Inspect 5. Inspect bearings (5, 15 and 20) forsplines for chipped, pitted, or excessively spalling, scoring pitting, brinelling, corrosionworn teeth. Inspect threads for damage. damage, cracked, or broken retainers, and for

roughness when rotated.

a. Pitting of any magnitude resulting fromsurface fatigue during operation is not 6. Visually inspect retaining rings (22 andpermissible on teeth of pinion. This may 29, figure 63-66), retainer (28), locking springappear as only a fine line of pin holes near (26), and nut (25), for deformity.pitch diameter and be detectable only with aside light source and a probe with a point of 7. Visually inspect freewheeling clutch outerapproximately 0.001 in. (0.0254 mm) radius. race (16) and freewheeling clutch inner raceA more severe example of this is shown on (18) for corrosion and excessive wear.figure 63-61, detail B. Minor pitting resulting Brinelling or indentations on either race,from corrosion is permissible within following which may be measured or felt with a probelimits: having an end radius of 0.030 in. (0.762 mm),

is cause for rejection of the race and clutch.(1) No more than 0.001 in. (0.0254 mm) Black oxide removal from inner race is not

deep and no more than 0.040 in. (1.016 mm) sufficient cause for rejection.wide or 0.080 in. (2.032 mm) long.

8. Inspect clutch 205-040-250 (Formsprag).(2) No more than 0.002 in. (0.508 mm)

deep and no more than 0.040 in. (1.016 mm) a. Visually inspect clutch assembly forwide or 0.100 in. (2.54 mm) long and located wear or damage. Use a 3X or 5X glass ason outer (i.e. adjacent to the heel) half of face required. Do not disassemble clutchof tooth and above pitch line; or located assembly during inspections of steps a.outside of wear pattern and outside of root through h. Replace assembly if any of theradius. following conditions exist.

b. Surface roughness detectable by b. Inspect retainer for bent or distorteddrawing probe along tooth in profile direction cross bars and flanges (figure 63-67).is cause for rejection if pitting occurred onmating member. c. Check fit of retainer by installing clutch

in outer race. Retainer shall be round and notc. Grinding scratches: Any scratches bind in outer race.

around which pitting or other damage occursare not permissible. d. Check for freedom of sprags in retainer

slots. Sprags shall not bind in retainer.d. Nicks, cuts, or dents caused by

handling or by foreign material going through e. Inspect retainer for wear on outermesh during operation are permissible diameter and on side flanges. Wear in excess

63-00-00Page 147

BHT-212-CR&O

1. Pinion 11. Packing 21. Shield2. Nut 12. Sleeve 22. Retainer ring3. Washer 13. Plug 23. Wear sleeve4. Bearing retaining plate 14. Packing 24. Seal5. Triplex bearing 15. Bearing 25. Nut6. Shim 16. Outer race 26. Lock spring7. Screw 17. Spacer 27. Packing8. Shim plate 18. Inner race 28. Retainer9. Cap 19. Freewheeling clutch 29. Retainer ring

10. Union 20. Bearing212-R-63-66

Figure 63-66. Main input quill

63-00-00Page 148

BHT-212-CR&O

of 0.004 in. (0.1016 mm) depth is not excess of 0.002 in. (0.05088 mm) fromacceptable. original surface, chips, or dents are not

acceptable.f. Inspect retainer, sprags, and springs for

corrosion. No corrosion pitting is acceptable. m. Inspect inside notch at each end ofsprag for wear caused by garter spring. Wear

g. Inspect sprags for heat discoloration, in excess of 0.002 in. (0.0508 mm) depth iscracks, chips, spalling, or surface breaking not acceptable.which may be from scuffing or scoring. Heatdiscoloration, cracks, chips, spalling n. Inspect garter spring outer diameter(including flaking of formchrome layer), and sides for wear by viewing through emptyscuffing, or scoring are not acceptable. retainer slot (figure 63-67). Wear in excess of

0.0015 in. (0.0381 mm) depth is noth. Inspect sprag inner and outer cam acceptable.

surfaces for wear using a 3X or 5X glass andgood light. Flat wear bands which are o. Inspect vacated retainer slot crossbarobservable are not acceptable, regardless of and end flanges for wear. Wear in excess ofwidth, if they extend more than 1/3 length of 0.004 in. (0.1016 mm) depth is not acceptablesprag. Light polished areas are acceptable. (figure 63-67).

i. Inspect sprag inner and outer cam p. Install sprag in retainer slot by insertingsurfaces for load contact pattern (figure 63- notch at lower end of sprag over lower sprag.67). An inner and/or outer cam load contact Pull an adjacent sprag inward to uncoverpattern within 0.030 in. (0.762 mm) of upper spring. Lift spring sufficiently to installrespective high-load edge of sprag cam is not in upper notch of sprag being installed. Verifyacceptable. correct orientation of sprag to other sprags

(figure 63-67).

CAUTION q. Repeat sprag removal and inspectionoperations, steps a. through q. on three othersprags approximately equally spaced aroundretainer.

THE CLUTCH SHOULD NOT BE retainer.COMPLETELY DISASSEMBLEDFOR INSPECTION. ONLY ONE 9. Inspect the following parts by magneticSPRAG SHALL BE REMOVED AT A particle (Code M) or fluorescent penetrantTIME AND BE REINSTALLED IN (Code F) as applicable. Demagnetize partsSAME ORIENTATION AS after magnetic inspection (BHT-ALL-SPM).REMOVED. IF MORE THAN ONESPRAG IS INADVERTENTLYREMOVED, REASSEMBLY SHALL Figure, Nomenclature CodeBE VERIFIED (FIGURE 63-67). Index No.

63-66, 1 Pinion Mj. Degrease clutch and allow to dry. 63-66, 12 Sleeve F

63-66, 16 Outer race Mk. With clutch lying on a flat surface, 63-66, 18 Inner race M

select one sprag and remove from retainer 63-66, 25 Retaining nut Msufficiently to lift garter spring out of spragend notch and release sprag (figure 63-67).

I. Inspect sides of sprag for wear (figure 10. Inspect parts dimensionally and replace63-67). Inspect corners of sprag cam surface parts which do not fall within inspection limitsfor chips, dents, or loss of material. Wear in (figure 63-48).

63-00-00Page 149

BHT-212-CR&O

CLUTCH RETAINER SPRAG INNER CAM SURFACE

ARROW INDICATEDRETAINER CROSS BAR DIRECTION OUTER

RACE DRIVES

SPRAG OUTER CAM SURFACE 212-R-63-67-1212-R-63-67-1

Figure 63-67. Clutch assembly (sheet 1 of 4)

63-00-00Page 150

BHT-212-CR&O

SPRAG OUTER CAM SURFACE

0.030 IN. (0.762 mm)

RETAINER CROSSBAROUTER CAM SURFACELOAD PATTERN

P/N SIDE

HIGH LOAD CAM EDGE

INNER CAM SURFACE OVER RUNNING PATTERNLOAD PATTERN

P/N SIDE

HIGH LOAD CAM EDGE0.030 IN. (0.762 mm)

NOTE

Replace clutch if contact load pattern is within 0.030 inch (0.762 mm) ofedge of sprag cam.

212-R-63-67-2

Figure 63-67. Clutch assembly (sheet 2)

63-00-00Page 151

BHT-212-CR&O

FORMSPRAG

FREEWHEELING CLUTCH - REMOVAL OR INSTALLATION OF SPRAG

FORMSPR A G

OUTER CAM

SPRAGWEAR CAUSED BY SPRING BUMPER

0.002 IN. (0.0508 mm) MAX.DEPTH OF WEAR ACCEPTABLE

SPRAG FRONT FLAT

MAX. DEPTH OFWEAR ACCEPTABLE0.002 IN. (0.0508 mm) 0.002 IN. (0.0508 mm) MAX.

INNER CAM DEPTH OF WEAR ACCEPTABLE212-R-63-67-3


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BHT-212-CR&O

MASKING TAPEA-A-883, TYPE I

CROSSBAR WEAR CHECK FULL CHECK ALL FOUR CORNERS OFLENGTH OF CROSSBAR BOTH SIDES SPRAG POCKET. WORN SHARP0.004 IN. (0.1016 mm) MAX. CORNER IS NOT ACCEPTABLEACCEPTABLE DEPTH OF WEAR

RETAINER FLANGE WEAR CHECK SPRING WEAR CHECK BOTHBOTH ENDS OF POCKET 0.004 IN. SPRINGS WEAR IN EXCESS OF

SPRINGS WEAR IN EXCESS OF

DEPTH OF WEAR 0.0015 IN. (0.0381 mm) INTO(0.10 1 6 mm) MAX ACCEPTABLE 0.00o1'5 IN. (0.0381 mm) INTODEPTH OF WEAR SRPING WIRE DIAMETER IS NOT

ACCEPTABLE

MASKING TAPEA-A-883, TYPE I

FREEWHEELING CLUTCH - RETAINER AND SPRING WEAR

ARROW SHOWS DIRECTION

OUTER RACE DRIVES

SPRING

SPRAG LOOKING DOWN

ARROW INDICATINGCLOCKWISE LOOKINGINTO SHAFT DURINGINSTALLATION

212-R-63-67-4


63-00-00Page 153

BHT-212-CR&O

2 4 5

17

10

13 121415


1 Pinion OD 3.1500 80.01 3.1505 80.02272 Bearing ID 3.1491 79.98714 3.1495 79.99733 Bearing OD 5.5113 139.98702 5.5118 139.999724 Sleeve Liner ID 5.5110 139.9794 5.5117 139.997185 Clutch Outer Race ID 5.1180 129.9972 5.1191 130.025146 Bearing OD 5.1174 129.98196 5.1181 129.999747 Bearing ID 3.7397 94.98838 3.7403 95.003628 Clutch Inner Race OD 3.7403 95.05362 3.7412 95.026489 Spline Pinion Over pins 3.2917 83.60918 3.2952 83.69808


10 Spline, Clutch Inner Race Between pins 2.8427 72.20458 2.8456 72.27824(Use 0.1440 IN. (3.6576 mm)diameter pins)

11 Clutch Inner Race OD 4.0636 103.21544 4.0646 103.24084(Dia. must not vary more than0.0002 (0.00508 mm))

12 Clutch Outer Race ID 4.8120 122.2248 4.8130 122.2502(Dia. must not vary more than0.0002 (0.00508 mm))

13 Clutch. Outer Race OD 5.3538 135.98652 5.3560 136.042414 Sleeve OD 6.7479 171.39666 6.7500 171.450015 Case ID 6.7500 171.4500 6.7521 171.5033416 Pinion OD 2.0090 51.0286 2.0096 51.0438417 Bearing OD 3.5429 89.98966 3.5433 89.9998218 Case Liner ID 3.5426 89.98204 3.5434 90.00236

212-R-63-68

Figure 63-68. Main input quill wear limits

63-00-00Page 154 Rev. 4

BHT-212-CR&O

NOTE b. Use suitable tool to grip and turn outWear limits are provided to show stud slowly to avoid seizure and breakage.Wear limits are provided to showrequired fit between mating parts. It c. Seized stud should be sawed off 0.060is not intended all dimensions be in. (1.524 mm) from liner surface. Do notchecked as prescribed overhaul adjacent studs.damage liner surface or adjacent studs.procedure. However, partsexhibiting evidence of wear of d. Remove seized or broken stud byphysical damage shall be checked drilling a 0.125 in. (3.175 mm) diameter holedimensionally. It is required that through stud in longitudinal direction. Theinner race (18, figure 63-66) and hole shall be centered in stud within 0.005 in.outer race (16 be measured to (0.127 mm) (0.010 in. (0.254 mm) TIR.determine acceptability. Counter drill this hole 0.187 to 0.913 in.

(4.7498 to 4.9022 mm) diameter to 0.040 in.63-70. Repair. (1.016 mm) depth.

e. Remove stud with EZY-OUT (orequivalent). Use an EZY-OUT which willengage the 0.125 in. (3.175 mm) diameter

NUMBER NOMENCLATURE hole.

C-100 Chemical Film Material f. Install new stud to project 0.490 to0.515 in. (12.446 to 13.081 mm) above

Chromic Acid surface of liner. Locate stud locking key 180°

C-108 Brush Cadmium from location of original key and install keyPlating Solution 0.005 to 0.030 in. (0.127 mm to 0.762 mm)

below surface of sleeve.C-317 Adhesive

4. Replace races (16 and 18) if clutchC-327 Promoter surfaces are cracked, spalled, brinelled,

Primer scored, pitted, or excessively worn.

C-407 Abrasive Pad 5. Replace wear sleeve (23) if worn orrough.

C-427 Barrier Materiala. Use end mill or hand-held grinder to cut

C-436 Paint Remover a groove almost through old wear sleeve (23);

C-464 India Stone avoid cutting through wear sleeve anddamaging outer race (16). Strike wear sleevewith rubber mallet to break uncut portion and

1. Replace all parts which exceed inspection remove sleeve from race.limits.

b. Clean old adhesive from outer race2. Replace all unserviceable parts. (16) with plastic scraper and nylon web

abrasive pad (C-407) or use paint remover3. Replace loose and/or damaged studs in (C-436). Inspect outer race for damage whichsleeve (12, figure 63-66). may have been incurred during removal of

wear sleeve.a. Remove stud locking key with a hard,

thin, hooked tool. The key may be partially NOTEdislodged by tapping key from outside towardcenter of hole with a pointed tool. Precautions shall be taken during

accomplishment of following steps tokeep wear sleeve and outer race

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BHT-212-CR&O

clean. Wear clean, white gloveswhen handling parts and change CAUTIONgloves when soiled. Cover workbench with clean barrier material (C-427). Avoid contact with all mold THE ADHESION PROMOTER USEDrelease agents such as silicone, IN FOLLOWING STEP IS HIGHLYwax, oil, grease, etc. Work area VOLATILE. USE IN WELLwhere bonding is done shall be VENTILATED AREA. KEEPmaintained at 65 to 82°F (18 to PROMOTER IN NON-ABSORBTIVE28°C) with relative humidity below CONTAINER AND KEEP LID75%. Keep area dust free to the TIGHTLY CLOSED WHEN NOT INextent bonding operations are not U S E EXPOSURE Taffected. ATMOSPHERE WILL CAUSE

Bonding steps shall be GRADUAL DECOMPOSITION,accomplished without delay between EXCEPT WHEN APPLIED TOsteps. Four hours is the maximum PARTS AND ALLOWED TO DRY.time interval between sandblasting SEDIMENT OR BROWN RESIDUEand next step. IN BOTTOM OF CONTAINER

INDICATES DECOMPOSITION OFc. Mask outer diameter of new wear PROMOTER TO EXTENT THAT IT

sleeve (23). Mask outer race (16) all over SHOULD BE DISCARDED. THE pHexcept surface which mates with wear sleeve RANGE OF PROMOTER SHALL BEand adjacent 0.062 in. (1.5748 mm) radius. 7 TO 8.Sandblast unmasked surfaces of these partswith 60 grit garnet at 5 to 10 psi (34.475 to f. Apply promoter (C-327) to unmasked68.95 kPa) and remove residue. Wrap parts portion of wear sleeve (23) and outer racein clean paper after sandblasting. (16) with a brush. Use a pure hog bristle

- brush with an unpainted handle. Apply onlyd. Apply grease removing primer (C-345) enough adhesion promoter to wet surfaces.

to unmasked portion of outer race (16) only; promoter to wet surfacesthis step is not applicable to wear sleeve. Stir Allow promoter to dry for minimum of thirtyprimer thoroughly before use. Scrub primer mutes at room temperature or for fifteeninto surface of outer race with nylon web minutes at 150 to 160°`F. If next step is not tointo surface of outer race with nylon webabrasive pad (C-407), use additional primer be accomplished immediately, wrap parts withas required to ensure outer race is clean. clean, moisture proof paper.

g. Mix adhesive (C-317) (33 parts B to100 parts A). Pot life of mixed adhesive is 30

The solvent in primer is to 50 minutes. Coat inside diameter of weartrichloroethane. Use primer in well sleeve (23) and mating surface on outer raceventilated area. (16) with adhesive. Press wear sleeve on

race with spherical relief on OD of weare. Allow primer (C-345) to dry to a white sleeve positioned at outer edge of outer race

powder. Remove dry powder with clean dry flush to 0.020 in. (0.508 mm) recessed (figurecheesecloth. Wear clean, white gloves while 63-69). Clean excess adhesive, leavinghandling parts. If next step is not to be chamfer between wear sleeve and race filledaccomplished immediately, wrap outer race with adhesive. Maintain 0.060 in. (1.524 mm)(16) with clean, moisture proof paper. minimum radius of adhesive contour (figure

63-69). Cure at room temperature for 24hours. After bonding and prior to assembly ofquill, ensure all traces of adhesive arecleaned from area of wear sleeve whichcontacts seal (24, figure 63-66).

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BHT-212-CR&O

6. Repair minor nicks, cuts, or dents on SPECIAL TOOLS REQUIREDpinion (1) by lightly polishing with fine Indiastone (C-464).stone (C-464). NUMBER NOMENCLATURE

7. Repair dents and nicks on sleeve (12) T101362 Sleeveflange top surface by polishing with fine Indiastone (C-464). Blend repaired area into flat T101588 Wrenchsurface with a minimum radius of 0.12 in.(3.048 mm). Finished repair shall be 63 RMSor better. Maximum depth, after repair, shall 1. Clean all parts with solvent (C-304).not exceed 0.030 in. (0.762 mm) depth. Drain excess.

8. Refinish parts after repair in accordance 2. Coat all parts with transmission oil andwith BHT-ALL-SPM as outlined below:ain excess.drain excess.

a. Aluminum parts: Touch up withchemical film material (C-100).

CAUTIONb. Magnesium parts: Remove all traces of

corrosion by immersion in chromic acid bath(BHT-ALL-SPM). Touch up parts with DO NOT HANDLE UNOILED PARTSchromic acid (C-103) or treat entire part with WITH BARE HANDS.magnesium alloy chemical film treatment(BHT-ALL-SPM). 3. Install spacer (17, figure 63-66) and

bearing (15) on inner race (18). Pressc. Cadmium plated steel parts: Treat assembled parts into flanged end of outer

reworked areas with brush cadmium plating race (16). Press on race of bearing which issolution (C-108) (BHT-ALL-SPM). in contact, do not press across bearing.

9. Replace parts not within allowable wear9. Replace parts not within allowable wear 4. Install retainer (28) in outer race withoutlimits. packing (27) and install retainer ring (29).

Packing (27) will be installed in a subsequent63-71. Assembly. step.

MATERIALS REQUIRED 5. Turn flanged end of outer race (16) downand place T101362 sleeve over inboard endof inner race. Place clutch (19) over sleeve

NUMBER NOMENCLATURE with flanged sides of cage up and dragsprings down. Position clutch between inner

C-028 Dry Lubricant and outer races. Remove T101362 sleeve.C-304 Solvent

6. If a Formsprag clutch is being used,C-328 Sealing Compound observe the following procedures during

installation.C-405 Lockwire installation.

a. Install clutch (19) with part number anddrive direction arrow toward flange side ofouter race (16).

b. Using a suitable size packing aroundoutside of clutch to hold sprags down,position clutch between inner and outer racesof couplings.

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BHT-212-CR&O

1. Sleeve2. Seal3. Outer race4. Wear sleeve

APPLY SEALANT HERE

- 0.3 IN. (7.62 mm)

0.020 IN. - - 0.060 IN. (1.524 mm) MINIMUM(0.508 mm) MAX. RADIUS ADHESIVE CONTOUR

212-R-63-69

Figure 63-69. Main input quill sealing

63-00-00Page 158

BHT-212-CR&0

c. Using both hands, slowly rotate outer (12) or be made specifically for thisrace counterclockwise while pushing clutch sleeve.into position with thumbs. Do not force clutchin place with drift or other mechanical means. 10. Identify shim plate for installation inAfter installation, remove packing used to specific location and/or determine requiredhold down sprags. thickness.

7. Remove retainer ring (29) and retainer a. Inspect shim plates and quill sleeve on(28). Support inner race of bearing (15) and which shim plate is to be installed for anpress bearing (20) into place between inner etched serial number. The same serialand outer races. Install shield (21) and number shall be on both parts. If parts cannotretainer ring (22). be identified by serial number, determine

required dimension of shim.8. Clean mating surfaces of seal (24) and

Isleeve (23) with solvent (C-304) and dry. b. Inspect quill sleeve for a referenceApply a film of sealing compound (C-328) to dimension which shall be metal stamped orseal (24) outer diameter in area shown in vibro-etched on part adjacent to mountingfigure 63-69. Note lip of seal shall face surface. Record this dimension and whereinboard and sealant application area is on located on sleeve.outboard portion of seal outer diameter. Pressseal into sleeve and clean excess sealant c. If a shim plate of correct part numberfrom sleeve and seal. but without a serial number is available,

measure thickness and record. Determine9. Measure depth of bearing liner in sleeve whether shim plate is correct for this(12, figure 63-46) from inner face of liner particular installation as follows:flange to inboard end surface of studs, andrecord. Hold triplex bearing (5) together and (1) Subtract shim plate thickness frommeasure width of outer races and record. reference dimension found on sleeve. It isSubtract bearing width from liner depth and required that resulting value fall withinprepare shim (6) to provide 0.000 to 0.001 in. required dimension given at bottom of page.(0.0 to 0.0254 mm) pinch on outer races ofbearings. Position shim in sleeve. A dull burr 11. Align inner races of three bearings somark, approximately 1/8 in. (3.1750 mm) in penciled line shows dull burr-marks of threediameter, is placed on end face of each bearings are in line. Position pinion (1) sobearing inner race, by bearing manufacturer, vibro-etched index marks on pinion shaft areto mark high point of race runout. Bearings aligned with vibro-etched index marks onshall be installed with inner races of the three bearings inner races.bearings positioned with dull burr mark onbearings in line. Before installing bearings,mark a pencil line on inner diameter of each NOTEbearing in line with burr mark. Use the line toalign bearings when installed on pinion. Align If bearings or pinion were replaced,V mark on bearings outer races and press it is necessary to vibro-etch indexbearings into sleeve (12) with apex of V marks (lnes) on new part, same aspointing into sleeve. Install bearing retaining onpart replaced, so bearings mayplate (4),washers (3), and nuts (2). Secure be checked for spinning after testnuts in pairs with lockwire (C-405). If not run. If bearings are replaced, ensurepreviously accomplished, install original shim du burr marks on inner races are inplate (8) with screws (7).plate (8) with screws (7). line when index marks are vibro-etched on races in line.

NOTE

It is mandatory that shim plate (8)have same serial number as sleeve

63-00-00Rev. 4 Page 159

BHT-212-CR&O

flanged end of outer race (16) up. CarefullyCAUTION j spray outside diameter of wear sleeve (23)

with dry lubricant (C-028). Exercise cautionto avoid coating parts other than wear sleeve

IF BEARINGS ARE REMOVED with dry film lubricant.FROM PINION FOR ANY REASONAFTER INSTALLATION, VISUALLY 14. Secure a 3/4 in. square bar in viseINSPECT COPPER PLATING. IF vertically, and position pinion on bar. PositionPLATING IS SCRATCHED OR clutch (assembled in steps 3. through 7.) onGOUGED, IT SHALL BE STRIPPED pinion splines. Install nut (25) and torque 350AND REPLACED (BHT-ALL-SPM), to 400 ft.lbs. (474.53 to 542.32 Nm) withBEFORE BEARING OR ITS T101588 wrench. Install lock spring (26).REPLAC EM ENT CAN BE Ensure lock spring is fully seated in groove.INSTALLED.

15. Place packing (27) on retainer (28).WHEN INSTALLING PINION INTO Coat all packings and mating surfaces withBEARING, USE CARE TO ONLY transmission oil prior to assembly. InstallAPPLY PRESSURE TO PINION retainer and secure with retainer ring (29).HUB AREA. PRESSURE APPLIEDAT GEAR TEETH CAN RESULT IN 16. Lubricate packing (11) with transmissionCRACKS BETWEEN HOLES IN oil and install on union (10). Install union inWEB AND POSSIBLE FAILURE OF sleeve (12). Install cap (9) on union.PINION.

17. Lubricate packing (14) with transmission12. Support bearing inner races and press oil and install on plug (13). Install plug intopinion shaft into bearings. Check pinion and sleeve (12).bearings for free rotation.

18. Check pinion for free rotation and check13. Place assembled inner and outer races freewheeling clutch for proper operation.and freewheeling clutch on work bench with


NUMBER(IN.) (MM) (IN.) (MM)

Main input quill 205-040-256-5 2.2620 57.4548 2.2625 57.4675sleeve

63-72. MAIN INPUT QUILL (212-040-263- paragraph 63-66. For overhaul of101). main input quill, 212-040-263-107,

refer to paragraph 63-78.

NOTE

For overhaul instructions for maininput quill, 212-040-363, refer to

63-00-00Page 160

BHT-212-CR&O




T101306 Wrench C-105 Corrosion Preventive

T101578 or Wrench set C-304 Solvent

T101588 Wrench set C-334 1.1.1-Trichloroethane

T101912 Plate1. Clean all quill parts with solvent (C-304).Use soft bristle brush to dislodge stubborn

1. Secure 3/4 in. square bar vertically in vise deposits. All parts except bearings may beand position quill on bar with pinion engaged cleaned with 1.1.1-trichloroethane (C-334) byon bar. vapor degreasing if desired.

2. Remove retainer ring (24, figure 63-70), 2. Dry parts with clean, lint-free cloths orplate (23), and packing (22). Remove dry, filtered, compressed air. Do not allowlockspring (21). Remove nut (20) with bearings to spin while drying.T101306 wrench and T101578 or T101588wrench set. Lift adapter (19) off pinion 3. Coat bearings with corrosion preventivesplines. Discard packing. (C-105) immediately after cleaning. Do not

handle unoiled bearings with bare hands.3. Position T101912 plate on pinion betweengear and sleeve. Support sleeve and press 4. inspect quill for corrosion damage topinion (1) out of triplex bearings (5) and threaded studs and stud holes beforesleeve (2). cleaning. No structural damage to threads or

holes is acceptable.4. Remove screws (11) and washers (10).Remove cap (9) from sleeve (2). Removeshim (4). Remove packing (3) from sleeve 63-75. Inspection.(2). Discard packing.

