BHT-206L4-MM-6

CHAPTER 63 — MAIN ROTOR DRIVE SYSTEM

TABLE OF CONTENTS

Paragraph Chapter/Section Page

Number Title Number Number

MAIN ROTOR DRIVE SYSTEM

63-1 Main Rotor Drive System ............................................................... 63-00-00 7

63-2 Allowable Leakage Rates for Main Rotor Drive System
Components ............................................................................. 63-00-00 7
63-3 Troubleshooting Main Rotor Drive System .................................... 63-00-00 7
63-4 Troubleshooting Transmission System..................................... 63-00-00 7
63-5 Troubleshooting Transmission Mounts..................................... 63-00-00 10A
63-6 Troubleshooting Freewheeling Assembly................................. 63-00-00 11
63-7 Oil Contamination .......................................................................... 63-00-00 11
63-8 Identification of Foreign Material............................................... 63-00-00 11
63-9 Transmission Oil Contamination............................................... 63-00-00 12
63-10 Freewheeling Unit Oil Contamination ....................................... 63-00-00 13
63-11 Transmission System Oil Servicing Drain Hoses........................... 63-00-00 13
63-12 Serviceability Check....................................................................... 63-00-00 13
63-13 Transmission Serviceability Check ........................................... 63-00-00 13
63-14 Freewheeling Assembly Serviceability Check .......................... 63-00-00 16
63-15 Main Driveshaft .............................................................................. 63-00-00 17
63-16 Main Driveshaft — Removal ..................................................... 63-00-00 17
63-17 Main Driveshaft — Cleaning ..................................................... 63-00-00 19
63-18 Main Driveshaft — Inspection................................................... 63-00-00 19
63-19 Main Driveshaft — Installation .................................................. 63-00-00 19
63-20 Main Rotor Mast............................................................................. 63-00-00 20
63-21 Main Rotor Mast — Removal.................................................... 63-00-00 20
63-22 Main Rotor Mast — Cleaning.................................................... 63-00-00 20
63-23 Main Rotor Mast — Inspection and Repair............................... 63-00-00 20A
63-24 Installation................................................................................. 63-00-00 23
63-25 Transmission.................................................................................. 63-00-00 23
63-26 Removal.................................................................................... 63-00-00 24
63-27 Cleaning.................................................................................... 63-00-00 26
63-28 Inspection and Repair............................................................... 63-00-00 26
63-29 Installation................................................................................. 63-00-00 27
63-30 Transmission — Operational Check ......................................... 63-00-00 28
63-31 Tachometer Generator................................................................... 63-00-00 28
63-32 Tachometer Generator — Removal.......................................... 63-00-00 29
63-32A Tachometer Generator — Inspection ....................................... 63-00-00 29
63-32B Tachometer Generator — 600-Hour/12-Month Inspection
and Lubrication Interval ............................................................ 63-00-00 29
63-33 Tachometer Generator — Installation....................................... 63-00-00 30F
63-34 Transmission Oil System ............................................................... 63-00-00 30F
63-35 Oil Pump ........................................................................................ 63-00-00 31G
63-36 Oil Pump — Removal ............................................................... 63-00-00 31G
63-37 Oil Pump — Inspection and Repair .......................................... 63-00-00 31G
63-38 Oil Pump — Installation ............................................................ 63-00-00 31
63-39 Oil Pump Inlet Screen .................................................................... 63-00-00 31
63-40 Oil Pump Inlet Screen — Removal ........................................... 63-00-00 31

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 1
BHT-206L4-MM-6

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-41 Inspection ................................................................................. 63-00-00 33

63-42 Installation................................................................................. 63-00-00 33
63-43 Electric Chip Detectors .................................................................. 63-00-00 34
63-44 Removal.................................................................................... 63-00-00 34
63-45 Inspection ................................................................................. 63-00-00 34
63-46 Installation................................................................................. 63-00-00 34
63-47 Transmission Oil Level Sight Gauge.............................................. 63-00-00 34
63-48 Removal.................................................................................... 63-00-00 34
63-49 Inspection ................................................................................. 63-00-00 35
63-50 Installation................................................................................. 63-00-00 35
63-51 Transmission OIl Jets .................................................................... 63-00-00 35
63-52 Removal.................................................................................... 63-00-00 35
63-53 Inspection ................................................................................. 63-00-00 35
63-54 Installation................................................................................. 63-00-00 35
63-55 Transmission Oil Pressure Regulating Valve................................. 63-00-00 37
63-56 Removal.................................................................................... 63-00-00 37
63-57 Inspection ................................................................................. 63-00-00 37
63-58 Installation................................................................................. 63-00-00 37
63-59 Adjustment................................................................................ 63-00-00 37
63-60 Transmission Oil Filter and Housing Assemblies........................... 63-00-00 38
63-61 Removal.................................................................................... 63-00-00 38
63-62 Inspection ................................................................................. 63-00-00 38
63-63 Installation................................................................................. 63-00-00 38
63-64 Transmission Oil Filter ................................................................... 63-00-00 38
63-65 Removal.................................................................................... 63-00-00 38
63-66 Cleaning and Inspection ........................................................... 63-00-00 40
63-67 Installation................................................................................. 63-00-00 40
63-68 Transmission Oil Temperature Bulb .............................................. 63-00-00 40
63-69 Removal.................................................................................... 63-00-00 40
63-70 Inspection ................................................................................. 63-00-00 40
63-71 Installation................................................................................. 63-00-00 42
63-72 Transmission Oil Bypass Valve ..................................................... 63-00-00 42
63-73 Removal.................................................................................... 63-00-00 42
63-74 Inspection ................................................................................. 63-00-00 42
63-75 Installation................................................................................. 63-00-00 42
63-76 Transmission Oil Thermostat ......................................................... 63-00-00 43
63-77 Removal.................................................................................... 63-00-00 43
63-78 Installation................................................................................. 63-00-00 43
63-79 Transmission Oil Filter Bypass Indicator........................................ 63-00-00 43
63-80 Removal.................................................................................... 63-00-00 43
63-81 Inspection ................................................................................. 63-00-00 43
63-82 Installation................................................................................. 63-00-00 44
63-83 Transmission Oil Thermoswitch..................................................... 63-00-00 44
63-84 Removal.................................................................................... 63-00-00 44
63-85 Inspection ................................................................................. 63-00-00 44
63-86 Installation................................................................................. 63-00-00 44
63-87 Transmission Oil Fittings................................................................ 63-00-00 45
63-88 Transmission Oil Fittings — Removal....................................... 63-00-00 45

63-00-00
Page 2 Rev. 13 25 FEB 2011 ECCN EAR99
 BHT-206L4-MM-6

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-89 Transmission Oil Fittings — Installation.................................... 63-00-00 45

63-90 Transmission Oil System Hoses and Tube Assemblies ................ 63-00-00 45
63-91 Transmission Oil System Hoses and Tube Assemblies
— Removal ............................................................................... 63-00-00 45
63-92 Transmission Oil System Hoses and tube Assemblies
— Cleaning and Inspection....................................................... 63-00-00 45
63-93 Transmission Oil System Hoses and Tube Assemblies
— Installation ............................................................................ 63-00-00 45
63-94 Bleeding — Transmission Oil Pressure Lines................................ 63-00-00 47
63-95 Transmission Oil Pressure Switch ................................................. 63-00-00 47
63-96 Transmission Oil Pressure Switch — Removal ........................ 63-00-00 47
63-97 Transmission Oil Pressure Switch — Inspection ...................... 63-00-00 47
63-98 Transmission Oil Pressure Switch — Installation ..................... 63-00-00 48
63-99 Transmission Oil Cooler................................................................. 63-00-00 48
63-100 Transmission Oil Cooler — Removal........................................ 63-00-00 48
63-101 Transmission Oil Cooler — Cleaning and Inspection ............... 63-00-00 48
63-102 Transmission Oil Cooler — Installation..................................... 63-00-00 50
63-103 Freewheel Assembly...................................................................... 63-00-00 50
63-104 Freewheel Assembly — Removal............................................. 63-00-00 54
63-105 Freewheel Assembly — Cleaning............................................. 63-00-00 55
63-106 Freewheel Assembly — Inspection and Repair........................ 63-00-00 56
63-107 Freewheel Assembly — Installation.......................................... 63-00-00 56
63-108 Freewheel Assembly — Operational Check ............................. 63-00-00 59
63-109 Transmission Mounts — Nodal Beam ........................................... 63-00-00 59
63-110 Transmission Mounts — Cleaning............................................ 63-00-00 59
63-111 Link Attachments ........................................................................... 63-00-00 59
63-112 Link Attachments — Removal .................................................. 63-00-00 59
63-113 Inspection and Repair............................................................... 63-00-00 61
63-114 Installation................................................................................. 63-00-00 61
63-115 Link Assemblies ............................................................................. 63-00-00 61
63-116 Removal.................................................................................... 63-00-00 61
63-117 Inspection and Repair............................................................... 63-00-00 62
63-118 Elastomeric Bearings Inspection .............................................. 63-00-00 62
63-119 Sealing of Elastomeric Components......................................... 63-00-00 62
63-120 Installation................................................................................. 63-00-00 62
63-121 Arm and Flexure Assembly............................................................ 63-00-00 63
63-122 Removal.................................................................................... 63-00-00 63
63-123 Inspection and Repair............................................................... 63-00-00 63
63-124 Installation................................................................................. 63-00-00 66
63-125 Support Assemblies ....................................................................... 63-00-00 67
63-126 Support Assemblies — Removal .............................................. 63-00-00 67
63-127 Support Assemblies — Inspection and Repair ......................... 63-00-00 67
63-128 Support Assemblies — Installation ........................................... 63-00-00 69
63-129 Transmission Restraint .................................................................. 63-00-00 69
63-130 Transmission Restraint — Removal ......................................... 63-00-00 70
63-131 Transmission Restraint — Inspection and Repair .................... 63-00-00 70
63-132 Transmission Restraint — Installation ...................................... 63-00-00 70