1. Inspect all parts visually for damage and5. Support sleeve (2) press triplex bearing excessive wear.(5) out of sleeve. Retain bearings as amatched set. 2. Inspect pinion (1, figure 63-70) for

chipped, dented, spalled, scuffed, and pitted6. Remove union (7) and packing (8). teeth. Inspect roller bearing surface forRemove plug (14) and packing (15) from cap spalling, scoring, pitting, brinelling,(9). Remove retainer ring (19). Discard indentations, and corrosion damage. Inspectpacking. splines for chipped, pitted, or excessively

worn teeth. Inspect threads for damage.7. Remove seal (12) from sleeve (16).

a. Pitting of any magnitude resulting fromsurface fatigue during operation is notpermissible on teeth of pinion. This mayappear as only a fine line of pin holes nearpitch diameter and be detectable only with aside light source and a probe with a point ofapproximately 0.001 in. (0.0254 mm) radius.A more severe example of this is shown onfigure 63-71, detail B. Minor pitting resulting

63-00-00Page 161

BHT-212-CR&O

from corrosion is permissible within followinglimits: Figure, Nomenclature Code

Index No.(1) No more than 0.001 in. (0.0254 mm)

deep and no more than 0.040 in. (1.016 mm) 63-70, 1 Pinion Mwide or 0.080 in. (2.032 mm) long. 63-70, 2 Sleeve M

63-70, 9 Cap F(2) No more than 0.002 in. (0.508 mm) 63-70, 16 Sleeve F

deep and no more than 0.040 in. (1.016 mm) 63-70, 21 Adapter Mwide or 0.100 in. (2.54 mm) long and located 63-70, 22 Nut Mon outer (i.e. adjacent to heel), half of face oftooth and above pitch line; or located outsideof wear pattern and outside of root radius.

7. Inspect parts dimensionally and replaceb. Surface roughness detectable by parts which exceed inspection limits (figure

drawing probe along tooth in profile direction 63-72)is cause for rejection if pitting occurred onmating member.

NOTEc. Grinding scratches: Any scratches

around which pitting or other damage occurs Wear limits are provided to showare not permissible. required fit between mating parts. It

is not intended all dimensions bed. Nicks, cuts, or dents caused by checked as a prescribed overhaul

handling or by foreign material going through procedure. However, partsmesh during operation are permissible exhibiting evidence of wear orprovided such damage is no more than 0.003 physical damage shall be checkedin. (0.0762 mm) deep and no more than 0.020 dimensionally.in. (0.508 mm) across in any direction, andcannot be felt with a probe having end radius 63-76 Repairof 0.030 in. (0.762 mm).

3. Inspect nut (22) for damaged threads. MATERIALS REQUIRED

4. Inspect sleeve (2) for corrosion damageand damaged threads. Sleeve flange nicks or NUMBERNOMENCLATUREdents which exceed 0.030 in. (0.762 mm) C-100 Chemical Film Materialdepth are cause for rejection of part.

C-103 Chromic Acid5. Inspect triplex bearings (5) for spalling,scoring, pitting, brinelling, corrosion damage, C-108 B r u s h Cad m i u mcracked or broken retainers, and for Plating Solutionroughness when rotated. C-242

C-242 Paint Remover

6. Inspect following parts by magnetic C-317 Adhesiveparticle (Code M) or fluorescent penetrant(Code F) as applicable. Demagnetize parts C-327 Promoterafter magnetic inspection (BHT-ALL-SPM).

C-345 Primer

C-407 Abrasive Pad

C-427 Barrier Material

C-464 India Stone

63-00-00Page 162

BHT-212-CR&O

SEAL LIP DIRECTION -

8 11 12

DETAIL B

0.085N (2.159mm)

2. Sleeve 11. Screw 20. Wear sleeve3. Packing 12. Seal 21. Adapter

4. Shim 13. Packing 22. Nut5. Triplex bearing 14. Plug 23. Lockspring6. Cap 15. Packing 24. Packing7. Union 16. Sleeve 25. Plate8. Packing 17. Packing 26. Retainer ring9. Cap 18. Pin2-R-63-70

212-R-63-70

Figure 63-70. Main input quill (212-040-263-101)

63-00-00Page 163

BHT-212-CR&O

A. Spiral Bevel Gear, Input Driven Gear Quill.Typical acceptable wear pattern.

B. Spiral Bevel Gear, Input Driven Gear Quill.Gear is spalled on the face of tooth. Anyspalling of this type Is unacceptable, and boththe gear and the mating pinion should bereplaced - even though the mating pinion maynot be spalled.

C. Input Pinion.Input drive quil wear pattern showing anonuniform wear pattern with a band of heavywear in the flank. This is maximum acceptablefor this condition.

212-R-63-71C0000

Figure 63-71. Main input gear quill (212-040-263-101) wear pattern

63-00-00Page 164

BHT-212-CR&O

1. Replace all parts which exceed inspection 68.950 kPa) and remove residue. Wrap partslimits, in barrier material (C-427) after sandblasting.

2. Replace all unserviceable parts. d. Apply grease removing primer (C-345)to unmasked portion of adapter (21) only (this

3. Replace wear sleeve (20, figure 63-70) if step is not applicable to wear sleeve). Stirworn or rough as follows: primer thoroughly in container before use.

Scrub primer into surface of outer race witha. Use end mill or hand-held grinder to cut nylon web abrasive pad (C-407). Use

a groove almost through old wear sleeve (20); additional primer as required to ensureavoid cutting through wear sleeve and adapter is clean.damaging adapter (21). Strike wear sleevewith rubber mallet to break the uncut portion e. Allow primer (C-345) to dry to a whiteand remove sleeve from adapter. powder. Remove dry powder with clean, dry,

cheesecloth. Wear clean, white, gloves whileb. Clean old adhesive from adapter (21) handling parts. If next step is not to be

with plastic scraper and abrasive pad (C-407) accomplished immediately, wrap adapter (21)or use paint remover (C-242). Inspect with barrier material (C-427).adapter for damage which may have beenincurred during removal of wear sleeve.

CAUTION

Exercise precautions during ADHESION PROMOTER USED INaccomplishment of the following THE FOLLOWING STEP IS HIGHLYsteps to keep wear sleeve and VOLATILE. KEEP PROMOTER INadapter clean. Wear clean white A NON-ABSORBTIVE CONTAINERgloves when handling parts and AND KEEP LID CLOSED WHENchange gloves when they become NOT IN USE. EXPOSURE TOsoiled. Cover work bench with ATMOSPHERE WILL CAUSEbarrier material (C-427). Avoid DECOMPOSITION EXCEPT WHENcontact with all mold release agents APPLIED TO PARTS ANDsuch as silicone, wax, oil, grease, ALLOWED TO DRY. SEDIMENTetc. The work area where bonding is OR BROWN RESIDUE IN BOTTOMaccomplished shall be maintained at OF CONTAINER INDICATES65 to 82°F (18 to 28°C) with relative DECOMPOSITION OF PROMOTERhumidity below 75%. Keep area dust TO EXTENT IT SHALL BEfree to the extent bonding operations DISCARDED. THE pH RANGE OFare not affected. PROMOTER SHALL BE 7 TO 8.

Bonding steps shall be f. Using a pure hog bristle brush with anaccomplished without delay between unpainted handle, apply promoter (C-327) tosteps. Four hours is maximum unmasked portion of wear sleeve (20) andallowable time interval between adapter (21). Apply only enough adhesionsandblasting and accomplishment of promoter to wet surfaces. Allow promoter tonext step. dry for minimum of thirty minutes at room

temperature or for fifteen minutes at 150 toc. Mask outer diameter of new wear 160°F (66 to 71°C). If next step is not to be

sleeve (20). Mask adapter (21) all over accomplished immediately, wrap parts withexcept surface which mates with wear sleeve barrier material (C-427).and adjacent 0.062 in. (1.5748 mm) radius.Sandblast unmasked surfaces of these parts g. Mix adhesive (C-317) (33 parts B towith 60 grit garnet at 5 to 10 psi (34.475 to 100 parts A). The pot life of mixed adhesive

is 30 to 50 minutes. Coat inside diameter of

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BHT-212-CR&O

wear sleeve (20) and mating surface on C-028 Dry Lubricantadapter (21) with adhesive. Press wearsleeve on adapter with radiused OD of wear C-304 Solventsleeve positioned at outer edge of adapter C-405 Lockwire(detail B, figure 63-70). Clean off excessadhesive, leaving chamfer between wearsleeve and adapter filled with adhesive. Cure 1. Clean all parts with and drain.at room temperature for 24 hours. Afterbonding and prior to assembly of quill ensure 2. Coat all parts with transmission oil andall traces of adhesive are cleaned from area drain excess.of wear sleeve which contacts seal (12).

4. Repair minor nicks, cuts, or dents on NOTEpinion (1) by lightly polishing with fine Indiastone (C-464). Do not handle unoiled parts with

bare hands.5. Repair dents and nicks on sleeve (2)flange top surface by polishing with fine India 3. Clean mating surfaces of seal (12, figurestone (C-464). Blend repaired area into flat 63-70) and sleeve (16) with solvent (C-304)surface with a minimum radius of 0.12 in. and dry. Note lip of seal shall face inboard.(3.048 mm). Finished repair shall be 32 RMS Install packing (17). Align sleeve (16) with pinor better. Maximum depth, after repair, shall (18) and press seal (12) into cap (9).not exceed 0.030 in. (0.762 mm) depth.

4. Assemble triplex bearings (5, figure 63-6. Refinish parts after repair in accordance 70), cap (9), and sleeve (2) as follows:with BHT-ALL-SPM as outlined below.

NOTEa. Aluminum parts: Touch up with brush NOTE

chemical film material (C-100).chemical film material (-100). A dull burr mark approximately 1/8in. (3.175 mm) in diameter is placed

b. Magnesium parts: Remove all traces in. (3.175 mm) in diameter is placedon end face of each bearing innerof corrosion by immersion in chromic acid n en facerace by bearing manufacturer, tobath (BHT-ALL-SPM). Touch up parts with race bearing maufacture acurer omark high point of race runout.corrosion preventive compound (C-103) or arig h intae t nnerBearings shall be installed with innertreat entire part with magnesium alloy beins sitinechemical film treatment (BHT-ALL-SPM). races three bearings positionedwith dull burr mark on three bearings

in line. Before installing bearings,c. Cadmium plated steel parts: Treat mark a pencil line on inner diameterrework areas with brush cadmium plating on

solution (C-108) (BHT-ALL-SPM) of each bearing in line with burrsolution (C-108) (BHT-ALL-SPM). mark. Use the line to align bearingswhen installed on pinion.

7. Replace parts not within allowable wearlimits. a. Align V marks on triplex bearings (5)

outer races. Align pencil line on triplex63-77. Assembly. bearing inner races. Support sleeve (2) and

press triplex bearings into sleeve (2) with

MATERIALS REQUIRED apex of V pointing up (figure 63-69).

Refer to BHT-ALL-SPM for specification and b. With sleeve (2) and triplex bearings (5)source. resting on end of sleeve (2), place cap (9) in

position with cap lip resting on face of triplexNUMBER NOMENCLATURE bearings outer race. Apply 30 to 50 Ibs.

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BHT-212-CR&O

1 3 52 4 6


1 Pinion OD 3.1500 80.01 3.1505 80.02272 Bearing ID 3.1491 79.98714 3.1495 79.99733 Bearing OD 5.9050 149.987 5.9055 149.99974 Sleeve liner ID 5.9047 149.97938 5.9054 149.997165 Spline, pinion Over pins 3.2917 83.60918 3.2952 83.69808


6 Spline, adapter Between pins 2.8427 72.20458 2.8456 72.27824(Use 0.1440 IN. (3.6576 mm)diameter pins)

7 Sleeve OD 6.7479 171.39666 6.7500 171.45008 Pinion OD 2.0090 51.0286 2.0096 51.04384

NOTE

1 Use pins with one side ground flat to 0.115 inch (2.921 mm) to provide clearance between pinsand root of spline teeth.

212-R-63-72

Figure 63-72. Main input quill (212-040-263-101) wear limits

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BHT-212-CR&O

(133.44 to 222.4 N) axial force uniformly toend of cap to seat it against triplex bearing CAUTION

c. Using a feeler gauge, measure gap IF BEARINGS ARE REMOVEDbetween cap (9) and sleeve (2). FROM PINION FOR ANY REASON

AFTER INSTALLATION, VISUALLYd. Prepare laminated shim(s) (4) 0.001 to INSPECT COPPER PLATING. IF

0.004 in. (0.0254 to 0.1016 mm) less than PLATING IS SCRATCHED ORmeasured in step c. which will provide a GOUGED, IT SHALL BE STRIPPED0.001 to 0.004 in. (0.0254 to 0.1016 mm) AND REPLACED (FIGURE 63-73)pinch on outer race of triplex bearing outer (BHT-ALL-SPM) BEFORErace. BEARINGS OR ITS REPLACEMENT

CAN BE INSTALLED.e. Remove cap (9) from sleeve.

7. Install packing (3) on sleeve (2). Position5. Align inner races of three bearings so shim (4) and cap (9) on sleeve (2), alignpencil line shows burr marks of three bearings screw holes, and install washers (10) andare in line. Position pinion (1) so etched screws (11). Leave screws loose.index marks on pinion shaft are aligned withindex marks on bearings inner races. 8. Using a feeler gage, check for 0.001 to

0.004 in. (0.0254 to 0.1016 mm) clearancebetween cap (9) and shim(s) (4). Tightenscrews and secure with lockwire (C-405) to

If bearings or pinion were replaced, anchor holes in cap. Verify screws (11) doit is necessary to vibro-etch index not protrude beyond mounting face of sleeve.marks (lines) on new part same as If screws protrude, a thin steel washer mayon part replaced so bearings may be be added under head of screw.checked for spinning after test run.If bearings are replaced, ensure burr 9. Apply dry lubricant (C-028) to OD of wearmarks on inner races are in line sleeve (20). Exercise caution to avoidwhen index marks are vibro-etched coating parts other than wear sleeve with dryon races in line. film lubricant.

nut 350 to 400 ft.lbs. (474.53 to 542.32 Nm)WHEN INSTALLING PINION INTO with T101578 or T101588 wrench set. InstallBEARING, USE CARE TO ONLY lockspring (23). Ensure lockspring is fullyAPPLY PRESSURE TO PINION seated in groove.HUB AREA. PRESSURE APPLIEDAT GEAR TEETH CAN RESULT IN 11. Place packing (24) on plate (25). CoatCRACKS BETWEEN HOLES IN packing (24) and mating surface withWEB AND POSSIBLE FAILURE OF transmission oil prior to assembly. InstallPINION. plate and secure with retainer ring (26).

6. Support bearing inner races (5) and press 12. Lubricate packing (8) with transmissionpinion shaft (1) into bearings. Check pinion oil and install on union (7). Install union (7) inand bearings for free rotation. cap (9).

13. Lubricate packing (15) with transmissionoil and install packing on plug (14). Installplug in cap (9).

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COPPER PLATING AREA

SPLINES

COPPER PLATINGIN GRIND RELIEFAREA IS OPTIONAL

NOTES

1. Copper plate indicated area 0.00004 to 0.00006inch (0.001016 to 0.001524 mm) thick.

2. Accomplish embrittlement relief within one hourafter plating. Temperature to be 260°F (129°C)for four to five hours.

212-R-63-73

Figure 63-73. Main input quill (212-040-263-101) pinion copper plating area

63-00-00Rev. 4 Page 169

BHT-212-CR&O

63-78. MAIN INPUT QUILL (212-040-263- 10. Remove cap (6) with union (7) and107). packing (8) from cap assembly (9). Discard

packing.

NOTE 11. Remove plug (13) with packing (14) from

For overhaul instructions for main cap assembly (9). Discard packing.input quill, 212-040-363, refer toparagraph 63-66. For overhaul of 12. Remove carbon ring (16) with packingmain input quill, 212-040-263-101, (15) from cap assembly (9).refer to paragraph 63-72.

13. Remove retaining ring (21) and separateseal retainer (20) from cap assembly (9).

63-79. Disassembly.14. Remove magnetic ring (17) and

SPECIAL TOOLS REQUIRED packings (18 and 19) from seal retainer (20).

NUMBER NOMENCLATURE 63-80. Cleaning.

T101588 Wrench set MATERIALS REQUIRED

T101912 Plate setNUMBER NOMENCLATURE

1. Secure 3/4 in. square bar vertically in vise C-105 Corrosion Preventiveand position quill on bar with pinion engagedon bar. C-304 Solvent

2. Remove retainer ring (27, figure 63-74), C-334 1.1.1-Trichloroethaneplate (26) and packing (25). Discard packing.

3. Remove lockspring (24) 1. Clean all quill parts with solvent (C-304).3. Remove lockspng (24). Use soft bristle brush to dislodge stubborn

deposits. All parts except bearings may be4. Mount T101588 wrench set on quill (figure cleaned with 1.1.1-trichloroethane (C-334) by

63-74). vapor degreasing if desired.

5. Remove nut (23). 2. Dry parts with clean, lint-free cloths ordry, filtered, compressed air. Do not allow

6. Lift adapter (22) off pinion (1) splines and bearings to spin while drying.separate T101588 wrench set from adapter.

3. Coat bearings with corrosion preventive7. Install T101912 plate set (figure 63-76) on (C-105) immediately after cleaning. Do notpinion (1, figure 63-74) shaft between gear handle unoiled bearings with bare hands.and sleeve (2). Support bearing inner raceand press pinion (1) out of triplex bearings (5)and sleeve (2). 63-81. Inspection.

8. Remove screws (11) and washers (10). NOTESeparate cap (9) from sleeve (2). Removeshim (4). Wear limits are provided to show

required fit between mating parts. It9. Support sleeve (2) press triplex bearings is not intended all dimensions beout of sleeve. Retain bearings as a matched checked as a prescribed overhaulset. Remove packing (3) from sleeve (2). procedure. However, partsDiscard packing. exhibiting evidence of wear or

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physical damage shall be checked ALLOW ANY FOREIGN PARTICLESdimensionally. TO CONTACT SEAL.

1. Inspect pinion (figure 63-77). a. Measure gap between magnetic ringand seal case using a clean, nonmetallic

2. Inspect sleeve (figure 63-78). feeler gage (figure 63-82).

3. Inspect triplex bearing (5, figure 63-74) b. Separate magnetic ring from carbonfor spalling, scoring, pitting, brinelling, ring by carefully pulling directly away fromcorrosion damage, cracked or broken each other.retainers, and roughness when rotated. Anydefect is cause for rejection. c. Visually inspect magnetic ring (using a

high intensity light) for scratches, nicks, and4. Inspect cap assembly (figure 63-79). cracks. A cracked ring is nonreparable and

shall be scrapped.5. Inspect seal retainer (figure 63-78).

d. Inspect magnetic ring back face and6. Inspect adapter (figure 63-81). I.D. surface conditions as follows:

7. Inspect retaining rings (21 and 27, figure (1) Position holes and voids under63-74) and lockspring (24) for obvious defects 0.020 in. (0.508 mm) diameter are acceptableand deformation. if less than 0.020 in. (0.508 mm) deep.

Zones of porosity shall not extend more than8. Inspect nut (23) for thread damage and 1/4 in. (6.35 mm) of the way across anyobvious defects. surface and shall not extend to within 0.070

in. (1.778 mm) of any edge.9. Inspect plate (26) for corrosion damageand nicks or burrs in seal groove which could (2) Edge chips on I.D. and O.D. of backcause leakage. face are acceptable if less than 0.0625 in.

(1.5875 mm) long and 0.020 in. (0.508 mm)10. Inspect magnetic seal as follows: wide.

NOTE (3) No cracks are permitted.

Magnetic seal is made up of a e. Inspect magnetic ring outside diametermagnetic ring (17, figure 63-74) and surface as follows:carbon ring (16) which is bonded toseal case. (1) Zones of porosity shall not extend

more than 1/4 of the way across any surface

CAUTION | mm) of any edge.

(2) Porosity holes are acceptable if lessSEAL INSPECTION PROCEDURE than 0.020 in. (0.508 mm) diameter and lessSHALL BE ACCOMPLISHED than 0.020 in. (0.508 mm) deep.UNDER CLEAN CONDITIONS.WEAR WHITE COTTON GLOVES (3) Edge chips are acceptable if lessWHILE HANDLING SEAL. DO NOT than 0.0312 in. (0.79248 mm) long andSLIDE MAGNETIC SEAL ON 0.0156 in. (0.39624 mm) wide.MAGNETIC RING. DO NOT ALLOWCARBON SEALING SURFACE OR (4) No cracks are permitted.SEALING ANNULUS ONMAGNETIC RING TO CONTACT f. Inspect magnetic ring sealing face asANY OTHER OBJECT. DO NOT follows:

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BHT-212-CR&O

(1) The sealing annulus is defined as SURFACE WITH ANY FOREIGNthe annulus which contacts with the mating OBJECT.carbon sealing surface plus an additional0.020 in. (0.508 mm) per side allowance. i. Reassemble seal by lining up two sealChips, nicks, and scratches are not allowed halves to final assembled position andon sealing annulus. carefully allow halves to pull together into

assembled condition and position.(2) The sealing annulus shall be free of

porosity holes and pits unless such defects j. If magnetic seal does not passare within limits of figure 63-82. Pits and inspection or damage limits (figure 63-82),porosity holes shall be clean and free of contact the following for instructions:foreign matter. No two pits and/or porosityholes may be aligned radially across sealing MAGNETIC SEAL CORP.annulus. 365 MARKET ST.

WARREN, RHODE ISLAND 02885(3) Porosity holes outside sealing ATTENTION: QUALITY ASSURANCE

annulus are acceptable if less than 0.020 in. TELEPHONE: (401) 247-2800(0.508 mm) diameter and less than 0.016 in.(0.4064 mm) deep. Zones of porosity shall not 11. Inspect the following parts by magneticextend more than 1/4 of the way across any particle (Code M) or fluorescent penetrantsurface and shall not extend within 0.070 in. (Code F) as applicable. Demagnetize parts(1.778 mm) of any edge. after magnetic inspection (BHT-ALL-SPM).

(4) Scratches outside sealing annulusare acceptable. Figure, Nomenclature Code

Index No.(5) Chipping on I.D. and O.D. edges is

acceptable provided it is outside sealing 63-74, 1 Pinion Mannulus and is less than 0.0625 in. (1.5875 63-74, 2 Sleeve Mmm) long and 0.020 in. (0.508 mm) wide. 63-74, 9 Cap F

63-74, 20 Seal retainer Fg. Visually inspect seal case and carbon 63-74, 22 Adapter M

ring assembly under a high intensity light. 63-74, 23 Nut MMinor scratches and nicks are permissible onseal case. Sealing surface of carbon sealshall show no visible scratches or pits whenviewed under a high intensity light. Damage 63-82. Repair.on edges of carbon sealing surface isallowable if no two damaged areas are MATERIALS REQUIREDaligned with one another in the radialdirection and if number and size of damagedareas are within carbon seal edge damage NUMBER NOMENCLATURElimits (figure 63-82).

C-201 Primerh. Inspect packing groove, remove any

foreign particles. The groove shall not have C-500 Crocus Clothany burrs which might damage packing. C-464 India Stone

CAUTION 1. Polish out minor nicks, cuts, or dents onpinion (1, figure 63-74) with fine India stone(C-464).

DO NOT SLIDE SEAL MATINGSURFACES AGAINST EACH 2. Polish out minor dents and nicks onOTHER AT ANY TIME. DO NOT sleeve (2) flange top surface with fine IndiaTOUCH EITHER SEALING

63-00-00Page 172 Rev. 3

BHT-212-CR&0

SEE DETAIL A

12. Alignment pin13. Plug14. Packing15. Packing16. Carbon ring17. Magnetic ring

1. Pinion 18. Packing2. Sleeve 19. Packing3. Packing 20. Seal retainer4. Shim 21. Retaining ring5. Triplex bearing 22. Main driveshaft curvic coupling adapter6. Cap 23. Nut7. Union 24. Lockspring8. Packing 25. Packing9. Cap assembly 26. Plate

10. Washer 27. Retainer ring 212-R-63-74

Figure 63-74. Main input quill (212-040-263-107)

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BHT-212-CR&0

1. Main driveshaft curvic coupling adapter 5. Extension bar (L-122)2. Strap 6. Nut3. Wing nut (MS35426-14) 7. Seal retainer4. Wrench assembly (T101588) 8. Input quill cap assembly

9. Input quill pinion

212-R-63-75

Figure 63-75. Tool application- T101588 wrench set

63-00-00Page 174

BHT-212-CR&O

1. Plate set (T101912)2. Triplex bearing3. Pinion gear

212-R-63-76

Figure 63-76. Tool application - T101912 plate set

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BHT-212-CR&O

0.1920 IN.

SEE DETAIL A (4.8768 mm) PINS

MIN. 3.2952 IN.

PINION204-040-700-101

DETAIL A

Main input quill teeth wear patternshowing a non-uniform wear pattern with aband of heavy wear in the flank. This is the

DETAIL B maximum acceptable for this condition.

NOTES

1. Inspect pinion teeth for chipping, dents, spalling, scuffing, and pitting. Pitting of any magnituderesulting from surface fatigue during operation is not acceptable on teeth of pinion. This mayappear as only a fine line of pin holes near pitch diameter and be detectable only with a side lightsource and a probe with a point of approximately 0.001 inch (0.0254 mm) radius. Minor pittingresulting from corrosion is acceptable within following limits:

a. No more than 0.001 inch (0.0254 mm) deep and no more than 0.040 inch (1.016 mm) wideor 0.080 inch (2.032 mm) long.

b. No more than 0.002 inch (0.0508 mm) deep and no more than 0.040 inch (1.016 mm) wideor 0.100 inch (2.54 mm) long and located on the outer (i.e. adjacent to the heel), half of theface of the tooth and above the pitch line; or located outside of the wear pattern and outside ofthe root radius.

c. Surface roughness detectable by drawing probe along tooth in profile direction is cause forrejection if pitting occurred on mating member.

d. Grinding scratches. Any scratches around which pitting or other damage occurs are notacceptable.

e. Nicks, cuts, or dents caused by handling or by foreign material going through mesh duringoperation are acceptable provided they are no more than 0.003 inch (0.0762 mm) and are nomore than 0.020 inch (0.508 mm) across in any direction, and cannot be felt with a probehaving end radius of 0.030 inch (0.762 mm).

2. Inspect wear pattern on teeth in accordance with detail B for maximum acceptable non-uniformwear pattern.

3. Inspect front of pinion that contacts roller bearing inside transmission for mechanical andcorrosion damage. Damage that can be detected visually is not acceptable.

4. If necessary, check pinion spline wear limits as shown in detail A. 212-R-63-77

Figure 63-77. Main input drive quill (212-040-263-107) pinion damage limits

63-00-00Page 176

BHT-212-CR&O

SEE DETAIL ADETAIL A A

INPUT QUILL SLEEVE214-040-097-003

NOTE

In Area A, light oxide coating is not a cause for rejection, provided not more than40 percent of any 1 inch square (25.4 mm) or 20 percent of total area of anysurface is affected.

212-R-63-78

Figure 63-78. Main input drive quill (212-040-263-107) sleeve damage limits

stone (C-464). Blend repaired area into flat 6. Polish out minor nicks, dents, andsurface with a minimum radius of 0.12 in. scratches on plate (26) with crocus cloth (C-(3.048 mm). Finished repair shall be 32 RMS 500).or better. Maximum depth after repair shallnot exceed 0.030 in. (0.762 mm) depth.

7. Refinish parts after repair (figure 63-83).

3. Polish out minor dents, nicks andscratches on exterior surfaces of cap (9) with 63-83. Assembly.crocus cloth (C-500). Replace loose ordeformed pin (12). Coat pin with unreduced MATERIALSprimer (C-201) immediately prior toinstallation.

NUMBER NOMENCLATURE4. Polish out minor nicks, dents, and C-024 Assembly Fluidscratches on curvic coupling adapter (22) withfine India stone (C-464). C-405 Lockwire

5. Polish out minor nicks, dents, andscratches on seal retainer (20) with crocus 1. Ensure all parts have been cleanedcloth (C-500). (paragraph 63-80).

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BHT-212-CR&O

0.250 IN.(6.35 mm)-- ---- SEE DETAIL B

NOTE

1. In Areas B, C, and D, maximum depth of pitting is 0.030 inch (0.762 mm),provided no more than 40 percent of any 1 inch (25.4 mm) square or 20 percent oftotal area of any surface is affected.

2. In Area D, inside bolt holes, maximum depth of pitting is 0.020 inch (0.508 mm),provided no more than 20 percent of wall area of any hole is affected.

3. In Area B, maximum depth of pitting is 0.010 inch (0.254 mm) in area of packing.

212-R-63-79

Figure 63-79. Main input quill (212-040-263-107) cap assembly damage limits

63-00-00Page 178

BHT-212-CR&O

AREA A

AREASEE DETAIL A

SEAL RETAINER212-040-126-101 DETAIL A

NOTES

IN AREA A:1. Light oxide coating is not cause for rejection provided not more than 40 percent of any

one inch (25.4 mm) square or 20 percent of total area of any surface is affected.

2. Nicks and dents are acceptable provided they do not exceed 0.030 inch (0.762 mm)depth.

IN AREA B:3. Maximum acceptable depth of pitting is 0.030 inch (0.762 mm) provided no more than

40 percent of any one inch (25.4 mm) square or 20 percent total area of any surface isaffected. 212-R-63-80

Figure 63-80. Main input quill (212-040-263-107) seal retainer damage limits

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BHT-212-CR&O

-USE 0.1440 IN. (3.6576 mm) PINSGRIND TO 0.115 IN. (2.921 mm)

SEE DETAIL A

MIN. 2.8427 IN. (72.20458 mm)MAX. 2.8456 IN. (72.27824 mm)

DETAIL A

CURVIC COUPLING ADAPTER212-040-190-101

NOTE

1. This part is dynamically balanced. Attempts to rework significantly damagedareas may cause high frequency vibration after installation.

2. Superficial damage permitted without polishing out.

212-R-63-81

Figure 63-81. Main input quill curvic coupling adapter damage limits

63-00-00Page 180

BHT-212-CR&O

0.025 IN. (0.635 mm)MINIMUM MEASURE WITHFEELER GAGE BETWEENSEAL CASE AND

ACCEPTABLE = A

-AASEGMENT OFCARBON RING SEAL CASE -- MAGNETIC RING

PIT LIMITS-CARBON RING

SIZE NUMBER AND LIMITS

Up to 0.010 IN. (0.254mm) 2 per inch minimum ofmaximum diameter 0.0625 IN. (1.5875 mm) apart /A

Upto0.060 IN. (0.1524 mm) 3 per inch minimum ofmaximum diameter 0.0625 IN. (1.5875 mm) apart

MAXIMUM MAXIMUM PROTRUSIONNO. OF CHIPS LENGTH OF CHIP INTO SEALING SURFACE

1 maximum 0.050 IN. (12.7 mm) 0.016 IN. (4.064 mm) sealface width

3 maximum 0.050 IN. (12.7 mm) 0.008 IN. (2.032 mm) sealface width

Morethan4 0.050IN. (12.7 mm) 0.004 IN. (0.1016 mm)seal face width

NOTES

Dimension A denotes width of sealing area surface.

No chip may be closer than A to another chip.

3. Edges of carbon sealing surface may be chamfered. Chamfer protrusion into sealing surface cannot exceed

5 percent of carbon sealing surface width.

Not acceptable, if two pits align in radial direction. 212-R-63-82

Figure 63-82. Magnetic seal damage limits

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BHT-212-CR&O

AREA A(FLANGE \

)kJ--^s / NOTES

1. Apply one coat polyamide epoxy prime (C-204) except asnoted at note 2. Refer to BHT-ALL-SPM for procedure toapply prime.

2. Do not prime indicated areas.

3. Apply brush cadmium plate to area A where originalINPUT SLEEVE cadmium plate has been removed. Refer to BHT-ALL-SPM

214-040-097-003 for cadmium plating procedures.

SEE NOTE 2 (ALL HOLES AND SPOT FACES)

SEE NOTE 2 SEE NOTE 2

SEE NOTE 2 (DRAIN BOSS AND HOLE)

SECTION A-A

CAP ASSEMBLY209-040-142-001

212-R-63-83-1

Figure 63-83. Main input quill processing requirements (sheet 1 of 3)

63-00-00Page 182

BHT-212-CR&O

NOTES

1. Apply brush cadmium plate to area A of curvic couplingadapter where original cadmium plate has been removed.Refer to BHT-ALL-SPM for cadmium plating procedures.

2. Touchup areas on plate P/N 212-040-187-1 where chemicalfilm has been removed. Use chemical film treatment foraluminum alloy. Refer to BHT-ALL-SPM for procedure toapply chemical film.

AREA A

AREA A

SECTION A-A

CURVIC COUPLING ADAPTER212-040-190-101

PLATE212-040-187-1

212-R-63-83-2

Figure 63-83. Main input quill processing requirements (sheet 2)

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BHT-212-CR&0

COPPER PLATING AREA

SPLINES

COPPER PLATINGIN GRIND RELIEFAREA IS OPTIONAL

NOTES

1. Copper plate indicated area 0.00004 to 0.00006inch (0.001016 to 0.001524 mm) thick.

2. Accomplish embrittlement relief within one hourafter plating. Temperature to be 260°F (129°C)for four to five hours.

I

212-R-63-83-3

Figure 63-83. Main input quill processing requirements (sheet 3)

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BHT-212-CR&O

NOTECAUTION

A dull burr mark, approximately 1/8in. (3.175 mm) in diameter, is placed

KEEP SEAL IN ORIGINAL on end face of each bearing innerPACKAGING UNTIL READY FOR race by bearing manufacturer toINSTALLATION. WHEN SEAL mark high point of race runout.PACKAGE IS OPENED, SEPARATE These marks will be used to alignSEAL BY PULLING MAGNETIC triplex bearings when installed onRING AND CARBON RING journal of pinion.STRAIGHT AWAY FROM EACHOTHER. SLIDING BETWEEN SEALBETWEEN SEAL a. Align manufacturers dull burr marks onHALVES MAY DAMAGE MATING inner bearing race.SURFACES. DO NOT PLACEMAGNETIC RING OR CARBONRING IN AREA WHERE METAL b. Mark (use felt tip pen) a line in inside

PARTICLES MAY BE ATTRACTED. diameter of bearing in line with manufacturingINSTALL SEAL BY HAND marks.PRESSING ONLY. PRIOR TOINSTALLATION OF SEAL, c. Ensure bearings are stacked with VLUBRICATE PACKINGS AND mark on outside diameter in line.MATING DIAMETERS SPARINGLYWITH ASSEMBLY FLUID (C-024). 5. Install triplex bearings (5, figure 63-74) in

sleeve (2).NOTE

NOTEDo not handle unoiled parts withbare hands. Align V marks on outer races of

bearing (5). Support sleeve (2) and2. Coat packings (18, figure 63-74) and seal press bearings into sleeve (2) withretainer (20) contact diameters with assembly apex of V pointing as shown (figurefluid (C-024). 63-74).

3. Install packing (18) on seal retainer. Ensure bearings are seated flatInstall magnetic ring (17) on seal retainer against shoulder of sleeve.(20).

If bearings or pinion were replaced,CAUTION it will be necessary to vibro-etch

index marks (lines) on new partsame as on part replaced, so

TRIPLEX BEARINGS SHALL BE bearings may be checked forREPLACED AS MATCHED spinning after test run. If bearingsSERIALIZED SET. are replaced, ensure burr marks on

inner races are in line when index4. Assemble and mark triplex bearings (5). marks are etched on races in line.

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BHT-212-CR&O

e. Peel shim (4) to thickness calculated inCAUTION step d.

f. Remove three screws (11), washersIF BEARINGS ARE REMOVED (10), and cap (9).FROM PINION FOR ANY REASONAFTER INSTALLATION, VISUALLYINSPECT COPPER PLATING. IF CAUTIONiPLATING IS SCRATCHED OR CAUGOUGED, IT SHALL BE STRIPPEDAND REPLACED (FIGURE 63-84) WHEN INSTALLING PINION INTO(BHT-ALL-SPM) BEFORE BEARING BEARING, USE CARE TO ONLYBEARING, USE CARE TO ONLY(OR A REPLACEMENT) CAN BE APPLY PRESSURE TO PINIONINSTALLED. HUB AREA. PRESSURE APPLIED

AT GEAR TEETH CAN RESULT IN6. Calculate new shim (4, figure 63-74) CRACKS BETWEEN HOLES INthickness as follows: WEB AND POSSIBLE FAILURE OF

THE PINION.NOTE

7. Install pinion (1) in triplex bearingShim thickness should be calculated assembly (5).to provide 0.001 to 0.004 in. (0.0254to 0.1016 mm) pinch on bearings. Itis necessary to calculate a new shim CAUTIO

bearing, or cap is replaced.IF BEARINGS ARE REMOVED

a. Assemble cap (9) on sleeve (2) without FROM SPIRAL BEVEL GEAR FORpacking (3) or shim (4). ANY REASON AFTER

INSTALLATION, STRIP AND APPLYb. Install three screws (11) with washers COPPER PLATE TO PINION

(10) loosely. (FIGURE 63-83).

c. Measure gap between flange of sleeve a. Heat triplex bearing assembly (5)(2) and cap (9) using feeler gage. uniformly 230 to 250°F (110 to 121°C).

d. Record measured gap and subtract a b. Wipe triplex bearing assembly (5) andconstant dimension of 0.004 in. (0.1016 mm). spiral bevel gear (1) journal diameter free ofSee example below. oil.

c. Align marks on three bearing innerMeasured gap 0.038 in. rings with mark on spline of pinion.

(0.9652mm) d. Support triplex bearing inner races.

Subtract constant dimension -0.004 in. e. Backup outboard bearing inner ring and(0.1016 press pinion through bearing until seatedmm) firmly against bearing inner ring.

This dimension equals thickness 0.034 in. f. Hold 18 to 20 tons (160128 to 17792 N)of shim to provide 0.001 to 0.004 (0.8636 pressure on pinion until assembly has cooledin. mm) to approximately room temperature.(0.0254 to 0.1016 mm)pinch on bearings.

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g. Lubricate pinion and triplex bearing 14. Secure a 3/4 in. square bar in visewith same oil used in transmission. vertically and position quill on bar with pinion

engaged on bar. Install nut (23) and torqueh. Check pinion and triplex bearing for nut 350 to 400 ft.lbs. (474.53 to 542.32 Nm)

free rotation. with T101588 wrench set. Install lock spring(24). Ensure lock spring is fully seated in

8. Coat packings (19, figure 63-74) and seal groove.retainer (20) contact diameters with assemblyfluid (C-024). 15. Place packing (25) on plate (26). Coat

packing (25) and mating surface with9. Install packing (19) on seal retainer (20). transmission oil prior to assembly. InstallAlign seal retainer (20) slot with cap plate and secure with retainer ring (27).alignment pin (12) and install seal retainer(20) on cap assembly (9). Install retaining 16. Lubricate packing (8) with transmissionring (21). oil and install on union (7). Install union (7) in

cap (9). Install cap (6) on union (7).10. Place adapter (22) with large end downand install cap assembly (9) over adapter. 17. Lubricate packing (14) with transmission

oil and install packing on plug (13). Install

CAUTION63-84. HYDRAULIC PUMP DRIVE

DO NOT ALLOW ASSEMBLY FLUID QUILL.(C-024) TO CONTACT CARBONSEALING SURFACE. 63-85. Disassembly.

11. Coat new carbon ring mating diameter SPECIAL TOOLS REQUIRED(16) and packing (15) with assembly fluid (C-U024). Install new packing (15) on carbon ring(16) and install carbon ring over lip of adapter NUMBER NOMENCLATURE(22) inside cap assembly (9).

T101305 Wrench12. Lubricate packing (3) with transmissionoil and install on sleeve (2). T101334 Bar

T101447 Holding fixtureNOTE NOTE T101449 Wrench

Allow previously assembled cap (9)and adapter (22) to remain on work T101519 Platebench with large and of adapter Alternate:down. This will prevent carbon ring(16) from sliding off adapter shaft T101446during assembly.

13. Position shim (4) on cap (9) and install 1. Place quill in T101447 holding fixture withsleeve (2) on cap (9) and adapter (22) by pinion facing down.aligning splines of pinion (1) with splines ofadapter (22). Align screw holes and install 2. Remove nut (7, figure 63-84) withscrews (22). Align screw holes and install T101449 wrench. Press seal (8) out of nutscrews (11) and washers (10). Tighten and remove packing (6). Discard packing.screws securely and lockwire (C-405).

3. Remove clip (5). Remove nut (4) withT101305 wrench. Remove washer (3).

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4. Support duplex bearings (1) on inner race 2. Inspect pinion (12, figure 63-84) forwith T101519 plate and press pinion (12) out spalled, scuffed, pitted, chipped, or dentedof sleeve. Remove cork (13) from pinion. teeth. Inspect splines on pinion (12) forDiscard cork. pitted, chipped, or excessively worn teeth.

Inspect pinion for damaged threads.5. Use T101334 bar to press duplexbearings (1) and spacer set (2) out of sleeve. 3. Inspect duplex bearings (1) for spalling,Keep duplex bearings and spacers together scoring, pitting, brinelling, corrosion damage,as a set. for cracked or broken retainers, and for

roughness when rotated.6. Remove three screws (11) and shim plate(10). Identify shim plate for reinstallation on 4 spect nuts (4 and 7) for damagedsame sleeve. threads.

5. Inspect sleeve (9) for corrosion damage,63-86. Cleaning. loose or damaged bearing liner, damaged

threads, and loose or damaged studs.

MATERIALS REQUIRED 6. Inspect the following parts by magneticparticle (Code M) or fluorescent penetrant

NUMBER NOMENCLATURE (Code F) as applicable. Demagnetize partsafter magnetic inspection (BHT-ALL-SPM).

C-105 Corrosion Preventive

C-304 Solvent Figure, Nomenclature CodeIndex No.

C-334 1.1.1-Trichloroethane63-84, 4 Nut M63-84, 7 Nut F

1. Clean all quill parts with solvent (C-304). 63-84, 9 Sleeve FUse soft bristle brush to dislodge stubborn 63-84, 12 Pinion Mdeposits. All parts except bearings may becleaned with 1.1.1-trichloroethane (C-334) byvapor degreasing if desired.

7. Inspect parts dimensionally and replace

2. Dry parts with clean, lint-free cloths or parts which exceed allowable inspection limitsdry, filtered, compressed air. Do not allow (figure 63-85).bearings to spin while drying.

NOTE3. Coat bearings with corrosion preventive(C-105) immediately after cleaning. Do not Wear limits are provided to showhandle unoiled bearings with bare hands. required fit between mating parts. It

is not intended all dimensions be

4. Inspect quill for corrosion damage to checked as prescribed overhaulthreaded studs and stud holes before procedure. However, partscleaning. No structural damage to threads or exhibiting evidence of wear orholes is acceptable. physical damage shall be checked

dimensionally.

5. Remove sealant with plastic scraper.

63-87. Inspection.

1. Inspect parts visually for damage andexcessive wear.

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1. Duplex Bearings2. Spacer Set3. Washer4. Nut5. Clip6. Packing7. Nut8. Seal9. Sleeve

10. Shim Plate11. Screw12. Pinion13. Cork

212-R-63-84

Figure 63-84. Hydraulic pump drive quill

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BHT-212-CR&O

63-88. Repair. 8. Refinish parts after repair in accordancewith BHT-ALL-SPM manual as outlined below:

MATERIALS REQUIRED a. Aluminum parts: Touch up with brushchemical film material (C-100).

NUMBER NOMENCLATUREb. Magnesium parts: Remove all traces of

C-100 Chemical Film Material corrosion by immersion in chromic acid bath(BHT-ALL-SPM). Touch up parts with

103 Chromic Acid chromic acid (C-103) or treat entire part withC-108 Bru sh Cad m i u m magnesium alloy chemical film treatment.

Plating Solutionc. Cadmium plated steel parts: Treat

C-211 Shellac reworked areas with brush cadmium platingsolution (C-108).

C-464 India Stone9. Replace parts which are not within

C-490 Cork Stopper allowable wear limits.

1. Replace all unserviceable parts. 63-89. Assembly.

2. Replace No. 16 short cork stopper (C- MATERIALS REQUIRED490) in pinion (12, figure 63-84). Applyshellac (C-211)to cork and install in position(figure 63-85) 0.25 to 0.31 in. (6.35 to 7.874 NUMBER NOMENCLATUREmm) in depth from flat surface of gear web. C-304 SolventC-304 Solvent

3. Replace parts which are cracked, broken, C-405 Lockwirewarped, or have malformed threads.

4. Replace duplex bearings as matched SPECIAL TOOLS REQUIREDserialized sets, if unserviceable.

NUMBER NOMENCLATURENOTE

T101305 WrenchRefer to BHT-ALL-SPM manual for T1017 Holdingrepair of studs and inserts, outlinedin steps 5., 6., and 7. T101449 Wrench

5. Repair sleeves have damaged or loose T101519 Platestuds or damaged threads. Alternate:

Alternate:

6. Repair dents and nicks on sleeve flange T101446top surface by polishing with fine India stone(C-464). Blend repaired area into flat surfacewith a minimum radius of 0.12 in. (3.048 mm). 1. Clean all parts with solvent (C-304) andFinished repair shall be 63 RMS or better. drain.Maximum depth, after repair, shall not exceed0.030 in. (0.762 mm). 2. Coat all parts with transmission oil and

drain excess.

7. Repair sleeves which have loose ormissing locked-in inserts or studs.

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NOTE b. Inspect quill sleeve for reference

located on sleeve.3. Install shim plate (10, figure 63-84) onsleeve (9) with three screws (11). Serial c. If a shim plate of correct part numbernumber of sleeve and shim plate shall be the but without a serial number is available,same, or new shim plate shall be ground to measure thickness and record. Determinecorrect thickness as follows: whether shim plate is correct for this

particular installation as follows:a. Inspect shim plate and quill sleeve onwhich shim plate is to be installed for an

dimension given below.


NUMBER(IN.) (MM) (IN.) (MM)

Hydraulic pump drive 204-040-399-5 2.2215 56.4261 2.2220 56.4388quill sleeve

CRACKS BETWEEN HOLES IN4. Duplex bearings (1) shall be installed as WEB AND POSSIBLE FAILURE OFmatched set. Ensure serial number is same PINION.on both bearings of set. Inner and outerspacers are matched set. Ensure serial 6. Support bearing inner race with suitablenumber is same on both spacers. sleeve and press pinion (12) into bearings.

5. Position sleeve (9) with studs up. Press 7. Position T101519 plate in vise with shortone bearing (1) of set into sleeve with thrust end of pins up. Position pinion on plate withside of outer race up. Use suitable plug when holes of pinion engaged on pins. Coatpressing bearings into sleeve to apply force to threads with transmission oil and installbearing outer race. Install spacer set (2). washer (3) and nut (4). Install nut withPress second bearing of set into sleeve with shoulder side of nut next to washer. Torquethrust side of outer race down so bearings are nut 30 to 40 ft.lbs. (40.674 to 54.232 Nm) withinstalled back-to-back. T101305 wrench. Install clip (5) to secure

nut.

CAUTION 8. Press seal (8) into nut (7) with lip of seal

groove on nut (7). Coat lip of seal, packing,WHEN INSTALLING PINION INTO and threads with transmission oil. HoldBEARINGS, USE CARE TO ONLY sleeve with T101447 holding fixture andAPPLY PRESSURE TO PINION install nut (7). Use T101449 wrench to torqueWEB AREA. PRESSURE APPLIED nut 150 to 220 ft.lbs. (203.37 to 298.276 Nm).AT GEAR TEETH CAN RESULT IN Secure nut to sleeve with lockwire (C-405).

Check pinion for free rotation.

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POSITION CORK 0.25 TO 0.31 IN.(6.35 TO 7.7874 mm) INBOARD FROMFLAT SURFACE OF GEAR WEB


1 Sleeve ID 2.6768 67.99072 2.6775 68.00852 Pinion shaft OD 1.5748 39.99992 1.5755 40.01773 Bearings OD 2.6769 67.99326 2.6774 68.005964 Sleeve OD 4.9989 126.97206 5.0000 127.00005 Case ID 5.0000 127.0000 5.0021 127.053346 Spline Between Pins 0.7207 18.30578 0.7263 18.44802


212-R-63-85

Figure 63-85. Hydraulic pump drive quill wear limits

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63-90. OFFSET ACCESSORY DRIVE 9. Install T101589 plate on pinion betweenQUILL. spacer (12) and duplex bearing (11) to

support inner face of bearings.

63-91. Disassembly. 10. Using aluminum pressing tool, presspinion (15) out of duplex bearing (11).

SPECIAL TOOLS REQUIRED 11. Remove spacer (12), roller bearing (13),and retaining ring (14) from pinion (15).

NUMBER NOMENCLATURE

T101305 Wrench 63-92. Cleaning.

T101568 Wrench MATERIALS REQUIRED

T101589 PlateNUMBER NOMENCLATURET101599 Pressing tool NUMBER

Spanner wrench C-105 Corrosion PreventiveAN8515-1 Spanner wrenchC-304 Solvent

1. Clamp T101568 wrench in vise with C-334 1.1.1-Trichloroethanesplined end up, position quill on wrench, withsplines of pinion engaged with wrench, andpinion (15, figure 63-86) teeth down. 1. Clean all quill parts with solvent (C-304).

Use soft bristle brush to dislodge stubborng of 7 deposits. All parts except bearings may be2. Bend locking tangs of lockwasher (7) out cleaned with 1.1.1-trichloroethane (C-334)bycleaned with 1.1.1-trichloroethane (C-334) byof recess in nut (8). Use AN8515-1 spanner degreasing if desired.

wrench to remove nut (8). Removelockwasher (7). 2. Dry parts with clean, lint-free cloths or

dry, filtered, compressed air. Do not allow3. Remove retainer (2) from gear (1) and bearings to spin while drying.support (3). Remove gear (1) from support(3). 3. Coat bearings with corrosion preventive

(C-105) immediately after cleaning.4. Place quill on press and press support (3)out of bearing (5).

CAUTION5. Place quill on T101568 wrench with pinionteeth down. Remove clip (9). Use T101305wrench to remove nut (10). DO NOT HANDLE UNOILED

BEARINGS WITH BARE HANDS.6. Remove retaining ring (14) from slot withsmall screwdriver. Remove quill from 4. Inspect quill for corrosion damage toT101568 wrench. threaded studs and stud holes before

cleaning. No structural damage to threads orholes is acceptable.7. Heat sleeve (6) with heat lamp and press holes is acceptable.

pinion (15) and bearing stack out of sleeve 5. Remove sealant with plastic scraper.(6).

7A. Remove retaining ring (4).