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 3
BHT-206L4-MM-6

TABLE OF CONTENTS (CONT)

Paragraph Chapter/Section Page

Number Title Number Number

63-133 Isolation Support ............................................................................ 63-00-00 71

63-134 Removal.................................................................................... 63-00-00 71
63-135 Inspection and Repair............................................................... 63-00-00 71
63-136 Installation................................................................................. 63-00-00 71
63-137 Stop Mounts................................................................................... 63-00-00 71
63-138 Removal.................................................................................... 63-00-00 71
63-139 Inspection and Repair............................................................... 63-00-00 72
63-140 Installation................................................................................. 63-00-00 72
63-141 Drag Pins and Up Stops ................................................................ 63-00-00 73
63-142 Removal.................................................................................... 63-00-00 73
63-143 Inspection and Repair............................................................... 63-00-00 73
63-144 Installation................................................................................. 63-00-00 73

FIGURES

Figure Page
Number Title Number

63-1 Transmission System Troubleshooting............................................................... 8

63-2 Freewheeling Assembly Troubleshooting ........................................................... 11
63-3 Corrective Action for Contamination Found in Transmission.............................. 14
63-4 Main Driveshaft ................................................................................................... 18
63-5 Main Rotor Mast.................................................................................................. 21
63-6 Pylon ................................................................................................................... 25
63-7 Transmission Oil Pump, Screen, and Electrical Chip Detectors ......................... 30
63-7A Tachometer Generator Driveshaft — Inspection ................................................ 30B
63-7B Interconnect Adapter — Inspection..................................................................... 30C
63-7C Tachometer Generator Driveshaft — Removal/Installation ................................ 30D
63-8 Transmission Oil System Schematic .................................................................. 32
63-9 Transmission Oil Pump Removal Tool Application ............................................. 33
63-10 Transmission Oil Jets and Relief Valve .............................................................. 36
63-11 Transmission Oil Filter and Housing ................................................................... 39
63-12 Transmission Oil Filter Housing and Fittings ...................................................... 41
63-13 Transmission Oil System .................................................................................... 46
63-14 Transmission Oil Cooler...................................................................................... 49
63-15 Freewheeling Assembly...................................................................................... 51
63-16 Seal Cap, Clutch, and Shaft Assembly Inspection.............................................. 57
63-17 Transmission Link Assembly and Attachment .................................................... 60A
63-18 Transmission Arm and Flexure ........................................................................... 64
63-19 Transmission Restraint ....................................................................................... 68

63-00-00
Page 4 Rev. 13 25 FEB 2011 ECCN EAR99
 BHT-206L4-MM-6

TABLES

Table Page
Number Title Number

63-1 Maximum Allowable Leakage for Main Rotor Drive System Components.......... 7
63-2 Oil Servicing Drain Hose Usage ......................................................................... 16

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 5/6
 BHT-206L4-MM-6

MAIN ROTOR DRIVE SYSTEM

63-1. MAIN ROTOR DRIVE SYSTEM 63-2. ALLOWABLE LEAKAGE RATES FOR MAIN
ROTOR DRIVE SYSTEM COMPONENTS
Main rotor drive system provides a means of
transmitting power from engine to main rotor. Main Table 63-1 presents a measurement of allowable
rotor drive system includes the following components: leakage rates, which may be used in conjunction with
transmission, main rotor mast, main driveshaft, and main rotor drive system troubleshooting.
freewheel assembly.

Table 63-1. Maximum Allowable Leakage for Main Rotor Drive System Components

COMPONENT TYPE MAXIMUM LEAKAGE RATE

Transmission and Freewheel Static Input quill leakage shall not

Assembly exceed 5 drops per minute. Total
transmission leakage at all
sources, including freewheel
assembly, must not exceed
10 drops per minute.

Transmission and Freewheel Dynamic 1 quart per 3 hours of operating

Assembly time.

Tail Rotor Gearbox Static Input quill leakage shall not

exceed 2 drops per minute. Total
leakage at all sources must not
exceed 6 drops per minute.

Tail Rotor Gearbox Dynamic 50% of normal sight gauge oil

level indication per 3 hours of
operating time.

63-3. TROUBLESHOOTING MAIN ROTOR checks, and other detailed procedures in this and other
DRIVE SYSTEM chapters of this manual.

Figure 63-1 through Figure 63-3 provide 63-4. TROUBLESHOOTING TRANSMISSION

troubleshooting procedures for main rotor drive SYSTEM
system. They include indications of trouble, probable
causes, and corrective actions to be taken. Transmission troubleshooting procedures (Figure 63-1)
Troubleshooting tables should be used along with are a brief summary of oil system transmission trouble
general information and other sources of information that may be encountered. Conditions involving obvious
such as: transmission oil system schematic, electrical major damage are omitted, as are those that would
wiring diagrams, operational checks, serviceability require evaluation by a competent authority.

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 7
BHT-2061-4-MM-6

TRANS OIL PRESS caution light

ON, but pressure indicator

0
within limits.

TRANS OIL TEMP caution light ON

and/or transmission oil
Install direct reading gauge to verify temperature indicator indicates

Cam
high oil temperature.

a0+
YES oil pressure. Check light wiring system
for continuity and for grounding.
Replace faulty wiring. V
(Volume 10, Chapter 9696)

I Oil cooler relative temperature of oil

00.0
'integral thermal' YES and of two oil tubes from
bypass valve on to oil cooler, immediately
Remove and replace pressure switch. malfunction or oil Fafter ine shutdown. Replace oil

$a)
YES (Volume 10, Chapter 96)96 Perform cooler internal if thermal bypass valve is
B ground run for functional check.
BHT-206L4-FM-1
(BHT-206L4-FM-1)
passages
clogged.,
faulty.

T
Remove oil cooler and check visually.
Replace if clogged. Flush out oil tubes,
check electric chip detectors and
pump screen for metal particles.
If chips are found identify
M metal particles and perform
serviceability check.
Transmission oil pressure indicates
VU)

low, but TRANS OIL PRESS

caution light not ON.
YES
Remove and inspect oil jets.
Clean clogged jets, replace damaged jets.

Leak
'transmission
in
tubing from
to
YES Check tubing from T
transmission to indicator for
pressure indicator leaks. Repair or replace
or faulty tubing. Check oil pump screen, electric chip
indicator. YES detectors and oil filter. If any chips
8 are found, retain them in a clean
container for subsequent investigation.

'ti
Remove and replace indicator. If chips are found, identify
Perform ground run for metal particles and perform
M functional check. serviceability check.
/1(Volume 10, Chapter 95 95)

YES
Check wiring.
Check pressure switch. 7
206L4-M-63-1-1

Figure 63.1. Transmission system troubleshooting (Sheet 1 of 2)

63.00-00
Page 8
 BHT-206L4-MM-6

Transmission oil pressure low on

indicator and TRANS OIL PRESS
caution light ON.

m
YES
0
Check lubricating oil for
evidence of foaming which
TRANS OIL TEMP caution light ON,
but oil temperature indicator
within limits.