8. Position sleeve (6) on press and pressbearing (5) out of sleeve.

63-00-00Rev.3 Page 193

BHT-212-CR&O

63-93. Inspection. is not intended all dimensions bechecked as prescribed overhaul

1. Inspect all parts visually for damage and procedure. However, partsexcessive wear. exhibiting evidence of wear of

physical damage shall be checked2. Inspect gear (1, figure 63-86) and pinion dimensionally.(15) for spalled, scuffed, pitted, chipped, ordented teeth. Inspect roller bearing surface 63-94. Repair.of pinion for spalling, scoring, pitting,brinelling, and corrosion damage. Inspectsplines on pinion for chipped, pitted, or MATERIALS REQUIREDexcessively worn teeth. Inspect pinion fordamaged threads. Inspect gear wear pattern NUMBER NOMENCLATURE

NUMBER NOMENCLATURE(figure 63-87).C-100 Chemical Film Material

3. Inspect bearings (5, 11, and 13) forspalling, scoring, pitting, brinelling, corrosion C-103 Chromic Aciddamage, and for cracked or broken retainers.Inspect bearings (5 and 13) for roughness C-108 Brush Cadmiumwhen rotated. Plating Solution

C-464 India Stone4. Inspect sleeve (6) for corrosion damage, C-464 India Stonefor loose or damaged bearing liners, and fordamaged threads. 1. Replace all unserviceable parts.

5. Inspect support (3), nut (8), and nut (10) 2. Replace duplex bearings as matchedfor damaged threads. serialized set, if unserviceable.

6. Inspect the following parts by magnetic 3. Replace parts that are cracked, broken,particle (Code M) or fluorescent penetrant warped, have malformed threads, or exceed(Code F), as applicable (BHT-ALL-SPM). wear or repair limits.Demagnetize parts after magnetic inspection.

4. Repair dents and nicks on sleeve flangetop surface by polishing with fine India stone

Figure, Nomenclature Code (C-464). Blend repaired area into flat surfaceIndex No. with a minimum radius of 0.12 in. (3.048 mm).

63-86, 1 Gear, accessory spur M Finished repair shall be 63 RMS or better.driving Maximum depth, after repair, shall not exceed

63-86, 3 Support M 0.030 in. (0.762 mm) depth.63-86, 6 Sleeve F63-86, 8 Nut bearing retaining M 5. Refinish parts, after repair, in accordance63-86 10 Nut, splinged retaining M with BHT-ALL-SPM as outlined below:63-86, 15 Pinion M

chemical film material (C-100).

7. Inspect parts dimensionally and replace b. Magnesium parts: Remove all traces ofparts which exceed inspection limits (figure corrosion by immersion in chromic acid bath63-88). (BHT-ALL-SPM). Touch up parts with

chromic acid (C-103) or treat entire part withmagnesium alloy chemical film treatment

NOTE (BHT-ALL-SPM).

Wear limits are provided to showrequired fit between mating parts. It

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BHT-212-CR&O

1. Gear

212-R-63-86

Figure 63-86. Offset accessory drive quill

63-00-00Page 195

BHT-212-CR&O

Spur Drive Gear, Offset Accessory Drive. Scuffing inthe root and at tip of the teeth . Maximum depthacceptable is 0.0004 Inch (0.01016 mm). Conditionshown Is In excess of 0.0004 Inch (0.01016 mm) andIs unacceptable.

Pinion Gear, Offset Accessory Drive. Typicalacceptable wear pattern.

Pinion Gear, Offset Accessory Drive. Scuffing In theroot and at the tip of the tooth. Maximum depthacceptable Is 0.0004 Inch (0.01016 mm). Condition

~shown Is In excess of 0.0004 Inch (0.01016 mm) andIs unacceptable.

Spur Driving Gear, Offset Accessory Drive. Typicalacceptable wear pattern.

212-R-63-87COOOO

Figure 63-87. Offset accessory drive quill gear wear pattern

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BHT-212-CR&O

c. Cadmium plated steel parts: Treat 6. Support inner race of bearing (5) withrework areas with brush cadmium plating suitable sleeve and press support (3) intosolution (C-108) (BHT-ALL-SPM). bearing (5).

63-95. Assembly. CAUTION

MATERIALS REQUIRED WHEN INSTALLING PINION INTOBEARING, USE CARE TO ONLY

NUMBER NOMENCLATURE APPLY PRESSURE TO PINIONHUB AREA. PRESSURE APPLIED

C-304 Solvent AT GEAR TEETH CAN RESULT INCRACKS BETWEEN HOLES INWEB AND POSSIBLE FAILURE OF

SPECIAL TOOLS REQUIRED PINION.

7. Support duplex bearing (11), at innerNUMBER NOMENCLATURE race, and press pinion (15) into sleeve (6).

T101568 WrenchT1 01 568 Wrench 8. Place gear (1) on support and installAN8515-1 Spanner wrench retainer (2). Ensure both ends of retainer are

fully engaged in holes in tang of gear.

1. Clean all parts with solvent (C-304). 9. Place T101568 wrench in vise, splined1. Clean all parts with solvent (C-304) ..end up. Position sleeve and pinion on wrenchwith pinion teeth down. Install nut (10) and

2. Coat all parts with transmission oil and torque 30 to 40 ft.lbs. (40.674 to 54.232 Nm)drain excess. using T101305 wrench. Secure nut with clip

(9).

NOTE 10. Place lockwasher (7) on support (3) withinner tangs engaged in slots of support.

Do not handle unoiled parts with Install nut (8) with beveled side next tobare hands. lockwasher using AN8516-1 wrench. Torque

nut 50 to 100 ft.lbs. (67.79 to 135.58 Nm).Bend two tangs of lockwasher (7) into slots of

3. Heat sleeve (6, figure 63-86) with a heat nut (8). Remove offset accessory drive quilllamp. Position sleeve on press, face up. from T101568 wrench.Support sleeve and press bearing (5) intosleeve with face of bearing up. Install 11. Check pinion and bearings for free

rotation.retaining ring (4).

4. Press duplex bearing (11) into sleeve (6),back-to-back. Duplex bearing shall be amatched set with same serial number on bothbearings.

5. Install spacer (12) with larger diameterend up. Press roller bearing (13) into sleeve(6). Install retaining ring (14).

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BHT-212-CR&O

5


1 Sleeve ID 5.5113 139.98702 5.5120 140.00482 Bearing OD 5.5112 139.98448 5.5118 139.99972

ID 4.3302 109.98708 4.3308 110.002323 Support OD 4.3308 110.00232 4.3314 110.017564 GearTeeth Overpins 6.0005 152.4127 6.0048 152.52192


5 GearSplines Between Pins 4.4416 112.81664 4.4444 112.88776(Use 0.1440 IN. (3.6576 mm)diameter pins)

6 Pinion Teeth Over pins 4.1895 106.4133 4.1928 106.49712(Use 0.2057 IN. (5.22478 mm)diameter pins)

7 Pinion Splines Between Pins 1.1251 28.57754 1.1306 28.71724(Use 0.0720 IN. (1.8288 mm)diameter pins)

8 Sleeve ID 3.1489 79.98206 3.1497 80.002389 Bearing OD 3.1492 79.98968 3.1496 79.99984

10 Pinion OD 1.8691 47.47514 1.8697 47.4903811 Sleeve ID 2.6768 67.99072 2.6775 68.008512 Bearing OD 2.6769 67.99326 2.6774 68.00596

ID 1.5745 39.9923 1.5749 40.0024613 Pinion OD 1.5748 39.99992 1.5755 40.017714 Sleeve OD 3.6252 92.08008 3.6260 92.100415 Case ID 3.6245 92.0623 3.6263 92.10802

212-R-63-88

Figure 63-88. Offset accessory drive quill wear limits

63-00-00Page 198Page 198

BHT-212-CR&O

63-96. ACCESSORY DRIVE AND SUMP. b. Remove screw (9) and seal (8) fromjet 4 (7).

63-97. Disassembly. c. Remove screw (10), jet 4 (7), andpackings (5 and 6). Discard packings.

SPECIAL TOOLS REQUIREDd. Remove union (25) and packing (24).

Loosen nut (17) and remove drain valve (16)NUMBER NOMENCLATURE with packing (18) and nut (17). Discard

packings.T101338 Jackscrew set

e. Loosen nut (21) and remove elbow(19) with packing (20) and nut (21). Remove

NOTE union (22) and packing (23). Discardpackings.

If accessory drive and sump is beingdisassembled for replacement of f. Remove sump plug (31) with packingpart(s), instead of overhaul, (30) and drain residual oil. Remove oil pumpdisassemble only to extent screen (33) and packing (32).necessary to replace part(s).

g. Remove chip detector (34) and1. Remove oil pump (31, figure 63-89) packing (37).(BHT-212-MM). Refer to paragraph 63-134for pump overhaul. h. Remove retainer (40), packing (41),

glass (42), and full level oil indicator (43).2. Remove hydraulic pump and tachometerdrive quill (4, figure 63-89) (BHT-212-MM). i. Remove retainer (38), packing (39),Refer to paragraph 63-122 for overhaul. glass (36), and low level oil indicator (35).

3. Remove filter (7, figure 63-89) (BHT-212- 7. Remove accessory drive quill shim platesMM). on sump case as follows:

4. Remove accessory case input quill as a. Remove shim plate (1) and screwsfollows: (29) for accessory case input quill. Identify

shim plate for reinstallation in same locationa. Remove nuts (16) and washers (17). on same case.

Use T101338 jackscrew set to pull accessorycase input quill (18) from case. Tightenjackscrews evenly to pull quill from case. NOTE

b. Remove retainer rings (19 and 22) and Serial number of shim plates shallpump driveshaft (21). be same as case serial number.

c. Refer to paragraph 63-103 for overhaul b. Remove shim plate (3) and screws (2)of accessory case input quill. for tail rotor drive quill. Identify shim plate for

reinstallation in same location on same case.5. Remove tail rotor drive quill (23, figure63-89) (BHT-212-MM). Refer to paragraph 63- c. Remove shim plate (28) and screws128 for quill overhaul. (27) for hydraulic pump and tachometer drive

quill. Identify shim plate for reinstallation in6. Remove accessory drive and sump case same location on same case.external components as follows:

a. Remove elbow (15, figure 63-90), nut(14), and packing (13). Discard packing.

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BHT-212-CR&O

13 14 16

1. Nut 292. Steel washer 113. Aluminum washer4. Hydraulic pump and

Tachometer drive quill5. Packing6. Packing7. Oil filter8. Aluminum washer

26. Steel washer 35. Aluminum washer27. Steel washer 36. Nut28. Nut 37. Tube29. Sump case 38. Tee30. Packing (2) 39. Tube31. Oil pump 40. Nut32. Bracket 41. Aluminum washer33. Steelwasher 42. Steelwasher 212-R-63-89

Figure 63-89. Accessory drive sump quills and oil pump

63-00-00Page 200

BHT-212-CR&O

29

28

27

626

36 34 20

RIGHT SIDE VIEW 1833 OF SUMP CASE

17 6

1. Shim plate 16. Drain valve 31. Plug2. Screw 17. Nut 32. Packing3. Shim plate 18. Packing 33. Pump screen4. Sump case 19. Elbow 34. Chip detector5. Packing 20. Packing 35. Oil level indicator (low)6. Packing 21. Nut 36. Glass7. Jet no. 4 22. Union 37. Packing8. Dyna-seal 23. Packing 38. Retainer9. Screw 24. Packing 39. Packing

10. Screw 25. Union 40. Retainer

12. Insert 27. Screw 42. Glass13. Packing 28. Shim plate 43. Oil level indicator (full)

15. Elbow 30. Packing

212-R-63-90

Figure 63-90. Accessory drive sump components and shims

63-00-00Page 201Page 201

BHT-212-CR&O

63-98. Cleaning. inspected to determine if rework is possibleas follows:

MATERIALS REQUIRED(1) Corrosion should be removed by

NUMBER NOMENCLATURE chromic acid bath method (BHT-ALL-SPM).

C-304 Solvent (2) Measure and record height of stud.

C-334 1.1.1 -Trichloroethane

C-436 Paint Remover (3) If corrosion has affected more thanone complete thread, replace case.

1. Clean all case parts with solvent (C-304). (4) If corrosion has affected less thanUse soft bristle brush to dislodge stubborn one complete thread, case shall be reworked.deposits. All parts may be cleaned with1.1.1-trichloroethane (C-334) by vapor b. Rework case (paragraph 63-100).degreasing if desired.

2. Inspect sight glasses (36 and 42, figure2. Dry parts with clean, lint-free cloths or 63-90) for discoloration and crazing.dry, filtered, compressed air.

3. Inspect indicators (35 and 43) for3. Use paint remover (C-436) to remove discoloration and chipped paint.paint from all painted parts.

4. Inspect oil filter (7, figure 63-89), chip4. Inspect case for corrosion damage to detector (34, figure 63-90), pump screen (33),

and drain valve (16) for damage andthreaded studs and stud holes before n ricorrosion.cleaning. No structural damage to threads orholes is acceptable.

5. Inspect oil tubes (37 and 39, figure 63-89)and related fittings for damage and corrosion.

5. Remove sealant with plastic scraper.

6. Inspect brackets (15 and 32) for cracks

63-99. Inspection. and corrosion.

1. Visually inspect sump case and 7. Inspect pump driveshaft (21) for damage

wear. Inspect case for loose and or damagedstuds.

8. Inspect sump case quill ports for anaverage diameter of 3.6250 to 3.6265 in.

a. In areas C, D, and E figure 63-91, (92.075 to 92.1131 mm).pitting to a maximum depth of 0.020 in. (0.508mm) is permitted provided no more than 40%

9. Inspect following parts by magneticof any 1.0 sq.in. (645.2 sq mm) and 20% of part (Code M) or fluorescent penetranttotal area of any surface is corroded. Cases (Code F) method (BHT-ALL-SPM).having corrosion on studs or on case Demagnetize all parts after magneticimmediately adjacent to studs shall be further inspection.

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BHT-212-CR&O

AREA A

SUMP CASEAREA B

0.450 IN.(11.43 mm) MIN.

0.896 IN.DIM E (22.7584 mm)

DIA.(REF)0.812 IN. DIM C

(20.6248 mm) ENGLARGED VIEW

DIA. (REF) OF SECTION IN AREA B

ENGLARGED VIEW BEFORE REWORK

OF SECTION IN AREA BAFTER REWORK

212-R-63-91

Figure 63-91. Sump and accessory drive inspection areas

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BHT-212-CR&O

is 0.089 in. (2.2606 mm). Check minimumFigure, Nomenclature Code boss height (dimension E).Index No.63-89, 21 Pump driveshaft M e. Treat reworked areas of case with63-89, 29 Sump case F chromic acid (C-103) or treat entire part with

magnesium chemical film treatment (BHT-ALL-SPM).

63-100. Repair. 4. Sump cases having corrosion aroundstuds shall be reworked as follows:

MATERIALS REQUIRED a. Using a 0.327 to 0.334 in. (8.3058 to8.4836 mm) diameter drill, counterdrill stud

NUMBER NOMENCLATURE holes to a maximum depth of 0.125 in. (3.175mm). Break all sharp edges, except in thread

C-103 Chromic Acid area.

C-308 Adhesive b. Treat surfaces after drilling withchromic acid (C-103) or treat entire part with

1. Damage frequently occurs to the sump magnesium alloy chemical film treatmentcase in area A, figure 63-91 by fretting with (BHT-ALL-M).an external oil hose. Fretting damage is c. Install new stud in reworked hole (BHT-acceptable in this area provided it does not ALLexceed 0.070 in. (1.778 mm) in depth andprovided total affected area does not exceed. holes shall be filled2.0 sq.in. (1290.4 sq mm). The affected area ith adhesie 8 flush ith to sur

on acceptable cases should be treated for with adhesive (C-308) flush with top surfaceon acceptable cases should be treated for of case.corrosion prevention as outlined in BHT-ALL-SPM. 5. Replace unserviceable parts.

2. Inspect area B for excessive wear in the Replace studs when loose or damaged.ID of oil passage. Case may have threadedplug or may use plug with packing andretainer ring. If case uses retainer ring, 63-101. Assembly.inspect for excessive wear. Replace case ifwear is sufficient to prevent proper sealing of MATERIALS REQUIREDoil by packing or proper fit of retaining ring.

3. Ports with retaining ring may be reworked NUMBER NOMENCLATUREas follows:

C-405 Lockwirea. Measure wall thickness of boss

(dimension C, figure 63-91). If minimum wallthickness is 0.140 in. (3.556 mm) or more, SPECIAL TOOLS REQUIREDcase may be reworked.

NUMBER NOMENCLATUREb. Drill existing 0.812 in. (20.6248 mm) NUMBER NOMENCLATUREdiameter hole to 0.750 in. (19.05 mm) depth. 212-040-001-3 Backlash tool

GIF-1c. Machine boss to AND10050-10 boss,

except for tap drill depth.

d. Measure wall thickness (dimension D,figure 63-90). Minimum acceptable thickness

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NOTE MIN.MAX.LOCATION (In./mm) (In./mm)

When installing quills, exercise care LOCATIONto properly mesh gear teeth with Accessory case input 4.7895 4.7900mating gear as quill is installed to quill (121.6533 (121.666avoid damage. It may be necessary mm) mm)to tap on quill to accomplishinstallation. Do not tap on end of Tail rotor drive quill 4.8685 4.8690gear. (123.6599 (123.6726

mm) mm)NAS1197 washers shall be replacedwith AN960JD washers. Hydraulic pump and 4.8685 4.8690

tachometer drive quill (123.6599 (123.67261. Inspect case to ensure oil passages are mm) mm)not obstructed. Position case on clean workbench or install in suitable support fixture.

3. Install retainer ring (22, figure 63-89),2. Install shim plates (1, 3, and 28, figure pump driveshaft (21) and retainer ring (19) in63-90) on case (4) with screws (2, 27, and pinion of accessory case input quill (18).29). The serial number of case and shimplates shall be the same or new shim plates 4. Heat case at port for accessory caseshall be ground to correct thickness. input quill (18) with a heat lamp. Coat mating

surfaces of quill sleeve and mounting porta. Inspect shim plate and accessory case with transmission oil, and install quill in case.

on which shim plate is to be installed for an Secure with six nuts (16) and washers (17).etched serial number. If parts cannot be Secure nuts in pairs with lockwire (C-405).identified by serial number, determinerequired dimension of shim. 5. Install oil pump (BHT-212-MM).

b. Inspect accessory case for reference 6. Install tail rotor drive quill (BHT-212-MM).dimension which shall be metal stamped orvibro-etched on part adjacent to mounting 7. Install no.2 hydraulic pump andsurface. Record this dimension and where tachometer drive quill (BHT-212-MM).located on case.

8. Install elbow (15, figure 63-90) withc. If a shim plate of correct part number packing (13) and nut (14). Install cap on

but without a serial number is available, elbow.measure thickness and record. Determinewhether shim plate is correct for this 9. Install two new packings (5 and 6) on oilparticular installation as follows: jet (7). Coat packings with transmission oil,

and install jet. Secure with screw (10).(1) Add shim plate thickness to Install new seal (8) and screw (9) in jet center

reference dimension found on accessory hole. Secure jet center screw (9) and jetcase. The resulting value shall fall within retaining screw (9) with lockwire (C-405).dimension listed below.

10. Install plug (31) and packing (30) inbottom of case.

11. Install packing (32) on pump screen(33). Coat packing and threads withtransmission oil and install pump screen incase. Torque pump screen 300 to 400 in.lbs.(33.894 to 45.192 Nm).

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12. Install chip detector (34) and packing(37). Torque chip detector housing 300 to CAUTION400 in.lbs. (33.894 to 45.192 Nm). OCCUR

13. Secure pump screen (33) and chip DO NOT ALTER SHIM PLATES ONdetector (34) together with lockwire (C-405). CASE OR QUILL SLEEVE TOSecure plug (31) to chip detector housing. OBTAIN BACKLASH. IF

BACKLASH IS NOT WITHIN14. Coat packings (39 and 41) with LIMITS, PARTS ARE IMPROPERLYtransmission oil and install on sight glasses A S S E M B L E D O R A R E(36 and 42). Install FULL indicator (43), sight DIMENSIONALLY INCORRECTglass, packing, and retainer ring (40) in upper (REFER TO STEP 2.a).sight glass port of case. Install LOW indicator(35), sight glass, packing and retainer ring a. Install 212-040-001-3 GIF-1 backlash(38) in lower sight glass port of case. Verify tool, on top of accessory drive sump andindicators are in proper ports. attach with three bolts. Tighten clamp on

backlash tool to secure pinion in accessoryI 15. Install oil filter (BHT-212-MM). case input quill (18, figure 63-88).

16. Install the following parts: b. Install 212-040-001-3 GIF-1, backlashtool, on tail rotor drive quill (23). Tighten

a. Install tee (39) in bracket (33) and backlash tool to clamp on inner coupling ofsecure with washer (36) and nut (37). tail rotor drive quill. Install dial indicator

support on one of tail rotor drive quill studs.b. Install packing (24, figure 63-90) on Install dial indicator on support and position to

union (25). Coat packing with transmission contact dowel pin in backlash tool. Takeoil and install union on scupper drain port in backlash reading at three places,case. approximately 120° apart, around gear and

record. Backlash shall be within 0.004 toc. Install tube (39, figure 63-89) between 0.010 in. (0.1016 to 0.254 mm). Remove

union (25, figure 63-90) and tee (38, figure backlash tools from tail rotor drive quill, but63-89). leave backlash tool on accessory case input

quill.d. Install packing (23, figure 63-90) on

union (22) and coat with transmission oil.Install union in port in bottom of case. NOTE

If backlash tool 212-040-001-3 GIF-e. Install elbow (19) on union (22) with If backlash tool 212-040-001-3 GIF-packing (20) and nut (21). (21) is unavailable, backlash may be

determined by an alternate method.

f. Install drain valve (16) in elbow (19) Take backlash readings at threewith packing (18) and nut (17). places approximately 120° apar

around gear at a distance (radius) of

g. Install tube (37, figure 63-88) between 1.227 in. (31.1658 mm) from geardrain valve and tee. Install union and packing center. Backlash shall be within

n tee (38). 0.004 to 0.010 in. (0.1016 to 0.254in tee (38). mm).

17. Check backlash of sump and accessorydrive assembly quills as follows: c. Install 212-040-001-3 GIF-1, backlash

tool, on pinion shaft of hydraulic pump andtachometer drive quill (4). Install dialindicator support on one of hydraulic pumpand tachometer drive quill studs. Install dialindicator on support and position to contactdowel pin in backlash tool. Take backlash

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BHT-212-CR&O

reading at three places approximately 120° (11). Hold pinion with T101568 wrench andapart around gear and record. Backlash shall remove bearing retaining nut (3) withbe within 0.004 to 0.010 in. (0.1016 to 0.254 T101305 wrench. Remove washer key (4).mm) for 212-040-365-007 and 0.014 to 0.022in. (0.3556 to 0.5588 mm) for 212-040-365- 2. Press pinion (11) out of sleeve.103. Remove backlash tools from hydraulicpump and tachometer drive quill. Remove 3. Hold sleeve (6) with T101455 plate andbacklash tool from input quill at top of remove bearing retaining nut (1) withaccessory drive sump. T101449 wrench.

NOTE NOTE

If backlash tool 212-040-001-3 GIF- In steps 4. and 5., exercise care to1, is unavailable, backlash may be properly position bearing removaldetermined by an alternate method. bar on bearings to avoid damagingTake backlash readings at three bearing or sleeve.places approximately 120° apartaround gear at a distance (radius) of 4. Remove retainer ring (10). Insert1.227 in. (31.1658 mm) from gear T101567 bearing removal bar through slot incenter. side of sleeve (6) and press roller bearing (9)

out of sleeve.

63-102. Painting. 5. Insert T101566 bearing removal barthrough slot in side of sleeve (6) and press

Paint accessory drive sump and case in duplex bearing (5) out of sleeve. Bearingaccordance with paragraph 63-43, as shall be retained as a matched set.applicable.

6. Remove three screws (8) and shim plate63-103. ACCESSORY CASE INPUT (7). Identify shim plate for reinstallation onQUILL. same sleeve.


MATERIALS REQUIREDSPECIAL TOOLS REQUIRED MATERIALS REQUIRED

NUMBER NOMENCLATURE NUMBER NOMENCLATURENUMBER NOMENCLATURE

T101305 Wrench C-105 Corrosion PreventiveT101305 WrenchC-304 Solvent

T 1 0 1 4 4 9 o r WrenchT101660 C-334 1.1.1 -Trichloroethane

T101455 Plate1. Clean all quill parts with solvent (C-304).

101566 Bar Use soft bristle brush to dislodge stubbornT101567 Bar deposits. All parts except bearings may be

cleaned with 1.1.1-trichloroethane (C-334) byT101568 Wrench vapor degreasing if desired.

2. Dry parts with clean, lint-free cloths or1. Remove nut locking clip (2, figure 63-92). dry, filtered, compressed air. Do not allowIf not previously accomplished, remove oil bearings to spin while drying.pump shaft retaining ring in base of pinion

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BHT-212-CR&O

3. Coat bearings with corrosion preventive 63-107. Repair.(C-105) immediately after cleaning. Do nothandle unoiled bearings with bare hands. MATERIALS REQUIRED

4. Remove sealant with plastic scraper.NUMBER NOMENCLATURE

63-106. Inspection. C-100 Chemical Film Material

C-103 Chromic Acid1. Inspect all parts visually for damage andexcessive wear. C-108 Brush Cadmium

Plating Solution2. Inspect nuts (1 and 3, figure 63-92) fordamaged threads. C-112 Cadmium Chromate

Conversion Coating

3. Inspect duplex bearings (5) for spalling,scoring, pitting, brinelling, corrosion damage, 1. Replace all unserviceable parts.cracked or broken retainers, and forroughness when rotated. 2. Replace pinion (11, figure 63-92) worn or

pitted in excess of limits (figures 63-93).4. Inspect sleeve (6) for corrosion damage,loose or damaged bearing liner, and damaged 3. Replace duplex bearings as a matched,threads. serialized set if unserviceable.