M
Check wiring system for
continuity and for grounding.
B can cause low fluctuating oil
pressure. Drain and refill to
YES
e Replace faulty wiring. Remove
and replace thermoswitch.
correct level with designated oil. (Volume 10, Chapter 9696) Perform
ground run for functional check.
(BHT 206L4-FM-1)

Check lubricating oil level. If oil YES

YES level is low enough to have Remove jets and inspect

e caused low pressure reading,

the transmission may have
been damaged. Perform
EN packings visually. Install oil
jets with new packings.
Transmission oil temperature
transmission serviceability check. indicates high, but TRANS
OIL TEMP caution light not on.
NJ
M M
Replace filter, service
transmission and make
Pressure serviceability check.
YES Check pressure relief valve
relief valve
out of adjustment,
leaking or
faulty.
8 for leaking. Replace packings
on relief valve body. Adjust
pressure relief valve. J
m
Faulty wiring,
faulty temperature
bulb, or faulty
YES
B
Check temperature bulb wiring
for continuity and grounding.
Replace faulty wiring.
(Volume 10, Chapter 96 96)
instrument.
Drain oil into clean container
and check visually. If it
appears that incorrect oil was NJ
used, save oil for subsequent Remove and replace
YES

YES
Transmission
filled with
improper
lubricating,
8 laboratory inspection. Notify
Product Support Department, Bell
Helicopter Textron to determine
whether conducting a
temperature bulb. Perform
ground run for functional
BHT-206L4-FM-1
check. (BHT-206L4-FM-1)

B Remove oil pump and inspect

visually. Replace faulty pump.
oil. transmission serviceability
check will suffice to make
the helicopter airworthy.
m
Remove and replace
instrument. (Volume 10, Chapter 9595)
Perform ground run for functional
check. (BHT206L4-FM-1)

2061-4-M-63-1-2

Figure 63.1. Transmission system troubleshooting (Sheet 2)

63.00.00
Page 9
 Bypass red indicator
in extended position.

YES Replace oil filter element

and perform serviceability
check.
7
NO

YES YES
Push red indicator in
and resume operation.

NO

Replace red indicator.

206L4M-63-1-3

Figure 63.1. Transmission system troubleshooting (Sheet 3)

63.00.00
Page 10
 BHT-206L4-MM-6

63-5. TROUBLESHOOTING TRANSMISSION beam arm. Therefore, no tuning should be required for
MOUNTS vibration isolation system. If there is a deterioration in
the isolation of 2/rev vibration, the following
Vibration isolation system is designed to isolate components should be checked for bond separation:
fuselage from main rotor vibration that occurs twice
per rotor revolution. This vibration has components • Nodal beam support assemblies
both in vertical direction and in-plane of rotor. In-plane
isolation is controlled by link geometry and spring rate
• Pylon restraint spring
of pylon restraint spring, neither of which is adjustable.
Vertical isolation is controlled by nodal beam spring
rate and amount of tuning weights added. All nodal • Nodal beam flexure assemblies
beams tested have been tuned for optimum 2/rev
isolation by adding 4 pounds of weight to each nodal • Pylon restraint support bushings

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 10A/10B
 131-IT-2061-4-MM-6

TRANS CHIP caution light segment

illuminated or metal particles

0-0
found on electric chip detector.

vi

M
Carry out serviceability
check or replace
freewheeling unit.
2061-4-M-63-2

Figure 63-2. Freewheeling assembly troubleshooting

63-6. TROUBLESHOOTING Refer to paragraph 63-8 for identification of

0U)

paragraph 63-8
FREEWHEELING ASSEMBLY. foreign material.

See figure 63-2 for troubleshooting

figure 63-2
63-8. IDENTIFICATION OF FOREIGN
freewheeling assembly. Take corrective MATERIAL.
action for oil contamination and metal
,..

particles, and make serviceability checks

(paragraph 63-12 and 63-16).
paragraph 63-12 63-16 MATERIALS REQUIRED

63-7. OIL CONTAMINATION. NUMBER NOMENCLATURE

c

Particles of foreign material found in C-407

C-407 Abrasive Pad
-..

-..

transmission or tail rotor gearbox electric chip

0..

F),

detectors, transmission filter, freewheeling C-431 Hydrochloric (Muriatic)

}W+

unit electric chip detector or in oil drained Acid

from systems may indicate that one or more
)_l

Q:3

C-432
C-432 Nitric Acid
parts have failed. These particles are not
`15

necessarily an indication that component is Sodium Chloride

.Q+

C-501
no longer serviceable (figure 63-3). Quantity,
figure 63-3
Q0)

source, form, and type of material found, and

service history of component must be taken 1. Inspect particles visually. If particles
0(0

into consideration. Service time accumulated cannot be recognized by color and hardness,
since new or overhaul, previous failures, and perform tests outlined in steps 2. through 6.
type of operation are important factors in
2. Following equipment is required to
O.E

determining further serviceability of the

component. Particles may be steel, silver, perform tests:
aluminum, magnesium, bronze, or phenolic.
E

63-00-00
Page 11
B HT-206 L4-M M-6

a. Permanent magnet. 6. Differentiate between copper and bronze

and magnesium as follows: Place a small
b. 50 percent by volume nitric acid (C-
C- C-432 in a test tube
amount of nitric acid (C-432)
and add a particle of material to be tested. If

>,o
432 and water solution.
432)

0-O
/L+
a bright green color is formed in acid, particle

0
c. 5 percent by weight sodium chloride (C-
C- is copper or bronze. If there is a rapid
501 and water solution.
501) emission of bubbles when particle is dropped

0
into acid, particle is probably magnesium.

0
d. Solution of hydrochloric (muriatic) acid
(C-431).
C-431
NOTE
e. Test tube. Phenolic and aluminum do not react

U.0
noticeable with nitric acid (C-432).
C-432
3. Check particles with permanent magnet.
Magnet will attract steel particles only.
63-9. TRANSMISSION OIL
4. Place a small quantity of 50 percent nitric CONTAMINATION.
C-432 solution in a test tube and add a
acid (C-432)
particle of material to be tested. If particle
does not dissolve, warm solution slightly. If WARNING
particle dissolves after warming, add a few
drops of 5 percent sodium chloride (C-501) C-501
solution. If white precipitate forms in the test
.-.

WHEN FOREIGN PARTICLES ARE

C'3

0
tube, the particle being tested is silver. Use of
(1)

any chemical product to remove silver plating

LARGE ENOUGH TO BE
La)

IDENTIFIED AS A PART OF A
is not permitted. Remove loose silver plating COMPONENT OF TRANSMISSION
using nylon web abrasive pad (C-407).
C-407
(La

OR MAST BEARING, REPLACE

TRANSMISSION OR MAST
NOTE BEARING AS INDICATED BY
LOCATION OF PARTICLE.
Silver plating flakes found in filter
>'i

during inspection is not cause for Transmission is equipped with a collector pan
rejection of transmission. If silver and chip detector immediately under upper
Q).

flakes are found, change oil, change mast bearing and a second chip detector in
con

filter, clean oil screen, flush sump. As a result, it is possible to isolate

C:3cq

transmission, and fill with lubricating source of metal particles to either ,mow
000-"(n

oil (Volume 2, Chapter 12). Silver

Chapter 12 transmission or mast assembly. If chips are
0

plating is a soft material used as an found on upper chip detector but not on
E

C'0

additional lubricant for gear meshing lower, a mast bearing problem is indicated. If
C

and, therefore, is not detrimental to chips are found on lower chip detector but not
transmission. on the upper, a transmission problem is
indicated.
5. Place a small amount of hydrochloric
0

C-431 in a test tube and add

(muriatic) acid (C-431)
a particle of material to be tested. If solution
releases bubbles rapidly, particle CAUTION 2

disintegrates, and a black residue forms,

(w)

particle being tested is probably aluminum or

..O

magnesium. Place a small amount of nitric WHEN TRANSMISSION OIL IS

C-432 in a test tube and add a second
acid (C-432) CONTAMINATED, OIL COOLER
_D)

AND FREEWHEELING UNIT MAY

-KO

particle of same material. If there is no

a)°

reaction with nitric acid, the particle is ALSO BE CONTAMINATED.

probably aluminum. TRANSMISSION OIL FILTER WILL
NORMALLY PRECLUDE THIS, BUT
U)=r

IF OIL FILTER HAS CLOGGED

ENOUGH TO CAUSE BYPASSING,

63-00-00
Page 12
 BHT-206L4-MM-6

THEN CONTAMINATION OF 2. For corrective action to be taken for

F-000
0<z

00Q

3-O
ABOVE COMPONENTS AND contamination of freewheeling unit, see figure
figure

(OD
ASSOCIATED OIL LINES CAN 63-3.
63-3
OCCUR.
63-11. TRANSMISSION SYSTEM OIL
1. Identify foreign particles found in SERVICING DRAIN HOSES.
transmission oil (paragraph 63-8).
paragraph 63-8
Operators who wish to obtain oil drain hoses

L"-
2. For corrective action to be taken for for transmission and/or freewheeling unit
contamination of transmission, see figure 63-
figure 63-
W00

should obtain part number from table

table 63-2
63-2.
33.