5. Inspect roller bearing (9) for spalling 4. Inspect sleeve flange top surface forscoring, pitting, brinelling, corrosion damage dents and nicks. If damage does not exceedscoring, pitting, brinelling, corrosion damage,and cracked or broken roller retainers. 0.030 in. (0.762 mm) depth, polish outand cracked or broken roller retainers. damage and blend repaired area into flat

surface with a minimum radius of 0.12 in.6. Inspect pinion (11) for spalled, scuffed, (3.048 mm). Finished repair shall be 63 RMSpitted, chipped, or dented teeth. Inspect roller or better. The maximum depth after repairbearing surface for spalling, scoring, pitting, must not exceed 0.030 in. (0.762 mm).brinelling, and corrosion damage. Inspectsplines for chipped, pitted or excessively worn 5 Refinish parts, after repair, in accordanceteeth. Inspect threads for damage. with BHT-ALL-SPM as outlined below:

7. Inspect the following parts by magnetic a. Aluminum parts: Touch up with brushparticle (Code M) or fluorescent penetrant chemical film material (C-100).(Code F) as applicable. Demagnetize partsafter magnetic particle inspection (BHT-ALL- b. Magnesium parts: Remove all traces ofSPM). corrosion by immersion in chromic acid bath

(BHT-ALL-SPM). Touch up parts with chromicacid (C-103) or treat entire part with

Figure, Nomenclature Code magnesium chemical film treatment (BHT-Index No. ALL-SPM).

63-92, 1 Nut F63-92, 3 Nut M c. Cadmium plates steel parts: Strip old63-92, 6 Sleeve F plating and replate using brush cadmium63-92, 11 Pinion M plating solution (C-108) (BHT-ALL-SPM).

Apply supplementary cadmium chromateconversion coating (C-112).

8. Inspect parts of accessory case input quilldimensionally as required (figure 63-93).

63-00-00Page 208 Rev.3

BHT-212-CR&O

Nut, Bearing Retaining2. Clip, Nut Locking3. Nut Bearing Retaining4. Washer, Key5. Duplex Bearings6. Sleeve7. Shim Plate8. Screw9. Roller Bearing

10. Retainer Ring11. Pinion 212-R-63-92

Figure 63-92. Accessory case input quill

63-00-00Page 209

BHT-212-CR&O

212-R-63-93-1

Figure 63-93. Accessory case wear limits (sheet 1 of 2)

63-00-00Page 210

MIN. MAXITEM NOMENCLATURE IN. mm IN. mm

1 Spline, Oil Pump Shaft Over pins 1.3410 34.0614 1.3480 34.2392(Use 0.0960 IN. (2.4384 mm)diameter pins)

2 Spline, Pinion Between pins 1.0908 27.70632 1.0966 27.85364(Use 0.0864 IN. (2.19456 mm)diameter pins)

3 Sleeve Liner ID 3.1490 79.9846 3.1499 80.007464 Bearing OD 3.1491 79.98714 3.1496 79.99984

ID 1.3777 34.99358 1.3781 35.003745 Shaft, Pinion OD 1.3780 35.0012 1.3786 35.016446 Spline, Pinion Over pins 1.3410 34.0614 1.3480 34.2392


7 Sleeve OD 3.6247 92.06738 3.6255* 92.08778 Case ID 3.6250 92.075 3.6265* 92.11319 Bearing Surface, Pinion OD 1.8691 47.47514 1.8696 47.48784

(P/N 212-040-150-1)Bearing Surface, Pinion OD 1.8692 47.47768 1.8696 47.48784(P/N 212-040-150-3)

10 Bearing OD 3.1492 79.98968 3.1496 79.9998411 Sleeve Liner ID 3.1489 79.98206 3.1497* 80.0023812 Nut13 Nut14 Sleeve Liner ID 2.8340 71.9836 2.8347 72.0013815 Bearing OD 2.8341 71.98614 2.8346 71.99884

ID 1.3777 34.99358 1.3781 35.0037416 Shaft, Gear OD 1.3780 35.0012 1.3786 35.0164417 Spline, Gear Over pins 1.4424 36.63696 1.4465 36.7411


18 Spline, Inner Coupling Between pins 1.1465 29.1211 1.1578 29.40812(Use 0.0960 IN. (2.4384 mm)diameter pins)

19 Teeth, Inner Coupling Over pins 2.1590 54.8386 2.1740 55.2196(Use 0.1080 IN. (2.7432 mm)diameter pins)

20 Splines, Outer Coupling Between pins 1.8290 46.4565 **(Use 0.1309 IN. (3.32486 mm)diameter pins)

21 Sleeve OD 3.6247 92.06738 3.6255* 92.087722 Case ID 3.6250 92.075 3.6265* 92.113123 Bearing Surface, Gear OD 1.8691 47.47514 1.8696 47.4878424 Bearing OD 3.1492 79.98968 3.1496 79.9998425 Sleeve Liner ID 3.1489 79.98206 3.1497* 80.0023826 Hydraulic Pump and Tachometer

Drive Quill (See figure 63-102for limits.)

27 Spline, Adapter Over pins 1.3410 34.0614 1.3480 34.2392(Use 0.0960 IN. (2.4384 mm)diameter pins)

28 Spline Adapter Between pins 1.0871 27.61234 1.0966 27.85364(Use 0.0864 IN. (2.19456 mm)diameter pins)

* Average dimension** Maximum depth of wear 0.005 inch (0.127 mm) (measure from unworn face of tooth). 212-R-63-93-2

Figure 63-93. Accessory case wear limits (sheet 2)

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BHT-212-CR&O

6. Replace parts which are not within vibro-etched on part adjacent to mountingallowable wear limits, surface. Record dimension and where

located on sleeve.

63-108. Assembly. c. If a shim plate of correct part numberbut without a serial number is available,

MATERIALS REQUIRED measure thickness and record. Determinewhether shim plate is correct for this

NUMBER NOMENCLATURE particular installation as follows:

C-304 Solvent (1) Subtract shim plate thickness fromreference dimension found on quill sleeve.

C-405 Lockwire The resulting value shall fall within dimensionlisted below:

SPECIAL TOOLS REQUIRED LOCATION MIN. MAX.(In./ (In./mm) mm)

NUMBER NOMENCLATUREWrench Accessory 0.9895 0.9900

case input quillT 1 0 1 4 4 9 or Wrench sleeveT101660

T101455 Plate 4. Press duplex bearings (5) into sleeve, (6),face-to-face, using suitable sleeve. Duplex

T101568 Wrench bearings shall be a matched set with sameserial number on both bearings.

1. Clean all parts with solvent (C-304) anddrain. 5. Press roller bearing (9) into sleeve (6)

using suitable sleeve and install retainer ring

2. Coat all parts with transmission oil and (10).drain.

NOTE CAUTI

Do not handle unoiled parts with WHEN INSTALLING PINION INTOWHEN INSTALLING PINION INTObare hands. BEARING, USE CARE TO ONLYAPPLY PRESSURE TO PINION3. Install shim plate (7, figure 63-92) on APPLY PRESSURE TO PINIONHUB AREA. PRESSURE APPLIEDsleeve (6) with three screws (8). Serial HUB AREA. PRESSURE APPLIED

number of sleeve and shim plate shall be the AT GEAR TEETH CAN RESULT INsame, or a new shim plate shall be ground to CRACKS BETWEEN HOLEScorrect thickness as follows: WEB AND POSSIBLE FAILURE OF

PINION.

a. Inspect shim plate and quill sleeve onwhich shim plate is to be installed for an 6. Support duplex bearings on inner raceetched serial number. If parts cannot be and press pinion (11) into bearings.identified by serial number, determinerequired dimension of shim plate. 7. Position T101568 wrench in a vise with

splined end up. Position quill on wrench withb. Inspect quill sleeve for reference pinion teeth down. Install key washer (4) and

dimension which shall be metal stamped or bearing retainer nut (3). Torque nut 180 to200 ft.lbs. (244.044 to 271.16 Nm) with

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BHT-212-CR&O

T101305 wrench. Install nut locking clip (2). 63-110. Disassembly.Remove quill from T101568 wrench.

SPECIAL TOOLS REQUIRED8. Hold sleeve (6) with T101455 plate andinstall bearing retaining nut (1). Use T101449wrench to torque nut 100 to 150 ft.lbs. NUMBER NOMENCLATURE(135.58 to 203.37 Nm). Secure nut withlockwire (C-405). T101447 Holding fixture

9. Check pinion (11) for free rotation. T101466 or late assemblyT101519

63-109. ROTOR BRAKE DRIVE QUILL T101600 Wrench(205-040-300).

1. Secure sleeve (12, figure 63-95) inNOTE T101447 holding fixture.

Quill assembly 205-040-300-1requires overhaul at 2400 hour 2. Cut lockwire and remove four bolts (3),intervals, however; 204-040-424-001 four washers (4), and disc (5) from flange (6).bearing used in quill shall bereplaced at 600 hours. 3. Remove nut (1), packing (2), from flange

(6).

4. Cut lockwire and using T101600 wrench,remove nut (9).

63-00-00Figure 63-94. DELETED Rev. 3 Page 213

BHT-212-CR&O

5. Remove packing (8) and press seal (7)from nut (9). Figure, Nomenclature Code

Index No.6. Hold duplex bearings (10) using T101519 63-95 1 Nut Mplate assembly and press pinion (15) from 63-95, 9 Nut Fsleeve (12).sleeve (12). 63-95, 15 Pinion M

63-95, 11 Spacer (Outer) MNOTE 63-95, 11 Spacer (Inner) M

63-95, 8 Sleeve FReplace bearings 204-040-424-1(10) at 600 hours (BHT-212-MM).

7. Remove bearings (10) and spacer set 4. Inspect parts dimensionally (figure 63-96).(11) from sleeve (12).

5. Inspect shims (9, figure 63-95) fordamage and corrosion.

NOTE

Do not remove ground shim (9) from 63-113. Repair.sleeve (12) unless damaged.

MATERIALS REQUIRED63-111. Cleaning.

NUMBER NOMENCLATUREMATERIALS REQUIRED

C-108 Brush CadmiumNUMBER NOMENCLATURE Plating SolutionNUMBER NOMENCLATURE

C-464 India StoneC-304 Solvent

1. Clean pas with solvent (C-304) 1. Dress splines and gear teeth with a fineIndia stone (C-464) if small nicks, burrs orscratches are visible.2. Dry with filtered, compressed air.

63-112. Inspection.CAUTION

1. Visually inspect parts for damage orexcessive wear (figure 63-96). DUPLEX BEARINGS (10, FIGURE

63-95) ARE SERIAL NUMBERED2. Inspect pinion (15) for chipped, broken or AND SHALL BE INSTALLED INexcessively worn teeth. MATCHED PAIRS. BOTH

BEARINGS OF A PAIR SHALL BE3. Inspect the following parts by magnetic FROM SAME MANUFACTURER.particle (Code M) or fluorescent penetrant(Code F) method (BHT-ALL-SPM) as BEARING SPACERS (14) AREindicated. Demagnetize all parts after FINISH GROUND TOGETHER ANDmagnetic inspection. SERIAL NUMBERED AND SHALL

BE REPLACED AS A MATCHEDSET.

2. Replace threaded inserts as necessaryusing procedure recommended by insertmanufacturer.

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BHT-212-CR&O

5

4 3

14

10

15 8

11. Spacer set12. Sleeve3.4.5.6. Flange7. Seal

Figure 63-95. Rotor brake quill (205-040-300)

63-00-009. Nut10. Bearing11. Spacerset12. Sleeve13. Shim14. Screw15. Pinion 212-R-63-95

Figure 63-95. Rotor brake quill (205-040-300)

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BHT-212-CR&O

3. Replace shim plate (13) as follows: 63-115. Assembly.

a. Remove three screws (14). MATERIALS REQUIRED

b. Inspect sleeve (12) for referencedimension which is stamped or etched NUMBER NOMENCLATUREadjacent to mounting surface. Recorddimension. C-405 Lockwire

c. Measure new shim plate thickness andsubtract this figure from reference dimension SPECIAL TOOLS REQUIREDrecorded from sleeve. The result shall be2.221 to 2.2220 in. (56.4261 to 56.4388 mm)after plating. NUMBER NOMENCLATURE

T101447 Holding fixtured. If resulting dimension is less than2.2215 in. (56.4261 mm), grind surface of T 1 0 1 4 4 6 o r Plate assemblyshim plate to obtain proper dimension. After T101519grinding, surface finish of shim plate shall be63 RMS or better. T101600 Wrench

e. Ensure screw mounting holes arecountersunk. Replate ground surface of shim 1. Place duplex bearings (10) and spacerusing brush brush cadmium plating solution set (11) in sleeve (12).(C-108) (BHT-ALL-SPM).

NOTE4. Repair corrosion and wear to sleeve(figure 63-97). Duplex bearings (10) are assembled

back-to-back on each side of spacer

63-114. Lubrication. set (11).

2. Support inner race of duplex bearingsMATERIALS REQUIRED (10) with T101519 plate assembly and press

pinion (15) into bearings (10).NUMBER NOMENCLATURE

3. If removed, install shim plate (13) withC-104 Corrosion Preventive three screws (14).

Compound

4. Install packing (8) and seal (7) on nut (9).

1. Lubricate bearings, gear, and matingsurfaces with a light coat of transmission oil. 5. Using T101600 wrench install nut (9) on

sleeve (12).2. Apply corrosion preventive compound (C-104) on threads. 6. Torque nut (9) 1800 to 2400 in.lbs.

(203.36 to 305.05 Nm).

7. Lockwire nut (9) to sleeve (12) usinglockwire (C-405).

8. Install flange (6) into sleeve (12) usingcare not to damage seal (7).

9. Install packing (2) on nut (1).

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BHT-212-CR&O

10. Using T101447 holding fixture install nut (1) Reinstall bolts (21) and washers(1) on sleeve assembly (12). (22) to prevent inadvertant assembly

separation.11. Torque nut (1) 600 to 1000 in.lbs. (67.79to 112.98 Nm). (2) Place assembly in an arbor press

and remove bolts (21) and washers (22).12. Install disc (5) onto flange (6) using fourwashers (4) and four bolts (3). (3) Apply sufficient pressure to separate

flange from disc.13. Lockwire two bolts (3) to nut (1) usinglockwire (C-405), two places. 4. Cut lockwire and remove bolts (10) and

washers (11). Remove retainer (8), packing(7), and shim plate (6). Mark shim plate for

63-116. ROTOR BRAKE DRIVE QUILL reinstallation. Remove bushing (16) and(412-040-123-101 AND -103). packings (15). Discard packings (7 and 15).

5. Press seal (9) from retainer (8). Discard63-117. Disassembly. seal.

SPECIAL TOOLS REQUIRED 6. Hold duplex bearings (4) using T101519plate assembly and press pinion (19) fromsleeve (13).NUMBER NOMENCLATURE sleeve (13).

I T101469 Holding tool 7. Remove bearings (4) and spacer set (5)from sleeve (13).

T101519 Plate assembly

Commercial Arbor press NOTE

Do not remove ground shim (17)1. Remove nut (3, figure 63-98) and packing from sleeve (13) unless damaged.(2) from flange (1). Discard packing (2).

8. Remove screws (18) and shim plate (17).2. Remove flange (1) from pinion (19). Identify shim plate for reinstallation.

3. If installed, remove rotor brake disc from 63-118. Cleaning.flange as follows:

a. Cut lockwire and using holding tool, MATERIALS REQUIREDT101469, restrain disc (20) and remove bolts(21) and washers (22). NUMBER NOMENCLATURE

b. Using hand pressure only, separate C-304 Solventflange (1) from disc (20).

1. Clean parts with solvent (C-304).c. If disc and flange cannot be separatedby hand pressure, proceed as follows:pressure, proceed as follows: 2. Dry with filtered, compressed air.

NOTE 63-119. Inspection.

Using an arbor press, or equivalent,to separate flange from disc requires 1. Visually inspect parts for excessive weardisc be inspected for warpage. or damage (figure 63-99).

63-00-00Page 217

BHT-212-CR&O

4

205-040-300-1 QUILL ASSEMBLY

ITEM NOMENCLATURE MIN. MAX. REPLACE

1 Sleeve ID 2.6768 in. (67.9907 mm) 2.6772 in. (68.0009 mm) 2.6775 in. (68.0085 mm)

2 Pinion shaft OD 1.5751 in. (40.0075 mm) 1.5755 in. (40.0177 mm) 1.5748 in. (39.9999 mm)

3 Bearing ID 1.5745 in. (39.9923 mm) 1.5748 in. (39.9999 mm)

OD 2.6770 in. (67.9958 mm) 2.6774 in. (68.0060 mm) 2.6769 in. (67.9933 mm)

4 Sleeve OD 4.9995 in. (126.9873mm) 5.0000 in. (127.0000 mm) 4.9989 in. (126.9721 mm)

5 Pinion spline 1.613 in. (40.9702 mm) 1.616 in. (41.0464 mm) 1.6114 in. (40.9296 mm)(Dimension over0.1200 dia. pins)

6 Flange - 1.3324 in. (33.8429 mm) 1.3342 in. (33.8887 mm) 1.3351 in. (33.9115 mm)(Dimension between0.0900 dia. pins)

7 Spacer (length) *1.775 in. (45.085 mm) 1.790 in. (45.466 mm) 1.7749 in. (45.0824 mm)

8 Bolt holes 0.260 in. (6.604 mm) 0.276 in. (7.010 mm) NA

* Spacers to be same length within 0.0002 inch (0.00508 mm).212-R-63-96-1

Figure 63-96. Rotor brake drive quill damage limits (205-040-300) (sheet 1 of 3)

63-00-00Page 218

BHT-21 2-CR&O

4

12

13

910

212-R-63-96-2

Figure 63-96. Rotor brake drive quill damage limits (205-040-300) (sheet 2)

63-00-00Page 219

BHT-212-CR&O

WEAR LIMITSNEW PART DIMENSIONS

MINIMUM MAXIMUM REPLACEinches/mm inches/mm inches/mm

1. Sleeve I.D. 3.1491 79.9871 3.1495 79.9973 3.1497 80.0024

2. Sleeve O.D. 4.9995 126.9873 5.0000 127.0000 4.9992 126.9797

3. Bearing I.D. 1.5745 39.9923 1.5748 40.0000 1.5750 40.0050

4. Bearing O.D. 3.1492 79.9897 3.1496 80.0000 3.1490 79.9846

5. Pinion O.D. (Brg Journal) 1.5751 40.0075 1.5753 40.0126 1.5749 40.0025

6. Pinion Spline (Measure over 1.6130 40.9702 1.6160 41.0464 1.6114 40.92960.1200 inch (3.048 mm)dia pins)

7. Spacer set I.D. 1.5780 40.0812 1.5880 40.3352 1.5900 40.3860

8. Spacer set O.D. 3.1320 79.5528 3.1420 79.8068 3.130 79.5020

9. Spacer set Width 1.5224 38.6690 1.5264 38.7706

10. Bushing O.D. 0.4280 10.8712 0.4300 10.9220 0.4270 10.8458

11. Flange Spline (Measure 1.3324 33.8430 1.3342 33.8887 1.3359 33.9319between 0.0900 inch(2.2860 mm) dia pins)

12. Flange I.D. 1.5767 40.0481 1.5771 40.0583 1.5773 40.0634

13. Flange O.D. 2.2460 57.0484 2.2480 57.0992 2.2450 57.0230

14. Seal Wear O.D. 1.8730 47.5742 1.8770 47.6758 0.001 0.0254depth

NOTE

Minimum length of spacer set, measured at three equally spaced points on each spacer, shall be no lessthan 1.5222 inches (38.6639 mm). Maximum variation shall not exceed (0.002 inches 0.0051 mm)between any of the six measurements.

212-R-63-96-3

Figure 63-96. Rotor brake drive quill damage limits (205-040-300) (sheet 3)

63-00-00Page 220

BHT-212-CR&O

ITEM NOMENCLATURE

A Effective area where rework allowed.

B Pilot diameter for rotor brake disc.

C Mating surface of flange with threaded hole for disc retaining bolt. Typical four places.

D Flange sealing surface.

E Circumference of flange with radiused expanded dimension for threaded hole to accommodatedisc retaining bolt. Typical four places.

F Inner flange diameter for support on pinion gear.

G Flange circumference other than radiused areas with threaded holes.

212-R-63-97-1

Figure 63-97. Quill assembly (205-040-300) support flange rework limits (sheet 1 of 2)

63-00-00Page 221

BHT-212-CR&O

ITEM REWORK INSTRUCTIONS

A Remove corrosion, nicks and scratches using file, grinder, or abrasive cloth or paper (C-423) as

applicable. Do not use chemicals. Polish or buff surface of reworked areas to a smooth, scratch-free

finish. Protect reworked area with epoxy polyamide primer (C-204) and lacquer (C-203), except where

restricted in following instructions. Brush cadmium plating is permitted over reworked area in lieu of

primer and paint. LHE cadmium plating solution (C-108) must be used, or part must be baked within

one hour after plating to relieve hydrogen embrittlement.

B Diameter B rework limited to 0.010 inch (0.254 mm) depth, but no more than 50 percent of effective

pilot diameter in any half-inch length around circumference. Do not paint pilot diameter.

C Area C rework limited to 0.010 inch (0.254 mm) depth, but no more than 50 percent mating surface

around hole, typical four places. Polish reworked area to smooth, scratch-free finish with minimum

radius of 0.19 inch (4.826 mm). Do not paint reworked mating surface. Brush LHE cadmium plating

solution (C-108) may be applied BHT-ALL-SPM).

D No damage or rework allowed in seal area. Minor damage outside sealing area may be reworked to

0.010 inch (0.254 mm) depth.

E Circumference E rework limited to 0.010 inch (0.254 mm) depth on radiused outer surface of flange

around hole, typical four places. Take care to remove an equal amount of material from flange 180°

from reworked area to maintain balance of part.

F No rework allowed. Check for wear. Reject flange if a measurable step of 0.0005 inch (0.0127 mm) or

more is evident.

G Rework flange in area G limited to 0.020 inch (0.508 mm) depth. Use care to remove an equal amount

of material from flange 180° from reworked area to maintain balance of part. Minimum acceptable

diameter of flange after rework is 2.81 inch (71.374 mm).

212-R-63-97-2

Figure 63-97. Quill assembly (205-040-300) support flange rework limits (sheet 2)

63-00-00Page 222

BHT-212-CR&O

2. Inspect pinion (19, figure 63-98) for f. Inspect flange (1) for mechanical andchipped, broken, or excessively worn teeth. corrosion damage.

3. Inspect the following parts by magnetic g. Inspect splines. Dimension betweenparticle inspection (Code M) or fluorescent 0.090 in. (2.286 mm) diameter pins shall bepenetrant inspection (Code F) methods: 1.3324 to 1.3342 in. (33.8429 to 33.8887

mm).

Figure, Nomenclature CodeIndex No. 63-120. Repair.

63-98, 1 Flange M63-98, 3 Nut M MATERIALS REQUIRED63-98, 5 Spacer (outer) M63-98, 5 Spacer (inner) M NUMBER NOMENCLATURE63-98, 8 Retainer F63-98, 13 Sleeve F C-100 Chemical Film Material63-98, 19 Pinion M63-98, 20 Disc M C-204 Primer

C-309 Methyl-Ethyl-Ketone(MEK)

4. Inspect parts dimensionally (figure 63-99).C-317 Adhesive

5. Inspect shims (6 and 17, figure 63-98) for C-334 1.1.1-Trichloroethanedamage and corrosion.

C-423 Abrasive Cloth or6. Inspect insert (14) for corrosion or Paperdamaged threads.

C-464 India Stone7. Inspect pilot hole in disc. Hole diametershall be 2.2478 to 2.2515 in. (57.094 to C-486 Cheesecloth57.188 mm).

1. Dress splines and gear teeth with fine8. Inspect disc for warpage as follows: India stone (C-464) if surface nicks, burrs, or

scratches are visible.a. Install inspection arbor (figure 63-102)

in pilot hole of disc. Install four bolts (AN4-5A)and washers (AN960-416).

CAUTIONb. Install arbor and disc assembly

between lathe centers.DUPLEX BEARINGS (4, FIGURE

c. While rotating disc, measure runout as 63-98) ARE SERIAL NUMBEREDindicator probe is swept across full radial AND SHALL BE INSTALLED INwidth of each friction surface (front and back). M ATC H E D P A I R S. BOTH

BEARINGS OF A PAIR SHALL BEd. Total indicator deflection shall not FROM SAME MANUFACTURER.

exceed 0.010 in. (0.254 mm).BEARING SPACERS (5) ARE

e. Measure rim thickness of disc. Rim FINISH GROUND TOGETHER ANDthickness shall not be less than 0.422 in. SERIAL NUMBERED AND SHALL(10.719 mm) at any point. BE REPLACED AS A MATCHED

SET.