3. Remove and replace oil cooler and 63-12. SERVICEABILITY CHECK.

M._

identify removed oil cooler as being

contaminated (paragraph 63-100 and 63-102).
paragraph 63-100 63-102 63-13. TRANSMISSION SERVICEABILITY
TAT

CHECK.
4. Thoroughly flush all oil lines leading to
3'Q
°(Q
°`<
min

and from oil cooler and freewheeling unit 1. Drain lubricating oil from transmission and

3
which are to be reused. Clean restrictor in oil collect oil in a clean container (Volume 2,
supply line. Chapter 12).
Chapter 12

5. Disassemble and clean oil filter housing 2. Inspect, clean, and reinstall electric chip
D):

N70
Ca)

and install new filter element (paragraph 63-

paragraph 63- detector and self-closing valve (paragraph 63-
paragraph 63-
65, 63-66 and 63-67).
65 63-66, 63-67 43).
43

6. Disassemble and clean freewheeling 3. Inspect drained oil for metal particles. If

Ego
assembly (paragraph 63-103).
paragraph 63-103 any particles are found, identify (paragraph
paragraph
63-8 Perform corrective action (figure
63-8). 63-3).
figure 63-3
63-10. FREEWHEELING UNIT OIL
00)

-r1

4. Inspect oil filter bypass indicator for

(J)
CONTAMINATION. bypass indication.

5. Remove and inspect oil filter element to

(-FRO.
WARNING determine extent of entrapped contaminants
(DD

and for damage to element.

6. If gross contamination of filter element
r'.

,3.'
WHEN FOREIGN PARTICLES ARE
LARGE ENOUGH TO BE and indication of filter bypass are found,
..'

IDENTIFIED AS A PART OF A remove and replace oil cooler and identify as

°:p,
COMPONENT OF FREEWHEELING being contaminated. Thoroughly flush all oil
=,Z

UNIT, REPLACE FREEWHEELING lines leading to and from oil cooler and
=F-

UNIT (PARAGRAPH 63-103). freewheeling unit which are to be reused.

Remove and inspect freewheeling lube
.................. restrictor on left side of cabin roof.
.....

'CAUT;ON' 7. If only minor contamination of filter

-s.

r+.

element is found and bypassing of filter is not

FOREIGN PARTICLES indicated, then procedures outlined in step 6.
DISCOVERED IN FREEWHEELING are not required. Install new filter element.
Remove and inspect oil jets and freewheeling
<<<

UNIT, MAY OR MAY NOT MEAN

Z=O

THAT TRANSMISSION IS lube restrictor on left side of cabin roof.

CONTAMINATED.
8. Remove, inspect, clean, and reinstall oil
1. Identify foreign particles found in screen (paragraph
paragraph 63-40 63-41 and 63-42).
63-40, 63-41, 63-42
freewheeling assembly oil (paragraph 63-8).
paragraph 63-8

63-00-00
Page 13
131-IT-2061-4-MM-6

STEEL CONTAMINATION

STEEL Detail A STEEL

Fuzz, fine hair-like particles. More than 10 flakes not exceeding
1164 inch (0.39 mm) in diameter and 114
inch (6.35 mm) in length found on

C:+
the upper chip detector only.
DETAIL A
M

i
Result
or normal
wear may have YES
exaggerated
B Replace mast bearing and

<.D)
appearance
because perform serviceability check.
of oil.

DETAIL B
Detail B&C
Particles in splinter or
More than 10 flakes not exceeding

--d#
granular form. 1164 inch (0.39 mm) in diameter and 1/4
inch (6.35 mm) in length found on
any chip detector.

i /
YES Perform serviceability check.

DETAIL C
B Replace transmission/
freewheeling unit if
necessary.
B
YES
e transmission/
Efreewheeling unit as
pplicable.

Detail D
Thin flakes not exceeding 1/64 inch (0.39 mm)
in thickness and 1/ 16 inch 0.58 mm) in
length. Quantity not to exceed 10
flakes.

DETAIL D
WHEN SMALL AMOUNTS OF METAL PARTICLES ARE FOUND IN

0=teO
TRANSMISSION OR FREEWHEELING ASSEMBLY COMPONENTS, OR
THERE IS SOME DOUBT ABOUT THE SUITABILITY OF THE COMPONENT
I Perform serviceability check. FOR CONTINUED SERVICE, A SERVICEABILITY CHECK SHALL BE
Replace transmission/freewheeling CONDUCTED. SERVICEABILITY CHECKS ARE A SPECIFIC REQUIREMENT
unit if necessary. / WHEN DIRECTED IN THE TROUBLESHOOTING PROCEDURES OR THIS
FIGURE.
206L4-M-63-3-1

Figure 63-3. Corrective action for contamination found In transmission (Sheet 1 of 2)

63.00.00
Page 14
 BHT206L4-MM-6

206L4_MM_63_0003b

Figure 63-3. Corrective Action for Contamination Found in Transmission (Sheet 2 of 2)

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 15
131-IT-2061-4-MM-6

9. Fill transmission to proper level (Volume

0
2, Chapter 12).
Chapter 12

Table 63-2. Oil servicing drain hose usage

CHIP DETECTOR PART NO. COMPONENT DRAIN HOSE PART NO.
B-3188B Main Transmission DB-3188
B-4713 Freewheeling Unit
NOTES:
zL Drain hoses listed are equipped with a standard hose length of 24 inches (610 mm). A
longer length drain hose may be obtained when ordering by adding a dash number to

O0(
drain hose part number which equals length of hose desired in inches. Example: A DB-
3188-50 drain hose would be 50 inches (1300 mm) in length.

.-.
(on
10. Prepare helicopter for ground run-up. NNNNNNNNN

0,0
Ground-run helicopter for one hour (BHT-
BHT- 'CAUTI'ON;
206L4-FM-1)
206L4-FM-1 and accomplish following at
completion of run:
FOREIGN PARTICLES

w>l--

_=a_
a. Remove electric chip detectors and DISCOVERED IN FREEWHEELING
inspect for metal particles. ASSEMBLY, MAY OR MAY NOT

0
MEAN THAT TRANSMISSION AND
b. Drain lubricating oil from transmission MAST BEARING ARE
and collect oil in a clean container. CONTAMINATED.

+..
c. Inspect lubricating oil for foreign 2. Inspect, clean, and reinstall electric chip

0(a
0

0
material. detector and self-closing valve (paragraph 63-
paragraph 63-

[I)
45).
45
d. If this inspection is being conducted

mom
because of metal particle contamination and 3. Inspect drained oil for metal particles. If

((f
number of metal particles has increased or if any particles are found identify (paragraph
paragraph

"--

C15
any particles are found which are large 63-8 Perform corrective action (figure
63-8). 63-3).
figure 63-3

Q-0)
enough to be identified as chips from a gear
or bearing, replace transmission. If number of 4. Inspect transmission oil filter for metal

a.-.
particles has decreased and only minute particles. If any particles are found identify
particles are found, perform steps 1. through (paragraph 63-8). Perform corrective action
paragraph 63-8

=='3

((f
10.c. again. If particles are found, remove (figure 63-3).
figure 63-3
transmission and freewheeling unit and repair

-i0
or overhaul as required (BHT-206L-CR&0). 5. Thoroughly flush return line from

(11
freewheeling assembly to transmission. Flush
63-14. FREEWHEELING ASSEMBLY hose with clean lubricating oil (Volume 2,
SERVICEABILITY CHECK. Chapter 12).
Chapter 12

1. Drain lubricating oil from freewheeling 6. Fill transmission to proper level with
assembly and collect oil in a clean container lubricating oil (Volume 2, Chapter 12).
Chapter 12
(Volume 2, Chapter 12).
Chapter 12
7. Prepare helicopter for ground run-up.

_-_
((DD
Ground run helicopter for one hour (BHT-
BHT-
206L4-FM-1)
206L4-FM-1 and accomplish following at
completion of run:

a. Remove electric chip detector and

Sao

c
-0a)
inspect for metal particles (steps 2. and 3.).
63.00.00
Page 16
 BHT-206L4-MM-6

b. Drain 1 quart (0.9 L) of lubricating oil from 1. Remove cowling and fairings for access to main
freewheel housing and collect oil in a clean container driveshaft (Chapter 71).
(Chapter 12).
2. Remove screws (9, Figure 63-4) and washers (8)
c. Inspect lubricating oil for foreign material from cover (7).
(step 3).
3. Remove six nuts (4), 12 steel washers (3), and
d. If this inspection is being conducted because six bolts (2).
of metal particle contamination, and number of metal
particles has increased, or if any particles are found 4. Remove six nuts (12), steel washers (13), and
that are large enough to be identified as chips from bolts (14).
bearing, clutch, or shaft, replace freewheel assembly.
If number of particles has decreased and only minute
particles are found, add lubricating oil to freewheel 5. Assemble each half of tool set by connecting two
brackets and cable assemblies with turnbuckle.
housing (Chapter 12), and release helicopter for
continued operation.
6. Install each tool set half by installing bracket in
groove of forward and aft coupling flexframes (11 and
63-15. MAIN DRIVESHAFT
17) of driveshaft (10).

Main driveshaft consists of flexible couplings installed

between freewheel assembly and transmission input NOTE
drive adapter flange. Flexible couplings accommodate Engine to transmission driveshaft should be
movement between transmission and freewheel compressed only to extent necessary for
assembly. removal.