2. Replace all unserviceable components.

63-00-00Page 223

BHT-212-CR&O

1. Flange

2. Packing3. Nut4. Duplex bearing5. Spacer set6. Shim7. Packing8. Retainer9. Seal

10. Bolt

43

21

11. Washer12. Clinchnut13. Sleeve14. Insert15. Packing16. Bushing 1717. Shim 1618. Screw19. Pinion 1520. Disc21. Bolt22. Washer 212-R-63-98

Figure 63-98. Rotor brake drive quill (412-040-123)

63-00-00Page 224

BHT-212-CR&O

412-040-123 QUILL ASSEMBLY

MIN. MAX REPLACEITEM NOMENCLATURE INCHES mm INCHES mm INCHES mm

1 Bearings ID 1.5745 39.9923 1.5748 39.9999 1.5750 40.0050OD 3.1492 79.9897 3.1496 79.9998 3.1490 79.984

2 Sleeve OD 4.9995 126.9873 5.0000 127.0000 4.9992 126.9793 Pinion Spline over 1.613 40.970 1.616 41.0464 1.6114 40.9296

(Use 0. 1200 in. pins(3.048 mm) dia.pins)

4 Flange Spline between 1.3324 33.8430 1.3342 33.8887 1.3359 33.9319(Use 0.0900 in. pins(2.2860 mm) dia.pins)

5 Sleeve ID 3.1491 79.9871 3.1495 79.9973 3.1497 80.00246 Pinion Shaft OD 1.5751 40.0075 1.5753 40.0126 1.5749 40.0025

212-R-63-99

Figure 63-99. Rotor brake quill (412-040-123) damage limits

63-00-00Rev. 4 Page 225

BHT-212-CR&O

3. Replace shim (17) as follows: cheesecloth (C-486) dampened with MEK (C-309). Bond clinch nut (12) in sleeve (13) with

a. Inspect sleeve (13) for reference adhesive (C-317).dimension which is stamped or etchedadjacent to mounting surface. Record g. Clean excess adhesive from threadsdimension. and surface of sleeve flange and hole. Clinch

nut shall be 0.010 in. (0.254 mm) minimumb. Measure new shim plate thickness and below surface of sleeve flange.

subtract this figure from dimension recordedfrom sleeve. The result shall be 2.2215 to h. Verify side of sleeve flange contacting2.2220 inches (56.4261 to 56.388 mm) after shim plate is flat and clinch nut does notplating. protrude above surface.

c. If resulting dimension is less than 6. Repair corrosion and damage to sleeve2.2215 inches (56.4261 mm) grind surface of (13) and retainer (8) (figures 63-100 and 63-shim plate to obtain proper dimension. After 101).grinding, surface finish of shim plate shall be63 RHR or better. 7. Remove scratches and light surface

corrosion from disc (20) using 400 to 600 gritd. Ensure screw mounting holes are abrasive cloth or paper (C-423). No further

countersunk. Replate ground surface of shim repairs are allowed. Do not exceed limits.using cadmium plating BHT-ALL-SPM.

8. Dress splines and threads of flange (1)4. Replace threaded inserts (14) as required with fine India stone (C-464) if surface nicks,(BHT-ALL-SPM). burrs, or scratches are visible (figure 63-103).

5. Replace clinch nuts (12) if damaged or 9. Refer to figure 63-103 for flange reworkloose. procedures and limits.

a. Use a drift or bolt threaded into nut to 63-121. Assemblydrive clinch nut out, being careful not todamage hole in sleeve flange.

MATERIALS REQUIREDb. Clean sleeve by vapor degreasing with

1.1.1 -trichloroethane (C-334). NUMBER NOMENCLATURENUMBER NOMENCLATURE

c. Clean up surface of sleeve flange to C-405 Lockwireremove any raised burrs.

d. Treat hole and any reworked areas on 1. Install duplex bearings (4, figure 63-98)sleeve with chemical film material (C-100) and spacer set (5) in sleeve (13).(BHT-ALL-SPM).

NOTEe. If clinch nut was tight before removal, NOTEcoat new nut with unreduced primer (C-204) Bearings (4) are assembled back-to-and drive nut (12) in place. Remove any back on each side of spacer set (5).raised burrs on sleeve flange face, andtouchup with chemical film material (C-100). 2. Support inner race of duplex bearings (4)

with plate assembly and press pinion (19) inf. If clinch nut was loose before removal, bearings (4)

remove cadmium plating from surfaces ofclinch nut contacting sleeve with abrasive 3. Install packings (15) on bushing (16) andcloth or paper (C-423). Clean clinch nut (12) install bushing (16) in sleeve (13).and mating surface of sleeve (13) with

63-00-00Page 226 Rev.3

BHT-212-CR&0

4. Press seal (9) in retainer (8). Install 7. Install packing (2) on nut (3) and usingpacking (7) in groove on retainer (8). T101469 holding fixture install nut (3) on

pinion (19). Torque nut 125 to 150ft.lbs. (1695. Install retainer (8) and peel shim (6) for to 203 Nm).0.002 in.(0.0508 mm) to 0.005 in. (0.121 mm)pinch fit on sleeve (13). Install four bolts (10) 8. Install disc (20) using washers (22) andand washers (11). Torque bolts 50 to 70 bolts (21). Secure nut (3) between bolts (21)in.lbs. (6 to 8 Nm). Secure bolts in pairs using using lockwire (C-405).lockwire (C-405).

6. Install flange (1) on splined end of pinion(19).

63-00-00Rev. 4 Page 226A/226B

BHT-212-CR&O

9. Check backlash as follows: and 19). Remove cover (4) using T101308jackscrew set. Lightly tap sprocket (26) as

a. Install quill assembly in transmission. cover is removed to prevent binding of shaft.Remove gaskets (14 and 22).

b. Mount dial indicator on transmission. 2. Remove sprocket (26) and chain (6).

c. Monut backlash tool 205-040-300-1GIF- 3. Remove retaining ring (7) and sprocket1 on rotor brake disc. With drive quill (8).stationary, measure backlash of rotor brakedisc with tool. 4. Remove six screws (25), retaining ring

(9), and shim (10). Identify shim ford. If tool is not available, measure reinstallation on same quill.

backlash tangentially at a distance of 1.421inches (36.0934 mm) out from center of rotor 5. Remove clip (11). Hold gear (33) withbrake disc. T101306 wrench and remove nut (12) with

T101305 wrench.

NOTE 6. Press gear (33) out of sleeve (15).

Backlash for 412-040-123-101 quillassembly is 0.012 to 0.020 inch CAUTION(0.3048 to 0.508 mm). CAUTION

Backlash for 412-040-123-103 quill EXERCISE CARE TO AVOIDassembly is 0.010 to 0.020 inch DAMAGING BEARINGS OR(0.254 to 0.508 mm). SLEEVE WHEN DOING NEXT

STEP. ENSURE REMOVAL BARSARE PROPERLY POSITIONED ON

63-122. NO. 1 HYDRAULIC PUMP AND BEARINGS.TACHOMETER DRIVE QUILL.

7. Remove retainer ring (32). Press rollerbearing (31) out of sleeve with T101333

63-123. Disassembly. removal bar. Press duplex bearing (13) out ofsleeve with T101334 removal bar.

SPECIAL TOOLS REQUIRED 8. Remove four screws (29) and shim plate(30). Identify shim plate for reinstallation on

NUMBER NOMENCLATURE same sleeve.

T101305 Wrench 9. Remove seals (5 and 28) from cover (4).

T101306 Wrench 10. Remove cork (24) from sprocket (26).Remove cork (34) from gear (33).

T101308 Jackscrew set

T101333 Removal bar 11. Remove bearings (23 and 27) fromsprocket (26). Use T101593 plate to remove

T101334 Removal bar bearings.

T101593 Plate

T101599 Pressing tool

1. Remove nuts (1, figure 63-104), washers(2, 3, 16, 17, 20, and 21), and three bolts (18

63-00-00Rev.3 Page 227

BHT-212-CR&O

B A

ITEM/ TYPE OF NOMENCLATURE INSPECTION LIMITAREA DAMAGE METHOD

A Wear Liner ID Measure 3.1497 Inches(80.0024 mm) max.

B Wear Pilot diameter Measure 4.9993 Inches(126.9822 mm) min.

C Corrosion Liner Visual

D Corrosion Pilot diameter Visual/ 0.005 Inchmeasure (0.127 mm) depth

40% of any onesquare Inch (645.2 sq.mm)5% of area of surface

D Mechanical Pilot diameter Visual/ 0.005 Inchmeasure (0.127 mm) depth

0.500 Inch(12.7 mm) length

E Corrosion/ Pilot diameter Visual/ 0.010 Inchmechanical measurre (0.254 mm) depth

20% of any onesquare Inch (645.2 sq. mm),20% of area surface

212-R63-1 00-1C0000

Figure 63-100. Rotor brake quill (412-040-123) sleeve assembly rework limits (sheet 1 of3)

63-00-00Page 228

BHT-212-CR&O

ITEM/ TYPE OF NOMENCLATURE INSPECTION LIMIT

AREA DAMAGE METHOD

F, K Corrosion/ O-ring groove & Visual None allowedmeachnical sealing daimeter

G, H Corrosion Shimming surface Visual/ 0.010 Inchmeasure (0.254 mm) depth

10% of any onesquare inch (645.2 sq. mm),10 % of areaof surface

G, H Mechanical Shimming surface Visual/ 0.010 Inchmeasure (0.254 mm) depth

0.500 inch(12.700 mm) length

I Corrosion/ Mounting pad Visual/ 0.020 Inchmechanical measure (0.508 mm) depth A

20% of surface

j Corrosion Bolt holes Visual/ 0.020 Inchmeasure (0.508 mm) depth A

20% of wall area

L, M Corrosion/ Al-cast and Visual/ 0.030 inch Amechanical machined surface measure (0.762 mm) depth

for Al-cast surface,0.020 inch A(0.508 mm) depthfor machined surface40% area of onesquare inch (645.2 sq. mm)or 20% of area of anysurface

ALL Corrosion/ Lube holes, threaded Visual None allowedmechanical insert holes, clinch

nut counter bore

ALL Looseness Insert, clinch nut, Visual None allowedliner pins

ALL Mechanical Shim screw holes Visual None beyondfirst thread

ALL Cracks Sleeve Fluorescent None allowedpenetrant 212-R-63-100-2

C0000

Figure 63-100. Rotor brake quill (412-040-123) sleeve assembly rework limits (sheet 2)

63-00-00Page 229

BHT-212-CR&O

NOTES

1 Only light superficial corrosion, easily removable with steel wool is allowed.

Damage or repair may not break into o-ring groove F.

3 Damage or repair may not extend closer than 0.060 inch (1.524 mm) from edges of lube holes, threadedinsert holes, threaded screw holes, clinch nut counter bores, and bolt holes.

4 Rework corrosion and mechanical damage by polishing with a fine India stone to minimum radii of0.12 inch (3.05 mm) and a surface finish of 63 RMS or better. Remove any raised material flush withsurrounding surface.

5 Do not polish out corrosion pitting.

6 Rework only to remove any raised material flush with surrounding surface using a fine India stone.

7 Spotface area I may be repaired if corrosion exceeds 0.020 inch (0.508 mm) depth by spotfacing to a0.680 ± 0.010 inch (17.272 ± 0.254 mm) diameter with 0.030 ± 0.010 inch (0.762 ± 0.254 mm) filletradius to a minimum flange thickness of 0.480 inch (12.192 mm) not including thickness of shim.Spotface surface must be concentric with bolt hole within 0.010 inch (0.254 mm) T.I.R. and parallel withsurface G within 0.002 inch (0.051 mm).

8. Remove all traces of corrosion on sleeve by immersion in hot chromic acid bath to clean up corrosionarea. All corrosion products must be removed.

9. Touch-up reworked areas with chromic acid or treat entire sleeve with corrosion treatment. Refinish byapplying Epoxy primer and acrylic lacquer, mask part to omit primer on mating surfaces.

212-R-63-100-3

Figure 63-100. Rotor brake quill (412-040-123) sleeve assembly rework limits (sheet 3)

63-00-00Page 230 Rev. 4

BHT-212-CR&O

G see view A for thread bosses

E

D

F

ITEM/ TYPE OF NOMENCLATURE INSPECTION LIMITAREA DAMAGE METHOD

ALL Corrosion/ N/A Visual/ None allowedcracks fluorescent

penentrant

A Mechanical Outer surface Visual/ 0.030 Inchmeasure (0.762 mm) depth

B Mechanical Seal seat Visual None allowed

C Mechanical O-ring groove Visual None allowed

D Mechanical Seat/race Visual None allowed

E, F Mechanical Oil hole/transfer Visual None allowedtube bore

G Mechanical Seat Visual/ 0.005 Inch 2measure (0.127 mm) depth

H Mechanical SurfaceVisual/ 0.010 Inch /34measure (0.254 mm) depth

212-R-83-101-1C0000

Figure 63-101. Rotor brake quill (412-040-123) retainer assembly rework limits (sheet 1of 2)

63-00-00Page 231

BHT-212-CR&O

NOTES

A No more than 40 percent of any one square Inch (645.2 sq. mm) or 20 percent of total area,after rework, may be damaged within limits.

A Damage shall not extend into o-ring groove.

A Damage shall not cover more than 20 percent of total area. No damage allowed Inthreaded holes or bolt holes.

A Polish out mechanical damage to produce 0.12 Inch (3.05 mm) minimum radii and asurface of 63 RMS or better using a fine India stone. Remove any raised material flushwith the surrounding surface.

A Rework only to remove any raised material flush with surrounding surface using a fineIndia stone.

6. Passlvate per QQ-P-35, Type II. Supplement chromate treatment Is not required.

212-R43-101-2CO00O

Figure 63-101. Rotor brake quill (412-040-123) retainer assembly rework limits (sheet 2)

63-124. Cleaning. 4. Coat bearings with corrosion preventive(C-105) immediately after cleaning. Do not

MATERIALS REQUIRED handle unoiled bearings with bare hands.

5. Remove sealant with plastic scraper.NUMBER NOMENCLATURE

C-105 Corrosion Preventive 63-125. Inspection.

C-304 Solvent 1. Inspect all parts visually for damage andexcessive wear (figure 63-105).

C-334 1.1.1 -Trichloroethane2. Inspect gear (33, figure 63-104) for

1. Inspect quill for corrosion damage to spalled, scuffed, pitted, chipped, or dentedthreaded studs and stud holes before teeth. Inspect roller bearing surface forcleaning. No structural damage to threads or spaling, scoring, pitting, brinelling, andholes is acceptable. corrosion damage. Inspect threads for

damage.

2. Clean all quill parts with solvent (C-304).Use soft bristle brush to dislodge stubborn 3. nspect sprockets (8 and 26) for brokendeposits. All parts except bearings may be and damaged teeth, and for excessive wear.deposits. All parts except bearings may becleaned by vapor degreasing with 1.1.1-trichloroethane (C-334) if desired. 4. Inspect chain (6) for wear Damage

which can be visually detected is not3. Dry parts with clean, lint-free cloths or acceptable.dry, filtered, compressed air. Do not allowbearings to spin while drying. 5. Inspect duplex bearing (13) and ball

bearings (23 and 27) for spalling, scoring,

63-00-00Page 232

BHT-212-CR&O

0.25 IN. (6.35 mm)-28 UNF-3B THRU

C__ HAMFER COUNTERSINK 90 X 0.260 IN. (6.604 mm)

0.060 IN. (1.524 mm) DIA, 4 PLACES EQ SPACEDX 45 2 PLACES -0.125 IN. (3.175 mm)

1.0 IN. (25.4 mm) 0.32 IN. 2 PLACESDIA 2 PLACES \ (8.128mm)

CHAMFER0.012 IN. (3.048 mm) 2 PLACES \

(7.874 mm) 0.3101N.(7.874 mm)

NOTES

1. Material: AISI 4340 steel per MIL-S-5000. Heat treat to RC 36-40 in accordance withMIL-H-6875.

2. Surface finish 125 microinches unless otherwise noted.

3. Break edges 0.015 in. (0.381 mm) radius or 0.015 in. (0.381 mm) x 40 to 50 ° chamfer

unless otherwise noted.

212-R-63-102

Figure 63-102. Rotor brake disc inspection arbor

63-00-00Page 233

BHT-212-CR&O

ITEM NOMENCLATURE

A Effective area where rework allowed.

B Pilot diameter for rotor brake disc.

C Mating surface of flange with threaded hole for disc retaining bolt. Typical four places.

D Flange sealing surface.

E Circumference of flange with radiused expanded dimension for threaded hole to accommodatedisc retaining bolt. Typical four places.

F Inner flange diameter for support on pinion gear.

G Flange circumference other than radiused areas with threaded holes.

212-R-63-103-1

Figure 63-103. Rotor brake drive quill (412-040-123) support flange rework limits (sheet1 of 2)

63-00-00Page 234

BHT-212-CR&O

ITEM REWORK INSTRUCTIONS

A Remove corrosion, nicks and scratches using file, grinder, or abrasive cloth or paper (C-423) asapplicable. Do not use chemicals. Polish or buff surface of reworked areas to a smooth, scratch-freefinish. Protect reworked area with epoxy polyamide primer (C-204) and lacquer (C-203), except whererestricted in following instructions. Brush cadmium plating is permitted over reworked area in lieu ofprimer and paint. LHE cadmium plating solution (C-108) must be used, or part must be baked withinone hour after plating to relieve hydrogen embrittlement.

B Diameter B rework limited to 0.010 inch (0.254 mm) depth, but no more than 50 percent of effectivepilot diameter in any half-inch length around circumference. Do not paint pilot diameter.

C Area C rework limited to 0.010 inch (0.254 mm) depth, but no more than 50 percent mating surfacearound hole, typical four places. Polish reworked area to smooth, scratch-free finish with minimumradius of 0.19 inch (4.826 mm). Do not paint reworked mating surface. Brush LHE cadmium platingsolution (C-108) may be applied BHT-ALL-SPM).

D No damage or rework allowed in seal area. Minor damage outside sealing area may be reworked to0.010 inch (0.254 mm) depth.

E Circumference E rework limited to 0.010 inch (0.254 mm) depth on radiused outer surface of flangearound hole, typical four places. Take care to remove an equal amount of material from flange 180ofrom reworked area to maintain balance of part.

F No rework allowed. Check for wear. Reject flange if a measurable step of 0.0005 inch (0.0127 mm) ormore is evident.

G Rework flange in area G limited to 0.020 inch (0.508 mm) depth. Use care to remove an equal amountof material from flange 180° from reworked area to maintain balance of part. Minimum acceptablediameter of flange after rework is 2.81 inch (71.374 mm).

212-R-63-103-2

Figure 63-103. Rotor brake drive quill (412-040-123) support flange rework limits (sheet2)

63-00-00Page 235

BHT-212-CR&O

END VIEW - COVER REM6VED

1. Nut 18. Bolt2. Steel Washer 19. Bolt3. Aluminum Washer 20. Steel Washer4. Cover 21. Aluminum Washer5. Seal 22. Gasket6. Chain 23. Bearing7. Retaining Ring 24. Cork8. Sprocket 25. Screw9. Retaining Ring 26. Sprocket

10. Shim 27. Bearing11. Clip 28. Seal12. Nut 29. Screw13. Duplex Bearing 30. Shim Plate14. Gasket 31. Roller Bearing15. Sleeve 32. Retainer Ring16. Aluminum Washer 33. Gear17. Steel Washer 34. Cork 212-R-63-104

I Figure 63-104. No. 1 hydraulic pump and tachometer drive quill

63-00-00Page 236 Rev. 3

BHT-212-CR&O

2 6

1213 8 8

M11. MA


1 Pinion OD 1.8691 47.47574 1.8696 47.487842 Bearing OD 3.1492 79.98968 3.1496 79.99843 Sleeve Liner ID 3.1489 79.98206 3.1497 80.002384 Pinion OD 1.3780 35.0012 1.3786 35.016445 Bearing ID 1.3777 34.99358 1.3781 35.003746 Bearing OD 2.8341 71.98614 2.8346 71.998847 Sleeve Liner ID 2.8340 71.9836 2.8347 72.001388 Sprocket OD 0.5901 14.98854 0.5909 15.008869 Bearing ID 0.5903 14.99362 0.5907 15.00378

10 Bearing OD 1.2592 31.98368 1.2598 31.9989211 Liner ID 1.2598 31.99892 1.2607 32.0217812 Sleeve OD 3.6247 92.06738 3.6255 92.087713 Case ID 3.6250 92.075 3.6265* 92.1131

* Average

212-R-63-105

Figure 63-105. No. 1 hydraulic pump and tachometer drive quill wear limits

63-00-00Rev.3 Page 237

BHT-212-CR&O

pitting, brinelling, corrosion damage, cracked 63-126. Repair.or broken retainers, and for roughness whenrotated. MATERIALS REQUIRED

6. Inspect roller bearing (31) for spalling,scoring, pitting, brinelling, corrosion damage, NUMBER NOMENCLATUREand for cracked or broken roller retainers.

C-100 Chemical Film Material7. Inspect sleeve (15) and cover (4) forcorrosion damage and for loose or damaged -103 Chromic Acidbearing liners. Inspect sleeve for damaged C-108 Brush Cadmiumthreads and for loose or damaged studs. Plating Solution

8. Inspect the following parts by magnetic C-116 Chromic Acidparticle (Code M) or fluorescent penetrant(Code F) method (BHT-ALL-SPM) as C-211 Shellacapplicable. Demagnetize parts after magnetic cORKparticle inspection.

Figure, Nomenclature Code 1. Replace all unserviceable parts.Index No.

63-104, 4 Cover F63-104, 8 Sprocket M 3. Replace cork plugs in gear (33) and63-104, 12 Nut M sprocket (26). Gear (33) requires a No. 1263-104, 15 Sleeve F cork stopper (C-490). Sprocket (26) requires63-104, 26 Sprocket M a No. 1 short cork. Secure corks in position63-104, 33 Gear M (figure 63-104) using shellac (C-211).

4. Replace duplex bearings (13, figure 63-104) as matched serialized set, if

9. Inspect parts dimensionally and replace unserviceable.parts which exceed inspection limits (figure63-105).

NOTE

NOTE Refer to BHT-ALL-SPM for repair ofstuds and insert outlined in steps 5.,

Wear limits are provided to show 6., and 7.required fit between mating parts. Itis not intended all dimensions be 5. Repair sleeves which have damaged orchecked as a prescribed overhaul loose studs or damaged threads in jackscrewprocedure. However, parts holesexhibiting evidence of wear orphysical damage shall be checked 6. Replace washer seats under shim platesdimensionally. if loose or missing.

7. Repair sleeves which have loose ormissing locked-in inserts or studs.

8. Inspect sleeve flange top surface fordents and nicks, if damage does not exceed0.030 in. (0.762 mm) depth, polish outdamage and blend repaired area into flatsurface with a minimum radius of 0.12 in.

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BHT-212-CR&O

(3.048 mm). The finished repair shall be 63 NOTERMS or better. The maximum depth afterrepair shall not exceed 0.030 in. (0.762 mm). Do not handle unoiled parts with

bare hands.9. Refinish parts after repair in accordancewith BHT-ALL-SPM, as outlined below: 3. Install shim plate (30, figure 63-104) on

sleeve (15) with screws (29). Serial numbera. Aluminum parts: Touch up with brush of sleeve and shim plate shall be same, or a

chemical film material (C-100). new shim plate shall be ground to correctthickness as follows:

b. Magnesium parts: Remove all traces ofcorrosion by immersion in chromic acid (C- a. Inspect shim plate and quill sleeve on116). Touch up parts with chromic acid (C- which shim plate is to be installed for an103) or treat entire parts with magnesium etched serial number. If parts cannot bealloy chemical film treatment (BHT-ALL-SPM). identified by serial number, determine

required dimension of shim plate.c. Cadmium plated steel parts: Treat

reworked areas with brush cadmium plating b. Inspect quill sleeve for referencesolution (C-108) (BHT-ALL-SPM). dimension which will be metal stamped or

vibro-etched on part adjacent to mounting10. Replace parts which exceed allowable surface. Record this dimension and wherewear limits. located on sleeve.

63-127. Assembly. c. If a shim plate of correct part numberbut without a serial number is available,

MATERIALS REQUIRED measure thickness and record. Determinewhether shim plate is correct for thisparticular installation as follows:

NUMBER NOMENCLATURE(1) Subtract shim plate thickness from

C-304 Solvent reference dimension found on quill sleeve.

C-405 Lockwire Resulting value, after plating, shall fall withindimensions below.

MIN.MAX.SPECIAL TOOLS REQUIRED LOCATION (In./mm) (In./mm)

NUMBER NOMENCLATURE Hydraulic pump andtachometer drive quill

T101305 Wrench sleeve:

T101306 Wrench 204-040-306-011 0.9760 0.9765

T101333 Removal bar (24.7904 (24.8031mm) mm)

T101599 Pressing tool204-040-306-101 0.9580 0.9585

(24.3332 (24.34591. Clean all parts with solvent (C-304) and mm) mm)drain.

2. Coat all parts with transmission oil. 4. Press duplex bearings (13) into sleeve(15) face-to-face with T101599 pressing tool.Duplex bearings must be a matched set withsame serial number on both bearings.

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BHT-212-CR&O

5. Press roller bearing (31) into sleeve (15) oil holes in ring and small hole for lockwire inwith suitable sleeve or T101333 removal bar. ring aligned on centerline between gear shaftInstall retainer ring (32). and tachometer drive. Install six screws (25)

and secure with lockwire (C-405). Installlockwire in pattern shown in figure 63-104.

CAUTION10. Check gear (33) for free rotation.

WHEN INSTALLING GEAR INTO 11. Place sprocket (8) on gear shaft with twoBEARING, USE CARE TO ONLY projections engaged in shaft slots. InstallAPPLY PRESSURE TO GEAR HUB retaining ring (7).AREA. PRESSURE APPLIED ATAREA. PRESSURE APPLIED AT 12. Press bearings (23 and 27) on sprocketCRACKS BETWEEN HOLES IN (26). Verify cork (24) is installed in sprocket.WEB AND POSSIBLE FAILURE OF Inspect chain (6) to ensure spring-lock isGEAR. properly installed on connecting link. Install

chain and sprocket (26) in sleeve with chainon both sprockets and with bearing on short

6. Support inner races of duplex bearings on both sprockets and with bearing on short(13) and press gear (33) into bearings. Verifycork (34) is installed in gear.cork (34) is installed in gear. 13. Install new seals (5 and 28) in cover (4)

with numbered sides of seals outboard. Coat7. Start nut (12) on gear (33). Hold gear with of oil seals with transmission oil. PlaceT101306 wrench and torque nut with T101305T101306 wrench and torque nut with T101305 gaskets (14 and 22) on sleeve (15). Positionwrench 80 to 100 ft.lbs. (108.464 to 135.58 cover (4) on sleeve (15). Install bolts (18 andNm). Remove tools and install clip (11). 19) with heads inboard as illustrated. Place

steel washers (17 and 20) under boltheads8. Measure distance from outer race of and aluminum washers (16 and 21) next toduplex bearings (13) to surface on sleeve (15) sleeve. Install aluminum washers (3), steelwhere retaining ring (9) is to be installed; use washers (2), and nuts (1). Place aluminuma depth micrometer to take measurement. washers next to cover. Torque 50 to 70 in.lbs.Measure height of flange on ring. Subtract (5.649 to 7.9086 Nm).sleeve dimension from ring dimension.Prepare a shim (10) to provide a 0.003 to 14. Check gear (33) for free rotation.0.006 in. (0.0762 to 0.1524 mm) pinch fit onbearing.