63-16. MAIN DRIVESHAFT — REMOVAL 7. Free driveshaft (10) from freewheel unit adapter
(15) and transmission adapter (1) by turning
turnbuckles while holding hex nuts on tool set to
SPECIAL TOOLS REQUIRED compress driveshaft.

NUMBER NOMENCLATURE
NOTE
206-240-003-101FM, Driveshaft Tool Set As turnbuckles are evenly tightened on
206-240-003-101FM-1, both sides, main driveshaft may not detach
407-240-009-101, from adapters on both ends. If this occurs
407-240-009-101FM, ease off on turnbuckles and allow
or driveshaft to return to install position. Two
407-240-009-121 bolts should be installed in diametrically
opposed locations through both end fittings
of driveshaft and adapters of transmission
input quill and freewheel unit. Four nuts
WARNING must be installed on four bolts fingertight.
Limited freeplay in these temporary bolts
will force detachment of driveshaft from
DRIVESHAFT ASSEMBLY IS NOT TO BE adapters on both ends as pressure is
TAKEN APART AND FASTENERS ARE reapplied with turnbuckles
NOT TO BE DISTURBED. DISASSEMBLY
OR DISTURBING FASTENERS IS CAUSE 8. Remove driveshaft (10) and place on suitable
FOR REPLACEMENT. surface.

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 17
BHT-206L4-MM-6

"TORQUE
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)

1. Transmission adapter
2. Bolt
Steel washers
(w)

3.
4. Nut
5. Forward firewall
6. Gasket
7. Cover
8. Washer
9. Screw
10. Main driveshaft
11. Coupling - (forward)
12. Nut
13. Steel washer
14. Bolt
15. Freewheeling assembly
16. Spacer
-16
17. Coupling - (aft)

Figure 63-4. Main driveshaft

63-00-00
Page 18
 BHT-206L4-MM-6

1. Assemble each half of tool set by connecting two

63-17. MAIN DRIVESHAFT — CLEANING
brackets and cable assemblies with turnbuckles.

2. Install each tool set half by installing bracket in

MATERIALS REQUIRED
groove of forward and aft coupling flexframes (11 and
Refer to BHT-ALL-SPM for specifications. 17) of driveshaft (10, Figure 63-4).

NUMBER NOMENCLATURE
NOTE
C-304 Drycleaning Solvent
Engine to transmission driveshaft should be
compressed only to extent necessary for
installation.
WARNING
3. Install driveshaft (10) between transmission input
adapter (1) and freewheel unit adapter (15).
DRIVESHAFT ASSEMBLY IS NOT TO BE
TAKEN APART AND FASTENERS ARE
NOT TO BE DISTURBED. DISASSEMBLY NOTE
OR DISTURBING FASTENERS IS CAUSE
FOR REPLACEMENT. To aid in alignment a bolt can be installed
through driveshaft fittings and transmission
1. Clean driveshaft with drycleaning solvent input adapter (1) and freewheel unit
(C-304). adapter (15) before tool set is removed.

4. Turn turnbuckle while holding hex nuts on tool set

63-18. MAIN DRIVESHAFT — INSPECTION
to loosen bracket and cable assemblies. Remove tool
set from driveshaft.
1. Visually inspect main driveshaft for corrosion,
surface damage, cracked flexures, and loose
hardware. Refer to BHT-206L-CR&O for damage 5. Line up bolt holes in aft end fitting of driveshaft
limits. (10) with freewheel unit adapter (15) bolt holes.

2. If a driveshaft is found with a loose bolt or nut, or

red colored powder is observed, or if a crack is found,
WARNING
remove driveshaft from service and contact Product
Support Engineering.
CORRECT TORQUING OF NUTS (4 AND
63-19. MAIN DRIVESHAFT — INSTALLATION 12) IS CRITICAL TO FLIGHT SAFETY.

SPECIAL TOOLS REQUIRED 6. Install six bolts (14) through aft end of freewheel
unit adapter (15), spacer (16) and aft end fitting of
driveshaft (10). Install six steel washers (13) and six
NUMBER NOMENCLATURE nuts (12). Torque nuts 50 to 70 inch-pounds. (5.65 to
206-240-003-101FM, Driveshaft Tool Set 7.91 Nm).
206-240-003-101FM-1,
407-240-009-101, 7. Install six bolts (2) through transmission input
407-240-009-101FM, adapter (1) and forward end fitting of driveshaft (10).
or
Install 12 steel washers (3) and six nuts (4). Torque
407-240-009-121
nuts 50 to 70 inch-pounds. (5.65 to 7.91 Nm).

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 19
BHT-206L4-MM-6

2. Remove main rotor hub and blades (Chapter 62).

CAUTION 3. Disconnect collective and cyclic flight controls

from swashplate (Chapter 67).
MAKE SURE COVER (7) IS NOT
DEFORMED AND THERE IS 4. Remove swashplate from mast (Chapter 67).
CLEARANCE BETWEEN IT AND MAIN
DRIVESHAFT (10).
5. Temporarily install main rotor mast nut on main
rotor mast (Chapter 62). Attach lifting eye clevis
8. Install cover (7) and serviceable gasket (6) on (T101897) to eye in main rotor mast nut. Attach
forward side of forward firewall (5) and secure with hoisting cable to lifting eye clevis and hoist.
screws (9) and washers (8).

6. Lift main rotor mast from transmission top case

9. Install cowling and fairings (Chapter 71). (2, Figure 63-5) and transmission.

63-20. MAIN ROTOR MAST 7. Place main rotor mast on suitable support.
Remove hoisting cable and lifting eye clevis. Remove
Main rotor mast is attached to transmission by a mast main rotor mast nut (Chapter 62).
locking plate and studs in top of transmission case.
8. Cover opening in top of transmission with hoisting
ring (206-240-001-101) to prevent entrance of foreign
SPECIAL TOOLS REQUIRED material or for hoisting transmission.

NUMBER NOMENCLATURE 63-22. MAIN ROTOR MAST — CLEANING

206-240-001-101 Hoisting Ring

T101897 Lifting Eye Clevis MATERIALS REQUIRED

Commercial Hoist, 600 Pound Refer to BHT-ALL-SPM for specifications.

(272 kg) Capacity,
Minimum NUMBER NOMENCLATURE

Commercial Hoisting Cable, C-304 Drycleaning Solvent

600 Pound (272 kg)
Capacity, Minimum

CAUTION
63-21. MAIN ROTOR MAST — REMOVAL

IF MAIN ROTOR MAST IS REMOVED, DO

NOTE NOT ALLOW BEARINGS TO SPIN.
Main rotor mast may be removed from
transmission while transmission is mounted DO NOT ALLOW SOLVENT TO CONTACT
on helicopter. LIP SEAL.

1. Remove cowling for access to transmission Clean main rotor mast with drycleaning solvent
(Chapter 71). (C-304) and dry with filtered compressed air.

63-00-00
Page 20 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-6

63-23. MAIN ROTOR MAST — INSPECTION AND MATERIALS REQUIRED

REPAIR
Refer to BHT-ALL-SPM for specifications.

MATERIALS REQUIRED NUMBER NOMENCLATURE

C-411 Steel Wool

Refer to BHT-ALL-SPM for specifications.
C-423 Abrasive Paper
NUMBER NOMENCLATURE
C-464 India Stone
C-108 Cadmium Plating
Solution
1. Visually inspect the main rotor mast for
C-204 Epoxy Polyamide mechanical damage and corrosion
Primer (BHT-206A/B/L-Series-CR&O).

63-00-00
ECCN EAR99 1 JUN 2012 Rev. 16 Page 20A/20B
 B HT-206 L4- M M-6

1. Stud nut and washers

2. Transmission top case
3. Seal bearing plate

206L4-M-63-5-1

Figure 63-5. Main rotor mast (Sheet 1 of 2)

63-00-00
Page 21
..t
BHT-206L4-MM-6

MAST ASSEMBLY
P/N 206-040-014-103

PACKING

206L4-M-63-5-2

Figure 63-5. Main rotor mast (Sheet 2)

63-00-00
Page 22
 BHT-206L4-MM-6

a. Polish out mechanical damage with fine 6. Carefully guide lower end of main rotor
abrasive cloth or paper (C-423)
C-423 and fine India mast into lower mast bearing and position
stone (C-464).
C-464 seal bearing plate (3, figure 63-5) over studs
figure 63-5
on transmission top case (2). Press main
b. Remove surface corrosion using fine rotor mast and seal bearing plate (3) in place.
steel wool (C-411).
C-411
7. Remove hoisting cable and T101897

5'm
2. After cleanup, exterior surfaces of main lifting eye clevis. Remove main rotor mast nut
+-'

rotor mast above seal bearing plate (3, figure

figure (Chapter 62).
Chapter 62
63-5) should be brush cadmium plated using
(0-am-m
(/)

63-5
brush cadmium plating solution (C-108)
C-108 per 8. Install swashplate over main rotor mast

.0+
(BHT-ALL-SPM).
BHT-ALL-SPM If surfaces cannot be and align with studs in top case. Ensure
cadmium plated, apply two spray coats of collective lever on swashplate is aligned with

-.C
C-204 for corrosion protection until
primer (C-204) collective flight control linkage (Volume 8,
plating can be accomplished. Do not use Chapter 67).
Chapter 67
primer below seal bearing plate (3).
9. Install new washers and new stud nuts (1,

n(0
63-24. INSTALLATION. figure 63-5) on each stud of transmission top
figure 63-5

N,-,0

0'O
case (2) and torque 100 to 140 inch-pounds
(11.30 to 15.82 newton-meters).
MATERIALS REQUIRED
10. Complete installation of swashplate and

,,.
NUMBER NOMENCLATURE collar set (Volume 8, Chapter 67).
Chapter 67

C-030
C-030 Turbine Oil 11. Install main rotor hub and blades
(Chapter 62).
Chapter 62
1. Remove 206-240-001-101 hoisting ring or
0

cover from top of transmission. 12. Connect collective and cyclic flight
c
V--

(U)

controls to swashplate (Volume 8, Chapter

Chapter
2. If a new or repaired transmission has 67).
67
(-o

been installed, pour one quart (0.9 liter) of

"'.

C-030 into top of transmission to

turbine oil (C-030) 13. Service transmission to proper level
lubricate gears and splines with a coating of (Volume 2, Chapter 12).
Chapter 12
oil.
14. Install cowling (Volume 9, Chapter 71).
Chapter 71
NOTE
1--

63-25. TRANSMISSION.
Mast 206-040-014-103 will require
r-.C

two packings, one in lower groove

and one against shoulder of liner Transmission provides a two-stage reduction
refer to figure 63-5.
figure 63-5
of 15.23 to 1.0 (6000 to 394 rpm). First stage
is a bevel gear arrangement with 3.26 to 1.0
((DD

3. Lubricate new packing with turbine oil (C-

C-
reduction; second stage reduction is obtained
(uE

030 and install on mast bearing liner.

030) with a planetary gear train providing 4.67 to
1.0 reduction. A complete hydraulic system
4. Prepare for lifting main rotor mast power pack is mounted forward of
E

(paragraph 63-21, step 5.).

paragraph 63-21
transmission and hydraulic pump is driven by
transmission accessory gear. Accessory drive
0

UST

5. Install assembled main rotor mast through gear provides a 1.42 to 1.0 reduction.
coca)

opening in top of transmission. Line up lower Transmission is mounted on cabin roof and
mast spline teeth with spline teeth in
incorporates nodal beam suspension and
planetary carrier. transmission restraint. Transmission is
mounted on two nodes and normal vibrations
o

and vertical movement are absorbed by a

E

flexure assembly.

63-00-00
Page 23
 BHT-2061-4-MM-6

SPECIAL TOOLS REQUIRED 9. Disconnect electrical wiring harness from

3.3
oil temperature bulb (8),oil thermoswitch
(10), lower and upper electric chip detectors
NUMBER NOMENCLATURE (30 and 34) and from hydraulic pump

(D<
--0
Commercial Hoist, 600 Lb (272 kg)
tachometer generator (29). Separate electrical
Capacity, Minimum cabling and clamps from attachment points on
transmission. Relocate electrical cabling to

-0-
+L-
Hoisting Cable, 600 Lb prevent interference during removal of

°)m
Commercial
(272 kg) Capacity, transmission (26).
Minimum
10. Remove lower electric chip detector (30)
T1 ID2102 Dehydrator from transmission (26) and drain lubricating

(En
oil (Volume 2, Chapter 12).
Chapter 12
I 206-240-001-101 Hoisting Ring
11. Remove hydraulic pump
generator (29) separately or together
- tachometer
63-26. REMOVAL. (paragraph 63-32 and Volume 4, Chapter
paragraph 63-32 29).
Chapter 29
It is recommended that hydraulic pump be

a_0
removed with hydraulic hoses attached to

(TLS
1. Disconnect battery and remove external
_.O

prevent draining hydraulic system. Discard all

-LO
power, if used.

0)U
gaskets if parts are separated.
2. Remove fairings and cowling to gain
access to work area (Volume 9, Chapter 71). 12. Disconnect transmission oil inlet and

=~m
Chapter 71
outlet hoses from two unions (7) on oil filter

E
O..
3. Remove main rotor hub and blades (1, and housing (9). Install protective caps and
figure 63-6) and pitch links (3) (Chapter
figure 63-6 62).
Chapter 62 plugs to prevent system contamination.
13. Disconnect oil pressure outlet hose from
NOTE oil pressure outlet reducer (17) located on left
rear of transmission (26). Disconnect
Transmission may be removed with freewheeling return oil hose from
swashplate, support and mast freewheeling oil return union (18) located just
installed. If this procedure is to be inboard of left stop mount (23). Install
used omit steps 4. and 5. protective caps and plugs to prevent system
contamination.
4. Remove collar set and idler (4) with boot,
and remove swashplate and support (5)
L()

14. Check hoist alignment with vertical

(SS
(Volume 8, Chapter 67).
Arm

Chapter 67 centerline of transmission (26). Remove all

slack from hoist and provide sufficient tension
5. Remove mast (2) (paragraph 63-21).
paragraph 63-21 to support transmission (26).
c

6. Install 206-240-001-101 hoisting ring on 15. Disconnect transmission restraint (16)

studs of transmission (26) and secure or from isolation support on transmission deck
U)..

reinstall mast nut if mast is installed. Attach by removing nut (15), washers (12, 13, and
-(Q

suitable hoist and clevis to lifting device 14), and bolt (11).
Chapter 7 7). Align hoist with
(Volume 2, Chapter
centerline of mast or transmission. Remove
...

16. Remove nuts (19) and stops (20) from

0

all slack from hoist. two drag pins (28).

7. Remove main driveshaft (paragraph 63-

paragraph 63- 17. Disconnect four link assemblies (27)
16).
16 from four link attachments (25) by removing
0

nuts (21) and support washers (22).

8. Disconnect cyclic control tubes (6 and 31,
figure 63-6) and collective control tube (32)
figure 63-6 18. Adjust tension on hoist and transmission
from bellcranks mounted on forward side of (26) and pull four link assemblies (27)
transmission (26) (Volume 8, Chapter 67).
Chapter 67 outboard from link attachments (25),
63-00-00
Page 24
 BHT-206L4-MM-6

1. Main rotor hub and blade

2. Mast
3. Pitch link
4. Collar set and idler
5. Swashplate and support
6. Cyclic control tubes
7. Union
8. Oil temperature bulb

3s;
9. Oil filter and housing
10. Oil thermoswitch
11. Bolt
12. Special washer
13. Special washer (maximum of three)
14. Steel washer
15. Nut
16. Transmission restraint
17. Reducer (oil pressure outlet)

11 12
14
13

*,& TORQUE
260 TO 360 IN-LBS
(29.3 TO 44.0 Nm)
15

18. Union (freewheeling oil return)

19. Nut
20. Stop
21. Nut
22. Support washer
23. Stop mount
24. Bearing washer
25. Link attachment
26. Transmission
27. Link assembly
28. Drag pin
29. Hydraulic pump -
tachometer generator
30. Electric chip detector (lower)
TORQUE 31. Cyclic control tube
36 TO 2041N-LBS 32. Collective control tube
(4.07 TO 23.0 Nm) 33. Collective link
34. Electric chip detector (upper)

206L4-M-63-6

Figure 63-6. Pylon

63-00-00
Page 25
BHT-206L4-MM-6

disconnect transmission (26) from helicopter. 63-28. INSPECTION AND REPAIR.

_-3
Check that all attachments between
transmission (26) and helicopter have been
,`_

C()
COT

MATERIALS REQUIRED
disconnected.

19. Carefully hoist transmission (26) from NUMBER NOMENCLATURE

_.Q.-+
coo
helicopter while providing adequate clearance

0-0
for two stop mounts (23) to clear drag pins C-100
C-100 Chemical Film Material
(28).
C-423
C-423 Abrasive Cloth or
20. Place transmission (26) on workbench or Paper
other suitable support.
:""
,:+

21. Remove and store oil filler cap, with NOTE

lanyard attached, in a sealed plastic bag.
QOM
0E0

Install T102102 dehydrator while transmission Total static or dynamic input quill
(1)

is removed. leakage should not exceed 10 drops

per minute. Total transmission
leakage at all sources must not

Eli
NOTE exceed 15 drops per minute.
An appropriate log book entry must
a)0

0(n
Ors

1. Inspect lower and upper electric chip

UN.
be made upon installation of detectors (7 and 25, figure 63-7) for metal
figure 63-7

Oa)
dehydrator.