63-128. TAIL ROTOR DRIVE QUILL.

I Example: INCH MM 63-129. Disassembly.

Ring 0.338 8.5852SPECIAL TOOLS REQUIRED

Sleeve -0.302 7.6708NUMBER NOMENCLATURE

0.036 0.9144T101307 Wrench

Pinch -0.003 to 0.0762 to0.006 0.15240.006 0.1524 T101333 Removal bar

T101334 Removal barShim 0.033 to 0.8382 to

0.030 0.762 T101455 Plate


9. Position shim (10) and retaining ring (9)on sleeve with notches in shim aligned with

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BHT-212-CR&O

SPECIAL TOOLS REQUIRED (CONT) 7. Remove retainer ring (6). Press rollerbearing (7) out of sleeve using T101333

NUMBER NOMENCLATURE removal bar.

T101600 or Wrench 8. Press duplex bearings (11) out of sleeveT101336 using T101334 removal bar.

9. Remove three screws (9) and shim plateNOTE (8). Identify shim plate for reinstallation on

same sleeve.For ease of maintenance, blockouter coupling to remain in outboard 10. Inspect grease for being very viscous(extended) position. This stabilizes (thick) and having a strong pungent odor.outer coupling during disassembly Refer to step 5.and assembly.

1. Remove retainer ring (28, figure 63-106), 63-130. Cleaning.plate assembly (27), centering spring (26),lock spring (25), and spring retainer (24). A 1/ MATERIALS REQUIRED4-20 threaded bolt may be used to facilitateremoval of spring retainer (24). Install bolt incenter of retainer and pull on bolt to withdraw NUMBER NOMENCLATUREretainer from inner coupling. Remove packing C-105 Corrosion Preventive(23) from retainer.

C-304 Solvent2. Hold female coupling (18) with T101307wrench, position square adapter through C-334 1.1.1-Trichloroethanewrench, and remove coupling retaining bolt(22) and washer (21).

1. Clean all quill parts with solvent (C-304).3. Remove couplings (18 and 20) from gear. Use soft bristle brush to dislodge stubborn

deposits. All parts except bearings may be4. Separate couplings and remove seal (17) cleaned with 1.1.1-trichloroethane (C-334) byfrom female coupling (18). vapor degreasing, if desired.

5. Position quill sleeve (10) in T101455 2. Dry parts with clean, lint-free cloths orplate. Remove bearing retaining nut (13) with dry, filtered, compressed air. Do not allowT101600 wrench. Remove seal (14) and bearings to spin while drying.packing (12) from nut.

3. Coat bearings with corrosion preventive6. Remove spacer (16) and press gear (4) (C-105) immediately after cleaning. Do notout of sleeve. Remove packing (15). Remove handle unoiled bearings with bare hands.retainer ring (1), funnel (2), and packing (3).Remove cork (5) from gear. 4. Remove sealant with plastic scraper.

63-131. Inspection.CAUTION

1. Inspect all parts visually for damage andexcessive wear.

IN STEPS 7. AND 8., EXERCISECARE TO PROPERLY POSITION 2. Inspect gear (4, figure 63-106) forBEARIN G REMOVAL BAR ON spalled, scuffed, pitted, chipped, or dentedBEARINGS TO AVOID DAMAGINGBEARINGS TO AVOIDS DAMAGING teeth. Inspect splines of gear for pitted,BEARING OR SLEEVE. chipped, or excessively worn teeth. Inspect

threads for damage.

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BHT-212-CR&O

3. Inspect sleeve (10) for corrosion damage, NOTEfor loose or damaged bearing liner, and fordamaged threads. If TEMP-PLATES are to be replaced,replace TEMP-PLATES after

completing entire inspection4. Inspect couplings (18 and 20) for chipped, procedure and couplings have beencracked, broken, pitted, or excessively worn determined serviceable and prior toteeth or splines (figure 63-108). lubricating couplings.

NOTE 5A. Inspect outer coupling (18) temperatureindicator TEMP-PLATES for deterioration,

Overtemperature indicator dots on debonding or discoloration of epoxy coatingtemperature indicator TEMP- that prevents interpretation of indicating dots.PLATES are of a white or light gray If deterioration, debonding, or discoloration ofcolor and turn black when exposed epoxy is found, replace TEMP-PLATES in

to an overtemperature condition. accordance with paragraph 63-133A.to an overtemperature condition.Chemical contamination can alsocause the indicating dots to turn 6. Inspect roller bearing (7, figure 63-106)black. for spalling, scoring, pitting, brinelling,

corrosion damage, and for cracked or brokenroller retainers.

5. Inspect outer coupling (18, figure 63-106)temperature indicator TEMP-PLATES fortemperature indicator TEMP-PLATES for 7. Inspect duplex bearings (11) for spalling,evidence of overtemperature indication. If scoring, pitting, brinelling corrosion damage,overtemperature indication is noted, perform cracked or broken retainers, and forcoupling overtemperature inspection as roughness when rotated.follows:

8. Inspect spacer (16) in seal contact areaa. Inspect outer coupling cadmium plating for roughness and wear.

for being discolored (circumferential tan orlight brown band) or blistered. If cadmium 9. Inspect bearing retaining nut (13) forplate discoloration or blistering is found, damaged threads.replace outer coupling and inner coupling.

10. Inspect coupling retaining bolt (22) forb. Inspect gear teeth of outer coupling damaged threads.

and inner coupling for being discolored(brown or blue) in the normally bright contact 11. Inspect following parts by magneticpatterns. If discoloration is found, replace particle (Code M) or fluorescent penetrantouter coupling and inner coupling. (Code F) (BHT-ALL-SPM) as applicable.

Demagnetize parts after magnetic particlec. Inspect outer coupling and inner inspection.

coupling under 5x to 10x magnification forteeth exhibiting signs of metal smearing orNomenclatureCodeFigure, Nomenclature Codetearing in the contact patterns. If smearing or Index No.tearing is founded, replace outer coupling andinner coupling.

63-106, 4 Gear Md. Inspect grease from couplings for being 63-106, 10 Sleeve F

very viscous (thick) and having a strong 63-106, 18 Coupling (female) Mpungent odor. If grease is found to be viscous 63-106, 20 Coupling (male) M(thick) and having a strong pungent odor,replace outer coupling and inner coupling.

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BHT-212-CR&O

12. Inspect parts dimensionally and replace MATERIALS REQUIRED (CONT)parts which exceed inspection limits (figure63-93). NUMBER NOMENCLATURE

C-490 Cork StopperNOTE

Wear limits are provided to show 1. Replace all unserviceable parts andrequired fit between mating parts. It seals.is not intended all dimensions bechecked as prescribed overhaul 2. Replace cork (5, figure 63-106) in gearprocedure. However, parts exhibiting (4). Use No. 9 short cork stopper (C-490).evidence of wear of physical Insert cork with shellac (C-211) into splineddamage shall be checked end of gear shaft ensuring cork is properlydimensionally. seated in gear shaft, but is not pressed so far

as to obstruct the 0.050 to 0.064 inch (1.270to 1.625 mm) diameter oil hole.

63-132. Repair.3. Replace tail rotor drive couplings (18 and

MATERIALS REQUIRED 20, figure 63-106), if cracked, chipped,excessively worn, or pitted in excess of limits(figure 63-108).

NUMBER NOMENCLATURE

C-100 Chemical Film Material 4. Replace sleeve (10) if bearing liner isloose or if there is corrosion between liner

C-103 Chromic Acid and sleeve.

C-108 Brush CadmiumPlating Solution 5. Inspect sleeve flange top surface for

dents and nicks. If damage does not exceedC-211 Shellac 0.030 in. (0.762 mm) depth, polish out

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BHT-212-CR&O

DETAIL A 5 18

1614 15

12

2 FunnelI 3. Packing

4. Gear

5. Cork6. Retainer ring7. Roller bearing

SEE DETAIL A 28 . plateScrew b

10. Sleeve

11. Duplex bearing12. Packing13. Bearing retaining nut14. Seal

15. PackingSpacer

17 Seal21 18. Outer coupling

20 19. Deleted

Inner coupling

NOTES

Used on 212-040-365-005 and subsequent. 23. Packing24. Spring retainer

Apply sealant (C-308) around nut (13) and 25. Lock springsleeve (10) after assembly. 26. Centering spring

27. Plate assemblyLocation of temperature indicator TEMP-PLATES 28. Retainer ring

212-R-63-106-1

Figure 63-106. Tail rotor drive quill (sheet 1 of 2)

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BHT-212-CR&O

SEAL (17) PARTIALLY SEATED SEAL (17) FULLY SEATED

OUTER COUPLING (18)INSTALLED

SPLINTS (18A) INVERTED ON INNER

INNER COUPLING (19)USED COUPLINGAS BACK-UP TO PUSH LIPOF SEAL (17) UP

DETAIL B

212-R-63-106-2212-040-365-023

Figure 63-106. Tail rotor drive quill (sheet 2)

damage and blend repaired area into flat 7. Replace parts which exceed allowablesurface with a minimum radius of 0.12 in. wear limits.(3.048 mm). The finished repair shall be 63RMS or better. The maximum depth after 8. Replace temperature indicator TEMP-repair shall not exceed 0.030 in. (0.762 mm). PLATES if necessary. Refer to paragraph 63-

133A.

6. Refinish parts, after repair, in accordancewith BHT-ALL-SPM, as outlined below: 63-133. Assembly.

a. Aluminum parts: Touch up with brush MATERIALS REQUIREDchemical film material (C-100).

NUMBER NOMENCLATUREb. Magnesium parts: Remove all traces of NUMBER

corrosion by immersion in chromic acid bath C-015 Lubricant (Tube Pack)(BHT-ALL-SPM). Touch up parts with chromicacid (C-103) or treat entire part with C-304 Solventmagnesium alloy chemical film treatment(BHT-ALL-SPM). C-308 Adhesive(BHT-ALL-SPM).

C-405 Lockwirec. Cadmium plated steel parts: Treat

reworked areas with brush cadmium platingsolution (C-108).

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BHT-212-CR&O

SPECIAL TOOLS REQUIRED Resulting value, after plating, must fall withindimensions listed below.

NUMBER NOMENCLATURE MIN-MAX.

T101307 Wrench LOCATION In./mm In./mm

T101333 Removal bar Tail rotor drive quill 0.9760 0.9765sleeve (24.7904 (24.8031

T101455 Plate mm) mm)


T101600 or Wrench 4. Press duplex bearings (11) into sleeveT101336 (10) face-to-face using T101599 pressing tool.

Duplex bearings shall be a matched set withsame serial number on both bearings.

1. Clean all parts with solvent (C-304) and1. Clean all parts with solvent (C-304) and 5. Press roller bearing (7) into sleeve (10)drain. using T101333 removal bar, or suitable

sleeve, and install retainer ring (6).2. Coat all parts with transmission oil.

NOTE f CAUTION

Do not handle unoiled parts withbare hands. WHEN INSTALLING GEAR INTO

BEARING, USE CARE TO ONLYAPPLY PRESSURE TO GEAR HUB

3. Install shim plate (8, figure 63-106) on AREA. PRESSURE APPLIED ATsleeve (10) with three screws (9). Serial GEAR TEETH CAN RESULT INnumber of sleeve and shim plate shall be the CRACKS BETWEEN HOLES INsame, or a new shim plate shall be ground to WEB AND POSSIBLE FAILURE OFcorrect thickness as follows: PINION.

a. Inspect shim plate and quill sleeve on 6. Ensure cork (5) is installed in gear (4)which shim plate is to be installed for an and check oil hole through wall of gear (4)etched serial number. If parts cannot be immediately inboard of cork to ensure it is notidentified by serial number, determine obstructed. Support duplex bearings (11) onrequired dimension of shim plate. inner race and press gear (4) into sleeve.

7. Apply adhesive (C-308) to faying surfaceb. Inspect quill sleeve for reference of seal (14) and nut (13). Press seal (14) intodimension which shall be metal stamped or nut (13). Position new packing (12) in groove

vibro-etched on part adjacent to mounting nut (13). Hold sleeve (10) with T101455surface. Record this dimension and where plate. Coat packing with transmission oil, and

install nut (13); use T101600 or T101336wrench to torque nut 100 to 150 ft.lbs.

c. If a shim plate of correct part number (135.58 to 203.37 Nm). Secure nut withbut without a serial number is available, lockwire (C-405). Apply adhesive (C-308)measure thickness and record. Determine around nut (13) and sleeve (10) as shown inwhether shim plate is correct for this detail A.particular installation as follows:

(1) Subtract shim plate thickness fromreference dimension found on quill sleeve.

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BHT-212-CR&O

NOTE 10. Place a small amount of lubricant (tubepack) (C-015), in internal splines of coupling

A workaid may be fabricated (figure (18). Insert inner coupling (20) into outer63-107) to aid installation of seal coupling (18) with small end through seal(17, figure 63-106). (17).

8. Coat packing (15) with transmission oil. 11. Coat lip of seal (14) with transmissionInstall packing (15) and spacer (16) on gear oil. Position couplings on splined end of gear(4). (4) with seal (14) in place. Place washer (21)

on coupling retaining bolt (22) and thread into9. Install seal (17) into outer coupling (18) gear. Hold outer coupling (18) with T101307seal groove as follows: wrench and use a square extension to torque

bolt (22) 80 to 100 ft.lbs. (108.46 to 135.58

a. Apply a light coat of lubricant (tube Nm).pack) (C-015) to outer circumference of seal(17). 12. Place packing (23) on spring retainer

(24). Coat packing with approved oil andb. Install seal (17) into outer coupling (18) insert into coupling retaining bolt (22). If one

seal groove with lip of seal toward internal hole in rim of spring retainer (24) does notsplines (19) of outer coupling (18), as shown align with a notch of inner coupling (20), pullin figure 63-106, detail A. retainer free of bolt, rotate 90° and reinstall.

Repeat if necessary to obtain alignment.When hole and notch are aligned, install lock

NOTE spring (25) through hole in rim of retainer andSeal (17) will be partially seated and notch of coupling. Ensure lock spring is fully

Seal (17) will be partially seated and engaged in notch.inner coupling (20) will be used as abackup, in reverse (detail A) to fullyseat outer circumference edge of NOTEseal into outer coupling (18) sealgroove. A 1/4-20 threaded bolt may be used

to remove spring retainer (24) fromc. Using inner coupling (20) as a backup, coupling retaining bolt (22).

and placed, as shown in detail A, firmly pressdown (hand pressure only) on outer coupling 13. Extend outer coupling (18) so seal (17)(18), simultaneously tuck outer circumference is out against spherical teeth on inneredge of seal (17) with workaid into outer coupling (20) and coat internal splines ofcoupling (18) seal groove. outer coupling (18) with lubricant (tube pack)

(C-015) to 0.12 in. (3.05 mm) depth over topd. Continue pressing around seal (17) of spline teeth. A workaid may be fabricated

with workaid until seal (17) is fully seated. (figure 63-110) to obtain depth of grease.Remove inner coupling (20) from outercoupling (18). 14. Place small end of centering spring (26,

figure 63-106) on boss of plate assembly (27).Install plate and spring in coupling (18) and

NOTE install retainer ring (28). (Refer to figure 63-93for cutaway view of installed components.)

Ensure inner coupling (20, figure 65-2) is correct for tail rotor drive quill,overall length is 2.07 to 2.08 in. NOTE(52.58 to 52.82 mm). Overall lengthof coupling for intermediate and tail The following step (15) applies torotor gearbox is 1.87 to 1.88 in. quill assembly, part number 212-(47.50 to 47.75 mm). 040-365-005 and sub.

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BHT-212-CR&O

1.0 IN. (25.4 mm) RADIUS

8 IN. (203.20 mm)

2.0 IN.(50.8 mm)

7.0IN. (177.80 mm)

0.125 IN.(3.18 mm) 0.25 IN.

1.0 IN. (25.4 mm) (6.35 mm)

NOTES

1. Make from plexiglass or similar material.

2. Remove all sharp edges. 212-R-63-107

Figure 63-107. Plastic seal installation workaid

15. Install new packing (3, figure 63-106) on 63-133A. REPLACEMENT - COUPLINGfunnel (2). Coat packing with transmission oil, TEMPERATURE INDICATOR TEMP-and position funnel in gear (4). Install retainer PLATES.ring (1).

MATERIALS REQUIRED16. Check gear (4) for free rotation. MATERIALS REQUIRED

17. Tag tail rotor drive quill with date of NUMBER NOMENCLATURElubrication and an entry made in componenthistorical record, if quill is to be returned to C-298 Epoxy Adhesivestock.

C-309 Methyl-Ethyl-Ketone18. When tail rotor drive quill is installed on (MEK)helicopter, an entry will be made in helicopter C-318 Cleaning Compoundlog and flex couplings lubrication log.

C-436 Paint RemoverI 19. Deleted.

1. Remove epoxy coating and TEMP-PLATES using paint remover (C-436). Repeatprocess until no trace of epoxy is present.

63-00-00Rev. 3 Page 246A

BHT-212-CR&O

c. Repeat water break-free test as statedCAUTION above.

BONDING SURFACE AND TEMP- CAUTIONPLATES MUST BE FREE OF ALLCONTAMINATION. ANYCONTAMINATION COULD ALLOW IN ORDER TO PREVENTTHE TEMP-PLATES TO COME OFF CONTAMINATION OF THE TEMP-OR INDICATE FALSE PLATES ADHESIVE BACKING,TEMPERATURE. ENSURE THAT WORK AREA AND

HANDS ARE THOROUGHLY2. Prepare outer coupling surface for CLEANED BEFORE WORKINGbonding by scrubbing surface clean with a WITH TEMP-PLATES.cloth moistened with a authorized cleaner, DO NOT PRESS OR RUB THEsuch as MEK (C-309) to remove al TEMP-PLATES WITH BAREcontamination. Before the cleaner solvent FINGERS DURING INSTALLATION

FINGERS DURING INSTALLATIONdries, wipe the surface dry with a clean cloth. ON THE COUPLING AS THIS WILLThe cleaned surface should be at least 0.500 CONTAMINATE THE SURFACES.inch (12.70 mm) larger than the TEMP- APPLY EPOXY COATING TO THEPLATES. Refer to figure 63-109 for location of TEMP-PLATES IMMEDIATELYTEMP-PLATES on outer coupling. FOLLOWING INSTALLATION OF

THE TEMP-PLATES ON3. Accomplish a water break-free test on the COUPLING.prepared bonding surface by applying distilledor demineralized water from a suitable 5. Carefully prebend the temperaturedispenser (such as a squeeze bottle). The indicator TEMP-PLATES to match the Vwater must flow into a continuous film without contour of coupling surface. Do not creasegathering into distinct water droplets within 25 the TEMP-PLATES sharply.seconds after application on the surface.Wipe dry with a clean cloth. Ensure the NOTEbonding surfaces are not subsequentlycontaminated. Working one TEMP-PLATE at a

time, repeat steps 6 and 7 until all4. If the coupling bonding surface will not TEMP-PLATES are installed onmeet the water break-free test requirements coupling.and you have ensured the cleaning materialsare not contaminated, clean coupling bonding 6. Remove protective backing from thesurfaces as follows. TEMP-PLATE and carefully position onto the

surface prepared in step 2.

NOTE 7. Using a clean cloth or cotton swab, workthe TEMP-PLATE into the contour of the

Follow the manufacturers coupling. A thoroughly cleaned firm rubberrecommendations for proper water (edge of a block type eraser) work aid may bemixtures. utilized to work TEMP-PLATE into full contact

with the coupling surface. Ensure the TEMP-a. Using an authorized alkaline cleaning PLATE is in full contact with the coupling

compound (C-318) and cloth, scrub the surface. Do not press or rub the TEMP-coupling bonding surface clear. Follow PLATE with bare fingers.cleaning with a thorough water rinse.

b. Thoroughly dry coupling surfaces.

63-00-00Page 246B Rev. 3

BHT-212-CR&O

NOTE CLEANING SOLVENT OR OTHERCHEMICALS DURING CURE.

Use of any epoxy adhesive other10. Allow epoxy coating to cure at room

authorized. temperature (approximately 60 to 100° F) fora minimum of six hours prior to aircraftoperation. For best results, allow epoxy to

8. Prepare Devcon 2-Ton epoxy adhesive cure overnight prior to operating aircraft or(C-298) as follows: exposing to oil or grease.

a. Pour equal amounts of epoxy Part A NOTEand Part B into a solvent proof container. An alternate source of heat can be

used if the temperature does notexceed 180° F.b. Vigorously mix Part A and Part B with a exceed 180° F.

brush such as an artist brush. 11. After one hour epoxy curing time atroom temperature, the epoxy coating total

c. Mix a few drops of authorized thinner, curing time can be accelerated by placing thesuch as MEK (C-309) may be added to the coupling in a temperature controlled oven for

one to two hours at a temperature of 150 toepoxy during the mixing operation to reduce 180° F (66 to 82° C)the viscosity to a level that permits uniformbrush application of the epoxy mixture. Do not 12. Following the cure, the TEMP-PLATESthin this mixture such that it runs when should conform to the contour of the couplingapplied to a vertical surface. The final and be free of lifted edges. Indicating dots onviscosity of the epoxy should be similar to a TEMP-PLATES must remain the original whiteheavy bodied paint. Too thin of a mixture may or light gray with no full or partial black

discoloration.seep into the temperature indicator TEMP- discoloration.PLATE and cause the indicator dots to turn 13. Accomplish an adhesion test on eachblack (in which event, the TEMP-PLATE must TEMP-PLATE installation. Press a 1 inchbe removed and replaced). Working time for (25.4 mm) wide strip of high adhesion tapethe mixture is approximately 15 minutes. onto the TEMP-PLATE and epoxy overcoat.

The tape should extend beyond the edge ofthe epoxy overcoat. Grasp one end of the9. Using a soft-bristled brush, uniformly tape at approximately 90 degrees from the

apply the epoxy coating over the TEMP- surface and remove tape in one abruptPLATES to a thickness of approximately motion. Lifting or peeling of the epoxy coating0.002 to 0.004 inch (0.508 to 0.1016 mm) or TEMP-PLATE is not acceptable. If lifting or(similar to a coat of paint). The coating should peeling is detected, remove and replacebe uniform in appearance, totally cover the TEMP-PLATE by repeating procedure.surface of the TEMP-PLATES and extendapproximately 0.25 inch (6.35 mm) beyondthe edges of the TEMP-PLATES.

CAUTION

DO NOT EXPOSE THE EPOXYCOATING TO OIL, GREASE,

63-00-00Rev.3 Page 247

BHT-212-CR&O

A Acceptable pattern typical of low operatingtime.

B Acceptable pattern typical of couplings whichhave operated with normal misalignment for alonger period of time than that shown in A.

C Acceptable pattern denoting operation athigher torque than that shown in A and B.

D Acceptable pattern showing a pitted tooth.This condition is acceptable on all teeth.

E Pattern shows a more severe condition oftooth pitting than that shown In D. There Isno metal projecting above the normal face ofthe tooth, indicating that the pitted area Ispolishing over. This condition may exist on allteeth. Couplings with pits larger than 1/32Inch (0.79375 mm) diameter should be re-placed. 212-R-63-108placed. coooo

Figure 63-108. Tail rotor drive coupling wear pattern

63-00-00Page 248

BHT-212-CR&O

0.74 ±0.030 IN.(18.79 ± 0.762 mm)

204-040-604-005 COUPLNGREF

6000-1 TEMP-PLATE (RED BORDER)2 REQD - 180 DEGREES APARTEQUALLY SPACED WITHIN 0.300 IN.(7.62 mm)

212-R-63-109

Figure 63-109. Tail rotor drive quill coupling TEMP-PLATE installation

63-00-00Rev. 3 Page 249

BHT-212-CR&O

-1.05 IN. 0.27 IN. (6.80 mm)(26.67 mm)

0.25 IN. (6.35 mm)

HANDLE LENGTH IS OPTIONAL

0.1 IN.(2.54 mm)RADIUS

TAIL ROTOR RADIUS (7.92 mm)

212-R-63-110

Figure 63-110. Workaid for lubrication of tail rotor drive coupling

63-00-00 0.357 IN. (31.75 mm)(9.53 mm)

0.05 IN.COUPLING (1.27mm) 0.312 IN.TAIL ROTOR RADIUS (7.92 mm)DRIVESHAFT MAKE LOCALLY FROM 1/4 IN. (6.35 mm) PLASTIC, OR SIMILAR MATERIAL

212-R-63-110

Figure 63-110. Workaid for lubrication of tail rotor drive coupling

63-00-00Page 250

BHT-212-CR&O

TRANSMISSION OIL PUMP

63-134. TRANSMISSION OIL PUMP. 2. Dry parts with clean, lint-free cloths ordry, filtered, compressed air. Do not allowbearings to spin while drying.

63-135. OVERHAUL.3. Coat bearings with corrosion preventive

63-136. Disassembly. (C-105) immediately after cleaning. Do nothandle unoiled bearings with bare hands.

1. Remove retainer ring (1, figure 63-111). 4. Remove sealant with plastic scraper.

CAUTION 63-138. Inspection.CAUTION

1. Inspect parts for damage.

DO NOT REMOVE ANY PART OFPUMP BY FORCING OR PRYING 2. Inspect bearings (3 and 10, figure 63-LOOSEN PARTS BY TAPPING 111), shaft (7), inner and outer gerotors (6LIGHTLY WITH A FIBER MALLET. and 5), and body (11) for scoring or

indentations.