(n"
particles and their self-closing valves for
leakage.
22. If transmission is removed for extended
maintenance, shipping or storage, perform
(u+

2. Inspect upper and lower cases of

(-0
BHT-206L-CR&O and BHT-ALL-
preservation (BHT-206L-CR&O BHT-ALL-
transmission (11) for nicks, scratches, and

-0)v
0_X}
SPM).
SPM
damage. Damage not exceeding 0.010 inch
0{'c

(0.254 mm) on aluminum top case and 0.020

63-27. CLEANING. inch (0.508 mm) on magnesium lower case
11/

.CE

may be blended out with 400 abrasive cloth or

MATERIALS REQUIRED paper (C-423).
C-423

NUMBER NOMENCLATURE NOTE

For damage exceeding above limits,
0)06

C-304
C-304 Solvent
refer to BHT-206E-CR&O
BHT-206E-CR&O manual.

a. Touchup treatment on magnesium parts

CAUTION shall be restricted to small areas that have
dichromate coating removed due to damage
and minor rework.
EXERCISE CAUTION TO PREVENT
SOLVENT FROM CONTACTING b. Apply chemical film material (C-100)
C-100 to
r0<
o=m
Dam

-<D

'03(-}

FLIGHT, CONTROL SYSTEM repaired aluminum and magnesium areas and

'7l

SEALED BEARINGS. a protective paint finish per (BHT-ALL-SPM).

BHT-ALL-SPM

Clean transmission with solvent (C-304)

C-304 and 3. Visually inspect all studs, attachments,
soft bristle brush. Dry with filtered hoses, and electrical cabling for condition and
D))

compressed air. security.

4. Visually inspect external components on

E°'
0

transmission for evidence of oil leakage and

damage.
63-00-00
Page 26
 BHT-206L4-MM-6

5. Visually inspect components of 6. Align transmission restraint (16) on

-l.

BCD
transmission mounts (Nodal Beam) and isolation support. Install bolt (11) with special

0)z
transmission restraint (16, figure 63-6) for
figure 63-6 washer (12) under bolthead, using up to three

<<O
condition and security. special washers (13) to fill gap between

O-0

'_(D
isolation support and restraint (16). Then

pp)
install two steel washers (14) and nut (15).

(Ti
6. Visually inspect flight control bellcranks
and supports for condition and security Torque nut (15) 260 to 390 inch-pounds (29.4
(Volume 8, Chapter 67).
Chapter 67 to 44.0 newton-meters) with nodal arms in
down stop position.
63-29. INSTALLATION. 7. Disconnect hoist from hoisting ring or

0
0
clevis.
MATERIALS REQUIRED
8. Position stops (20) on spindle of drag

Q.=
pins (28). Install nuts (19) and turn until

O.0
NUMBER NOMENCLATURE contact is made with stops then turn nuts an
C-030
C-030 Turbine Oil additional 90 to 120 degrees.

C-405 Lockwire 9. Remove protective caps and plugs.

0330h
C-405

a.-
Connect freewheeling oil return hose to

0
freewheeling oil return union (18) located by

((DD
stop mount (23). Clamp freewheeling hose to

O-0
NOTE
left arm of transmission restraint (16).
Remove T102102 dehydrator if
installed and reinstall filler cap. 10. Connect oil pressure outlet hose to oil

wQD
pressure outlet reducer (17) located above

+..
1. Install 206-240-001-101 hoisting ring to left stop mount (23) and aft of pressure relief
,.+

top case studs on transmission or reinstall valve.

main rotor mast and mast nut and attach
0+.

suitable hoisting clevis. Attach hoist to 11. Connect oil inlet and outlet hoses to
mtg.

(°n
hoisting ring or clevis and carefully lift unions (7) on oil filter and housing (9). Ensure

Ill
L++

°(°
transmission into position for installation in oil inlet hose is connected to forward union
.O«

(On

helicopter. and outlet hose to aft union. Clamp inlet and

outlet hoses to right aft link assembly (27).
(°n

2. Install transmission restraint (16, figure

figure
-
0'a

63-6 to stop mounts (23), if removed

63-6) 12. Install hydraulic pump tachometer
(paragraph 63-144).
paragraph 63-144 generator (29) (paragraph 63-33 and Volume
paragraph 63-33
4, Chapter 29).
Chapter 29
3. Check bore of two stop mounts (23) to
--a
3'+

0-0)
30.
0

ensure serviceable packings are bonded in 13. Route electrical cabling from under
-
0.2

lower radius groove. hydraulic pump tachometer generator (29)

_-E0
O'0

up along external oil tube to top case of

C(0

0'C

Insert a bearing washer (24) on shank of transmission (26). Clamp electrical cabling at
SDI
4.
each link attachment (25). Carefully lower three equally spaced locations along external
.On

transmission (26), guiding stop mounts (23) oil tube.

_=NWO

D)0

over drag pins (28) and transmission restraint

(16) into isolation support. Lower transmission a. Connect D1 B20 and D2B20N electrical
=(D
(N)

(26) until four link assemblies (27) may be wires to oil temperature bulb (8) on oil filter
positioned on splindles of four link and housing (9). Secure connector with
U-0

attachments (25). C-405 to oil temperature bulb (8).

lockwire (C-405)
Con

5. Secure four link assemblies (27) to link b. Connect D3G20 electrical lead to oil
attachments (25) with support washers (22) thermoswitch (10) on oil filter and housing (9).
-(n
_-.
((f

and nuts (21). Torque nuts (21) 36 to 204 Torque nut on thermoswitch 6 inch-pounds
inch-pounds (4.07 to 23.0 newton-meters). (0.56 newton-meters).

63-00-00
Page 27
BHT-206L4-MM-6

b. Cyclic and collective flight control system

c. Connect electrical lead (W62C20) to upper operation normal with HYD BOOST ON.
electric chip detector (34) and electrical lead
(W62D20) to lower electric chip detector (30).
c. Check transmission (26) for oil leaks.

14. Remove hoisting ring from top of transmission

d. If a new, overhauled, or internally repaired
(26), if used, and pour 1 quart (0.9 L) of turbine oil
transmission has been installed, perform run-in checks
(C-030) into transmission for initial lubrication of upper
and inspection (paragraph 63-30).
gears and bearings. If mast was not removed from
transmission omit this step and step 15.
24. Reinstall fairings and cowling (Chapter 71).

15. Install mast (2) in top of transmission (26)

63-30. TRANSMISSION — OPERATIONAL
(paragraph 63-24).
CHECK

16. Install oil filler cap lanyard and bracket to

swashplate mounting stud. Install swashplate and NOTE
support (5) and collar set and idler (4) (Chapter 67). Perform this operational check after each
installation of a new, overhauled, or
17. Connect cyclic control tubes (6 and 31, internally repaired transmission.
Figure 63-6) and collective control tube (32) to
bellcranks mounted on forward side of transmission 1. Perform ground run-in cycle for 20 minutes
(26). Connect collective link (33) to collective lever and (BHT-206L4-FM-1). Monitor indicators to ensure oil
swashplate and support (5) (Chapter 67). pressure and temperature stabilize and remain within
limits. Adjust pressure as required (Figure 63-1).

18. Install main motor hub and blades (1) and pitch
2. After shutdown, accomplish following
links (3) (Chapter 62).
requirements:

19. Install main driveshaft (paragraph 63-19). a. Remove and inspect electric chip detectors for
metal particles. If metal particles are found, investigate
20. Service transmission (26, Figure 63-6) to proper to determine cause (Figure 63-3).
level and hydraulic reservoir to proper level
(Chapter 12). b. Remove and inspect oil filter for metal
particles.
21. Check rigging of collective and cyclic flight control
systems (Chapter 67). c. Remove and inspect No. 1 and No. 2 oil jets
and freewheel lube restrictor on left side cabin roof.
Visually inspect jets for distortion, cracks, cut
22. Check transmission (26, Figure 63-6) for correct packings, and foreign material.
installation of all parts, mounting hardware, clamping,
and safety devices. d. Visually inspect oil at sight gauge for
discoloration and contamination.
23. Prepare helicopter for ground run-up. Ground run
helicopter (BHT-206L4-FM-1) and accomplish the e. Inspect transmission and attached
following: components for oil leaks.

a. Transmission oil pressure. Verify that TRANS 63-31. TACHOMETER GENERATOR

OIL PRESS caution segment light is out with
increasing pressure at 38 PSI (262 KPa) maximum A tachometer generator for main rotor RPM indicating
and ON with decreasing pressure at 30 ±2 PSI (207 system is mounted on transmission oil pump and
±14 kPa) operating pressure in green arc. hydraulic pump.

63-00-00
Page 28 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-6

63-32. TACHOMETER GENERATOR — 63-32B. TACHOMETER GENERATOR —

REMOVAL 600-HOUR/12-MONTH INSPECTION AND
LUBRICATION INTERVAL
1. Disconnect electrical leads to tachometer
generator (20, Figure 63-7).