2. Remove retainer plate (2). Do not remove 3. Inspect shaft (7) by magnetic particlebearing (3) from retainer plate. inspection (BHT-ALL-SPM). Demagnetize

shaft after magnetic particle inspection.3. Remove inner gerotor (6) and shaft (7)and outer gerotor (5). 4. Inspect parts for corrosion damage and

for excessive wear.4. Remove retainer rings (4 and 9). Removeinner gerotor and key (8) from shaft. Do not 5. Inspect following parts dimensionally andremove bearing (10) or dowel pin (14) from replace parts which exceed inspection limits.body (11).

5. If damaged, remove insert (12) and ring NOTE(13).

Wear limits are provided to showrequired fit between mating parts. it

63-137. Cleaning. is not intended all dimensions bechecked as prescribed overhaul

MATERIALS REQUIRED procedure. However, parts exhibitingevidence of wear of physicaldamage shall be checked

NUMBER NOMENCLATURE dimensionally.

C-105 Corrosion Preventive MIN. MAX.LOCATION (In./mm) (In./mm)

C-304 Solvent

C-334 1.1.1-Trichloroethane Outer Gerotor Width 0.7080 0.7085C-334 1.1.1-Trichloroethane(17.9832 (17.9959mm) mm)

1. Clean all pump parts with solvent (C-304).Use soft bristle brush to dislodge stubborndeposits. All parts except bearings may becleaned with 1.1.1-trichloroethane (C-334) byvapor degreasing if desired.

63-00-00Rev.3 Page 251

BHT-212-CR&O

MIN.MAX. 63-140. Assembly.LOCATION (In/mm) (In./mm)

MATERIALS REQUIREDBody Chamber Width 0.7100 0.7105 MATERIALS REQUIRED

(18.034 (18.0467mm) mm) NUMBER NOMENCLATURE

Allowable Chamber 0.0015 0.0027 C-304 SolventFace Clearance (0.0381 (0.06858

mm) mm) 1. Clean all parts with solvent (C-304) and

Outer Gerotor OD 2.1220 2.1225 drain.(53.8988 (53.9115 2. Coat all parts with transmission oil and

drain excess.

Body ID 2.1250 2.1255(56.261 (56.2737 NOTEmm) mm)

Do not handle unoiled parts withAllowable Clearance 0.0025 0.0040 bare hands.

(0.0635 (0.1016mm) mm) 3. Install retainer ring (9, figure 63-111) in

inboard groove on shaft (7).Driveshaft OD 0.4985 0.4990

(12.6619 (12.6746 4. Insert key (8) in shaft (7) and install innermm) mm) gerotor (6) so keyway engages key. Install

retainer ring (4) on outboard end of shaft (7).Bearing ID 0.5000 0.5005

(12.700 (12.7127 5. Install shaft (7) in body (11). Install outermm) mm) gerotor (5) over inner gerotor (6).

Allowable Clearance 0.0010 0.0025 6. Install retainer plate (2) on shaft (7).(0.0254 (0.0635 Ensure dowel in body (11) engages hole inmm) mm) plate (2).

7. Install retainer ring (1) in body (11).Retainer ring has a beveled and a flat side.

63-139. Repair. Flat side must be against plate. Ensure ringis fully seated in groove.

1. Replace worn or damaged parts.

8. Rotate shaft (7) to ensure internal parts2. Replace pump if housing, bushings, or turn freely.gerotor are excessively worn or scored.

3. Replace parts which exceed allowablewear limits.

63-00-00Page 252

BHT-212-CR&O

1. Retainer Ring 8. Key2. Retainer Plate 9. Retainer Ring3. Bearing 10. Bearing4. Retainer Ring 11. Body5. Outer Gerotor 12. Insert6. Inner Gerotor 13. Ring7. Shaft 14. Dowel Pin

212-R-63-111

Figure 63-111. Transmission oil pump

63-00-00Page 253/254

BHT-212-CR&O

TRANSMISSION MOUNT COMPONENTS

63-141. TRANSMISSION MOUNTCOMPONENTS. CAUTION

The following paragraphs provide repair andoverhaul information for the transmission LIMIT MOTION TO A MAXIMUM OFmount friction damper, lift link, and pylon 0.500 IN. (12.7 MMN).isolation mount bolt.

2. Load damper to measure sliding frictionbetween damper inner member (4, figure 63-

63-142. FRICTION DAMPER. 112) and housing (2). Initial load (mayexceed 500 lbs. (226.8 kg)) shall drop to

63-143. Inspection. between 115 lbs. (52.164 kg) and 180 lbs.(81.648 kg) once sliding is initiated.

1. Inspect bearing (1, figure 63-112) forwear. Maximum acceptable radial play is 63-146 LIFT LINK0.004 in. (0.1016 mm).

2. Inspect boot (3) for holes and 63-147. Inspection and repair.deterioration. Damage which can be detectedvisually is not acceptable.

MATERIALS REQUIRED3. Inspect external surfaces of housing (2)and inner member (4) for corrosion and NUMBER NOMENCLATUREmechanical damage. Superficial mechanicaldamage is acceptable without repair. Minor C-108 B r u s h C a d m i u mcorrosion and mechanical damage is Plating Solutionacceptable if polished out.

C-204 Primer

63-144. Repair. C-352 Sealant

MATERIALS REQUIRED 1. Inspect lift link using magnetic particlemethod (BHT-ALL-SPM), if any crack(s) are

NUMBER NOMENCLATURE found, scrap lift link.

C-423 Abrasive Cloth or 2. Mechanical damage, not exceeding 0.005Paper in. (0.127 mm) is permissible, except 2.50 in.

(63.5 mm) on each side (figure 63-113). Norepairs are permissible in shaded area.

Polish out minor mechanical and corrosiondamage on external surfaces of housing (2) 3 Corrosion to depthof 0.005 in. (0.127and inner member (4) with 400 grit abrasive mm) should be cleaned up by bead blastingcloth or paper (C-423). or shot peening. No repairs are permissible

in shaded area. Brush brush cadmium plating63-145. Testing. solution (C-108) or apply two coats of primer

(C-204) to repaired area.1. Install damper in test fixture capable ofsupporting 1000 lbs. (453.6 kg). 4. Inspect bearings for radial and axial

movement. Radial movement of 0.010 in.(0.254 mm) and axial movement of 0.030 in.

63-00-00Page 255

BHT-212-CR&O

(0.762 mm) is permissible. If bearing(s)exceed these wear limits, replace bearing(s) CAUTIONas follows:

DO NOT STAKE PARTS AFTERRETAINING COMPOUND HAS

CAUTION CURED.

PRESSING OUT A f. Within 30 minutes after assembly, stakePREGROOVED BEARING WITH A in lift link using roll staking tool, RST1016STEEL OUTER RACE, CAREFULLY (BHT-ALL-SPM). Remove excess sealant (C-CUT AWAY AND REMOVE ROLL 352) using clean dry cloth.STAKED LIP ON ONE SIDE OFBEARING USING A FLY CUTTER. 63-148. PYLON ISOLATION MOUNTDO NOT CUT INTO PART. BOLT.

a. Press out unserviceable bearings. 63-149. Inspection and repair.

b. Mask off lift link (except for bores) andclean bore by glass bead blasting. Do not MATERIALS REQUIREDpeen more than minimum required for cleanup. No local abrading with any abrasive is NUMBER

NUMBER NOMENCLATUREpermitted.C-423 Abrasive Cloth or

c. Measure bore three places 120° apart. PaperBore diameter shall be within 1.4380 to1.4383 in. (36.5252 to 37.9635 mm). If borecannot be honed to tolerance or if there are 1. Inspect bolt for mechanical and corrosionany remaining corrosion pits in bore, link damage (figure 63-114).shall be scrapped.

2. Repair light scratches, nicks andd. Apply a coat of sealant (C-352) to outer corrosion using 400 grit abrasive cloth or

diameter of replacement bearing and to bore paper (C-423) maintaining surface finish of 63of lift link. RMS.

e. Press bearing into lift link makingcertain bearing is centered equally from eachside of link.

63-00-00Page 256

BHT-212-CR&O

1. Bearing2. Housing3. Boot4. Inner member

212-R-63-112

Figure 63-112. Friction damper assembly

63-00-00Page 257

BHT-212-CR&O

2.50 IN.(63.5 mm)

2.50 IN.(63.5 mm)

212-030-104



CRACKS ALLOWED None None

MECHANICAL DAMAGE None 0.005 IN. (0.127 mm)

CORROSION DAMAGEBEFORE REPAIR None 0.005 IN. (0.127 mm)AFTER REPAIR None 0.005 IN. (0.127 mm)

MAXIMUM AREA PERFULL DEPTH REPAIR

NUMBER OF REPAIRS

EDGE CHAMFER

BEARING WEAR LIMITSRADIAL 0.010 IN. (0.254 mm)AXIAL 0.030 IN. (0.762 mm)

212-R-63-113

Figure 63-113. Lift link damage and repair limits

63-00-00Page 258

BHT-212-CR&0

2.55 IN.(6.477 cm)

BOLT212-030-096-1


TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS

MECHANICAL None 0.005 In. (0.127 mm)

CORROSIONBEFORE CLEANUP None 0.025 In. (0.635 mm)

AFTER CLEANUP None 0.005 In. (0.127 mm)

MAXIMUM AREA PER None 0.06 Sq. In.

FULL DEPTH REPAIR (38.70 mm2)

NUMBER OF REPAIR AREAS None One

EDGE CHAMFER None 0.015 In. (0.381 mm)

THREAD DAMAGE None

212-R-63-114

Figure 63-114. Pylon isolation mount bolt damage and repair limits

63-00-00Rev. 4 Page 259

BHT-212-CR&O

Table 63-4. Magnetic Particle Inspection

NOTES: 1. Magnetization currents given in the following table are applicable tomagnetic particle inspection apparatus using DIRECT CURRENT (D.C.). Ifan ALTERNATING CURRENT (A.C.) apparatus is used adjust the current asfollows: ALTERNATING CURRENT (A.C.) = .667 x DIRECT CURRENT(D.C.)

2. Ferrous parts requiring magnetic particle inspection that are not addressed in theattached material are to be inspected in accordance with the general proceduresoutlined in MIL-STD-1949.

3. Part numbers listed applies to all successive dash numbers for that componentunless otherwise specified.

SET-UP AND MAGNETIZATIONNUMBER NOMENCLATURE CURRENT REQUIREMENTS

212-040-005-013 MAIN DRIVE SHAFT COMPONENTS

204-040-184-001 NUT SET-UP: PLACE PART OVER 1.5 IN.10, FIGURE 63-3 DIAMETER CENTRAL CONDUCTOR.

CURRENT FOR PRIMARY DIAMETERS:MAGNETIZE AT 1990 AMPS.

(OMIT COIL SHOT).

212-040-687-001 COUPLING SET-UP: PLACE PART OVER 2 IN. DIAMETER8, FIGURE 63-8 CENTRAL CONDUCTOR.

CURRENT FOR PRIMARY DIAMETERS:MAGNETIZE AT 2820 AMPS. OPTIONALCURRENT FOR SECONDARY DIAMETERS:MAGNETIZE AT 1420 AMPS.

(OMIT COIL SHOT).



LARGE I.D. OF PART: MAGNETIZE AT 3APPROXIMATELY EQUAL SPACED RADIALLOCATIONS ON CENTRAL CONDUCTOR.

SET-UP: 5 TURN COIL SHOT.

DISK SHAPED PORTION OF PART: PLACEPART IN BOTTOM OF COIL. MAGNETIZE AT3000 AMPS.

ROTATE PART ONE-QUARTER TURN ANDREPEAT.

63-00-00Page 260 Rev. 4

BHT-212-CR&0

Table 63-4. Magnetic Particle Inspection (Cont)

SET-UP AND MAGNETIZATIONPART NUMBER NOMENCLATURE CURRENT REQUIREMENTS

212-040-686-001 DRIVESHAFT SET-UP: PLACE PART OVER 2 IN. DIAMETER6, FIGURE 63-3 CENTRAL CONDUCTOR.

CURRENT FOR PRIMARY DIAMETERS;MAGNETIZE AT 2000 AMPS.


WITH PART SUPPORTED ON THECONDUCTING ROD BETWEEN THE CONTACTPLATES, MAGNETIZE AT 2400 AMPS.

204-040-366-015 & -021 MAST ASSEMBLY COMPONENTS

204-040-307-001 LINER SET-UP: PLACE PART OVER 2 IN. DIAMETER14, FIGURE 63-21 CENTRAL CONDUCTOR.


LARGE I.D. OF PART: MAGNETIZE AT 4APPROXIMATELY EQUAL SPACED RADIALLOCATIONS OF CENTRAL CONDUCTOR.


DISK-SHAPED PORTION OF PART: PLACEPART IN BOTTOM OF COIL. MAGNETIZE AT3000 AMPS.


204-040-115-001 NUT SET-UP: PLACE PART OVER 2 IN. DIAMETER16, FIGURE 63-21 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

63-00-00Rev. 4 Page 261

BHT-212-CR&0


SET-UP AND MAGNETIZATION 0PART NUMBER NOMENCLATURE CURRENT REQUIREMENTS

204-011-450-007 MAST POLE SET-UP: PLACE PART OVER 1.5 IN.3, FIGURE 63-21 DIAMETER CENTRAL CONDUCTOR.


ROTATE IN 120 DEGREE INTERVALS ANDREPEAT.


HOLD PART IN BOTTOM OF COIL WITH LONGAXIS APPROXIMATELY 90 DEGREES FROMCURRENT FLOW IN THE COIL. MAGNETIZEAT 9500 AMPS.

REPEAT ABOVE OPERATION IN 1 FOOTINCREMENTS ALONG PART FOR THE FULLLENGTH.

204-040-309-101 NUT SET-UP: PLACE PARTS OVER 2 IN.20, FIGURE 63-21 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-001-015, -043, -059, -123 TRANSMISSION ASSEMBLY COMPONENTS

204-040-117-003 ADAPTER SET-UP: PLACE PART OVER 1.5 IN.8, FIGURE 63-32 DIAMETER CENTRAL CONDUCTOR.




DISK-SHAPED PORTION OF PART: PLACEPART IN BOTTOM OF COIL SO THAT THELONGITUDINAL AXIS OF THE PART ISPERPENDICULAR TO COIL AXIS. MAGNETIZEAT 15,000 AMPS.


63-00-00Page 262 Rev. 4

BHT-212-CR&0






(OMIT COIL SHOT).





DISK-SHAPED PART: DO COIL SHOT ASFOLLOWS: LAY PART FLAT IN BOTTOM OFCOIL. MAGNETIZE AT 3000 AMPS.

ROTATE ONE-QUARTER TURN AND REPEAT.

205-040-230-003 SUN GEAR-UPPER SET-UP: PLACE PART OVER 2 IN. DIAMETER11, FIGURE 63-32 CENTRAL CONDUCTOR.



DISK-SHAPED PART: DO COIL SHOT ASFOLLOWS: PLACE PART FLAT IN COIL.MAGNETIZE AT 3000 AMPS.


63-00-00Rev. 4 Page 263

BHT-212-CR&0



205-040-229-003 SUN GEAR-LOWER SET-UP: PLACE PART OVER 2 IN. DIAMETER23, FIGURE 63-32 CENTRAL CONDUCTOR.


DISK-SHAPED PART: PLACE PART INBOTTOM OF COIL. MAGNETIZE AT 3000AMPS.


205-040-231-005, RING GEAR SET-UP: PLACE PART OVER 2 IN. DIAMETER-009 36, FIGURE 63-32 CENTRAL CONDUCTOR.



(OMIT COIL SHOT).

214-040-206-001, ADAPTER SET-UP: PLACE PART OVER 0.7 IN.-101 3, FIGURE 63-20 DIAMETER CENTRAL CONDUCTOR.



HOLD PART IN BOTTOM OF COIL WITHLONGITUDINAL AXIS PARALLEL TO COILAXIS. MAGNETIZE AT 2770 AMPS.

63-00-00Page 264 Rev. 4

BHT-212-CR&O



205-040-230-001, SUN GEAR, UPPER SET-UP: PLACE PART OVER 2 IN. CENTRAL-005 11, FIGURE 63-32 CONDUCTOR.






204-040-360-005 & -103 UPPER PLANETARY ASSEMBLY COMPONENTS

204-040-130-005 SHAFT SET-UP: PLACE PART OVER 0.7 IN.1, FIGURE 63-50 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

204-040-397-001 CARRIER SET-UP: PLACE PART OVER 2 IN. DIAMETER8, FIGURE 63-50 CENTRAL CONDUCTOR.




DISK-SHAPED PORTION OF PART: PLACEPART IN BOTTOM OF COIL. SHOOT AT 3000AMPS.


63-00-00Rev. 4 Page 265

BHT-212-CR&0





(OMIT COIL SHOT).

204-040-132-001 RACE SET-UP: PLACE PART OVER 1.0 IN.5, FIGURE 63-50 DIAMETER CENTRAL CONDUCTOR.


SET-UP: 5 TURN COIL.

PLACE PART IN BOTTOM OF COIL SUCHTHAT THE LONGITUDINAL AXIS OF THEPART IS 90 DEGREES TO THE DIRECTION OFTHE CURRENT FLOW THROUGH THE COIL.MAGNETIZE AT 3000 AMPS.

205-040-233-001 PINION SET-UP: PLACE PART OVER 2 IN. DIAMETER4, FIGURE 63-50 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

204-040-784-005 & -101 LOWER PLANETARY ASSEMBLY COMPONETS

212-040-782-101 BOLT SET-UP: 5 TURN COIL SHOT.9, FIGURE 63-51

HOLD PART IN BOTTOM OF COIL WITHLONGITUDINAL AXIS PARALLEL TO COILAXIS. MAGNETIZE AT 3000 AMPS.



(OMIT COIL SHOT).

63-00-00Page 266 Rev. 4

BHT-212-CR&O



212-040-789-101 SPACER SET-UP: PLACE PART OVER 0.5 IN.17, FIGURE 63-51 DIAMETER CENTRAL CONDUCTOR.


204-040-786-001 PLATE SET SET-UP: PLACE PART OVER 2 IN. DIAMETER12, FIGURE 63-51 CENTRAL CONDUCTOR.






63-00-00Rev. 4 Page 267

BHT-212-CR&0



204-040-785-003 SPIDER SET-UP: PLACE PART OVER 2 IN. DIAMETER13, FIGURE 63-51 CENTRAL CONDUCTOR AT FOUR (4) INSIDE

LOCATIONS BETWEEN LEGS.

CURRENT FOR BODY DIAMETER:MAGNETIZE AT 2200 AMPS.

SET-UP: PLACE PART OVER 2 IN. DIAMETERCENTRAL CONDUCTOR AT EACH LEG.

CURRENT FOR EACH LEG SHOT: MAGNETIZEAT 4800 AMPS.

SET-UP: PLACE PART OVER 0.7 IN.DIAMETER CENTRAL CONDUCTOR THRUEACH LEG HOLE.

CURRENT FOR EACH LEG HOLE: MAGNETIZEAT 1200 AMPS.


PLACE PART FLAT IN COIL, LEGS UP, WITHTWO (2) LEGS ON COIL AXIS. CURRENT FORCOIL SHOT AT 3000 AMPS.,

ROTATE PART ONE-QUARTER TURN ANDREPEAT COIL SHOT.

412-040-785-101, SPIDER SET-UP: PLACE PART OVER 2 IN. DIAMETER-103 13, FIGURE 63-51 CENTRAL CONDUCTOR.




DISK-SHAPED PART: LAY PART FLAT INBOTTOM OF COIL. MAGNETIZE AT 3000AMPS.


63-00-00Page 268 Rev. 4

BHT-212-CR&O



204-040-130-005 SHAFT SET-UP: PLACE PART OVER 0.7 IN.1, FIGURE 63-51 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).



(OMIT COIL SHOT).

204-040-132-001, RACE SET-UP: PLACE PART OVER 1.0 IN DIAMETER-101 5, FIGURE 63-51 CENTRAL CONDUCTOR.



PLACE PART IN BOTTOM OF COIL SUCHTHAT THE LONGITUDINAL AXIS OF THEPART IS 90 DEGREES TO THE DIRECTION OFTHE CURRENT FLOW THROUGH THE COIL.MAGNETIZE AT 3000 AMPS.

205-040-233-001, GEAR SET-UP: PLACE PART OVER 2 IN. DIAMETER-105 4, FIGURE 63-51 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-365-003, -017 & -023 ACCESSORY AND TAIL ROTOR DRIVE QUILL ASSEMBLYCOMPONENTS


CURRENT OF PRIMARY DIAMETERS:MAGNETIZE AT 1120 AMPS.

(OMIT COIL SHOT).

63-00-00Rev. 4 Page 269

BHT-212-CR&0



212-040-150-001, PINION SET-UP: PLACE PART OVER 0.7 IN.-003, -005 11, FIGURE 63-92 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-365-005, -019 & -025 TAIL ROTOR DRIVE QUILL ASSEMBLY COMPONENTS

204-040-603-009 COUPLING SET-UP: PLACE PART OVER 1.0 IN.20, FIGURE 63-106 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).



(OMIT COIL SHOT).

214-040-151-001, GEAR SET-UP: PLACE PART OVER 0.7 IN.-005,-009 4, FIGURE 63-106 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-156-101 SPACER SET-UP: PLACE PART OVER 1.0 IN.16, FIGURE 63-106 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

63-00-00Page 270 Rev. 4

BHT-212-CR&O



212-040-365-103 & -007 HYDRAULIC DRIVE AND SINGLE BOOST QUILL ASSEMBLYCOMPONENTS

204-040-112-001 SPROCKET SET-UP: PLACE PART OVER 1.0 IN. CENTRAL8, FIGURE 63-104 CONDUCTOR.

CURRENT FOR PRIMARY DIAMETER:MAGNETIZE AT 1030 AMPS.

(OMIT COIL SHOT).



(OMIT COIL SHOT).

204-040-333-001 SPROCKET SET-UP: PLACE PART OVER 0.219 IN.ASSEMBLY DIAMETER CENTRAL CONDUCTOR.

26, FIGURE 63-104CURRENT FOR PRIMARY DIAMETERS:MAGNETIZE AT 1509 AMPS. OPTIONALCURRENT FOR SECONDARY DIAMETERS:MAGNETIZE AT 452 AMPS.

CAUTION - CENTRAL CONDUCTOR MAYGET VERY HOT**

(OMIT COIL SHOT).

212-040-149-001 GEAR ASSEMBLY SET-UP: PLACE PART OVER 0.5 IN.33, FIGURE 63-104 DIAMETER CENTRAL CONDUCTOR.


**CAUTION - CENTRAL CONDUCTOR MAYGET VERY HOT**.

(OMIT COIL SHOT).

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BHT-212-CR&0



204-040-379-003 ACCESSORY DRIVE QUILL ASSEMBLY COMPONENTS

204-040-102-017 PINION ASSEMBLY SET-UP: PLACE PART OVER 0.7 IN.12, FIGURE 63-84 DIAMETER CENTRAL CONDUCTOR.



(OMIT COIL SHOT).



(OMIT COIL SHOT).

204-040-362-013 & -103 MAIN INPUT BEVEL GEAR QUILL ASSEMBLY COMPONENTS

204-040-324-005 SHAFT SET-UP: PLACE PART OVER 2 IN. DIAMETER11, FIGURE 63-59 CENTRAL CONDUCTOR.



PLACE PART IN COIL SUCH THAT THELONGITUDINAL AXIS OF THE PART IS 90DEGREES TO AXIS OF COIL. MAGNETIZE AT2600 AMPS.

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BHT-212-CR&0



204-040-701-101, GEAR SET-UP: PLACE PART OVER 2 IN. DIAMETER-003 12, FIGURE 63-59 CENTRAL CONDUCTOR.






204-040-357-007 PLATE SET-UP: PLACE PART OVER 2 IN. DIAMETER9, FIGURE 63-59 CENTRAL CONDUCTOR.






212-040-263-101 & -107 MAIN INPUT QUILL ASSEMBLY COMPONENTS

204-040-184-001 NUT SET-UP:PLACE PART OVER 1.5 IN. DIAMETER23, FIGURE 63-74 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

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BHT-212-CR&O



204-040-700-101 PINION SET-UP: PLACE PART OVER 0.7 IN.1, FIGURE 63-74 DIAMETER CENTRAL CONDUCTOR.



(OMIT COIL SHOT).

212-040-190-001, ADAPTER SET-UP: PLACE PART OVER 2 IN. DIAMETER-001 22, FIGURE 63-74 CENTRAL CONDUCTOR.





214-040-097-003 SLEEVE SET-UP: PLACE PART OVER 2 IN. DIAMETER2, FIGURE 63-74 CENTRAL CONDUCTOR.





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BHT-212-CR&0



212-040-363-001 MAIN INPUT QUILL ASSEMBLY COMPONENTS



(OMIT COIL SHOT).

204-040-700-001 PINION SET-UP: PLACE PART OVER 0.7 IN.1, FIGURE 63-66 DIAMETER CENTRAL CONDUCTOR.


**CAUTION - CENTRAL CONDUCTOR MAYGET VERY HOT**

(OMIT COIL SHOT).

212-040-364-001 RACE SET-UP: PLACE PART OVER 2 IN. DIAMETER16, FIGURE 63-66 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-367-001 RACE SET-UP: PLACE PART OVER 2 IN. DIAMETER18, FIGURE 63-66 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-208-001 OFFSET ACCESSORY AND TAIL ROTOR DRIVE QUILL ASSEMBLYCOMPONENTS



(OMIT COIL SHOT).

63-00-00Rev. 4 Page 275

BHT-212-CR&O





(OMIT COIL SHOT).212-040-201-001 GEAR SET-UP: PLACE PART OVER 2 IN. DIAMETER

1, FIGURE 63-86 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).212-040-202-001 PINION SET-UP: PLACE PART OVER 1 IN. DIAMETER



(OMIT COIL SHOT).212-040-207-001 SPACER SET-UP: PLACE PART OVER 2 IN. DIAMETER



OMIT COIL SHOT).(TABLE I.D. 922003)

63-00-00Page 276 Rev. 4

Documents

BHT-212-CRO-3[1].PDF Repair Manual Main Rotor