SPECIAL TOOLS REQUIRED

2. Remove nuts (15) and aluminum washers (14),
and remove tachometer generator (20) and hydraulic
pump (18) from transmission (11). NUMBER NOMENCLATURE

3. Remove nuts (17) and aluminum washers (16). Item No. 1 Workaid
Remove tachometer generator (20) from hydraulic
pump (18). Remove and discard gaskets (19 and 21). Item No. 2 Workaid

NOTE:
4. If tachometer generator (20) and hydraulic pump
(18) are not to be reinstalled, secure oil pump (13) to For Item No. 1 and No. 2, refer to Figure 63-7C.
transmission (11) with spacers or extra aluminum
washers (14 and 16) and nuts (15 or 17).

63-32A. TACHOMETER GENERATOR — MATERIALS REQUIRED

INSPECTION
Refer to BHT-ALL-SPM for specifications.
1. Inspect the tachometer generator (20,
Figure 63-7) for general condition. NUMBER NOMENCLATURE

2. On S/N 52001 through 52263 Pre TB C-304 Drycleaning Solvent

206L-03-211, inspect the transmission oil pump shaft
splines and tachometer generator splines for wear and C-561 Grease
damage. For damage limits, refer to BHT-206L-CR&O,
Chapter 63.
1. Remove the tachometer generator (20,
Figure 63-7) (paragraph 63-32).
3. On S/N 52001 through 52263 Post TB
206L-03-211, and S/N 52264 and subsequent, inspect
as follows:
CAUTION
a. Inspect the transmission oil pump shaft
splines for wear and damage. For damage limits, refer
to BHT-206L-CR&O, Chapter 63.
DO NOT USE HYDRAULIC PRESS TO
REMOVE THE DRIVESHAFT.
b. Remove the retaining ring (34, Figure 63-7)
EXCESSIVE PRESSURE CAN DAMAGE
and the adapter (33) from the tachometer generator
THE TACHOMETER GENERATOR
driveshaft.
HOUSING.
c. Inspect the tachometer generator driveshaft
for wear and damage (Figure 63-7A). 2. Using an arbor press or equivalent and workaids
No. 1 and No. 2, remove the driveshaft (1,
d. Inspect the adapter (33, Figure 63-7) for wear Figure 63-7C) from the tachometer generator (3). The
and damage (Figure 63-7B). retaining clip (2) can be reused if serviceable.

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 29
BHT-206L4-MM-6

Figure 63-7. Transmission Oil Pump, Screen, and Electrical Chip Detectors (Sheet 1 of 2)

63-00-00
Page 30 Rev. 13 25 FEB 2011 ECCN EAR99
 BHT-206L4-MM-6

Figure 63-7. Transmission Oil Pump, Screen, and Electric Chip Detectors (Sheet 2 of 2)

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 30A
BHT-206L4-MM-6

A
C
B

TACHOMETER GENERATOR
(206-076-373-001 AND 206-375-202-101)

REF INPSECTION
NO. LTR CHARACTERISTIC METHOD LIMIT

1. A Corrosion/mechanical Visual/measure

2. B Corrosion/mechanical Visual/measure 0.002 inch (0.05 mm)

maximum depth.

3. B Spline wear Visual/measure Permitted if damage or wear 1

cannot be felt with a 0.020 inch
(0.508 mm) spherical radius probe.

4. C Corrosion/mechanical Visual/measure 0.002 inch (0.05 mm)

maximum depth.

5. C Corrosion/mechanical Measure between 0.2258 inch (5.7353 mm) 1

0.0360 inch (0.9144 mm) maximum.
diameter pins.

6. D Corrosion/mechanical Visual/measure 0.002 inch (0.05 mm)

maximum depth.

7. D Corrosion/mechanical Measure between 0.040 0.3192 inch (8.1076 mm)

inch (1.016 mm) minimum.
diameter pins.

NOTE
1 Nicks on ends of the splines not exceeding 0.010 inch (0.2 mm) deep may be polished smooth with a
fine India stone.
206LS_MM_63_0008

Figure 63-7A. Tachometer Generator Driveshaft — Inspection

63-00-00
Page 30B Rev. 13 25 FEB 2011 ECCN EAR99
 BHT-206L4-MM-6

Figure 63-7B. Interconnect Adapter — Inspection

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 30C
BHT-206L4-MM-6

ARBOR PRESS

WORKAID NO. 1
SEE DETAIL A

WORKAID NO. 2
SEE DETAIL B

1
1

2 2
3 3

(VESPEL ADAPTER NOT

SHOWN FOR CLARITY)

TACHOMETER GENERATOR TACHOMETER GENERATOR

(206-076-373-001) (206-375-202-101)

206LS_MM_63_0010a

Figure 63-7C. Tachometer Generator Driveshaft — Removal/Installation (Sheet 1 of 2)

63-00-00
Page 30D Rev. 13 25 FEB 2011 ECCN EAR99
 BHT-206L4-MM-6

1.49 IN.
(37.85 mm)

0.80 IN.
(20.32 mm)

0.25 IN. 1.00 IN.

(6.25 mm) (25.40 mm)

WORKAID NO. 1
MATERIAL: ALUMINUM

DETAIL A

3.00 IN.
(76.20 mm)
1.60 IN.
(40.64 mm)

0.84 IN.
(21.34 mm)

WORKAID NO. 2
MATERIAL: ALUMINUM

DETAIL B

1. Driveshaft
2. Retaining clip
3. Tachometer generator

GREASE (C-561)

206LS_MM_63_0010b

Figure 63-7C. Tachometer Generator Driveshaft — Removal/Installation (Sheet 2 of 2)

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 30E
BHT-206L4-MM-6

63-33. TACHOMETER GENERATOR —

INSTALLATION
CAUTION

MATERIALS REQUIRED
DO NOT PERMIT SOLVENT TO ENTER
THE INTERNAL PORTION OF THE Refer to BHT-ALL-SPM for specifications.
TACHOMETER GENERATOR. SOLVENT
CAN DAMAGE THE BEARINGS AND NUMBER NOMENCLATURE
ELECTRICAL COMPONENTS.
C-002 Hydraulic Fluid

3. Taking care to ensure the solvent does not enter C-561 Grease
the tachometer generator (3), clean the internal
splines with drycleaning solvent (C-304) and a small
1. Remove nuts (15, Figure 63-7) and aluminum
brush. Clean the mating splines of the driveshaft (1)
washers (14), or spacers securing oil pump (13) to
with drycleaning solvent (C-304) and a small brush. transmission (11).
Dry the splines with low pressure filtered compressed
air.
2. Apply a thin coating of grease (C-561) to mating
shaft and splines of tachometer generator (20) and
4. Inspect the internal splines of the tachometer hydraulic pump (18).
generator (3) and the splines of the driveshaft (1)
(Figure 63-7A). 3. On S/N 52001 through 52263 Pre TB
206L-03-211, apply a thin coating of grease (C-561) to
a. If the internal splines of the tachometer mating shaft and splines of tachometer generator (20)
and oil pump (13).
generator (3, Figure 63-7C) are damaged beyond
limits, the tachometer generator can be returned to
Bell Helicopter Textron for repair. Refer to NOTE
IL GEN-04-98.
Do not apply any lubricant to the internal or
external splines of the adapter (33). The
b. If the splines of the driveshaft (1) are use of grease lubricant can result in
damaged beyond limits, replace the driveshaft. deterioration of the adapter.

5. Install the driveshaft (1) into the tachometer 4. On S/N 52001 through 52263 Post TB
generator (3) as follows: 206L-03-211, and S/N 52264 and subsequent, install
the adapter (33) and the retaining ring (34) in the
tachometer generator shaft splines.
a. Install the retaining clip (2) on the
driveshaft (1). 5. Position new gasket (21) on studs at installed oil
pump (13) and install tachometer generator (20) with
b. Lubricate the internal splines of the electrical connector pointing inboard. Install electrical
tachometer generator (3) and the mating driveshaft (1) cable bracket and clamp on lower outboard stud,
splines with grease (C-561). ground wire terminal to lower inboard stud and secure
with thin aluminum washers (14) and nuts (15). Torque
nuts 50 to 70 inch-pounds (5.6 to 7.9 Nm).
c. Insert the driveshaft (1) in the tachometer
generator (3).
NOTE
6. Install the tachometer generator (3) (paragraph Make sure hydraulic pump case is full of
63-33). hydraulic fluid (C-002) before installation.

63-00-00
Page 30F Rev. 13 25 FEB 2011 ECCN EAR99
 BHT-206L4-MM-6

6. Position new gaskets (19) on studs of tachometer 63-35. OIL PUMP

generator (20). Install hydraulic pump (18) to
tachometer generator. Align shafts as parts are mated. The oil pump, tachometer generator, and hydraulic
Tachometer generator shaft may be rotated by rotating pump are mounted together on the forward side of the
main rotor hub and blade assembly. Secure hydraulic transmission and all are driven by the accessory drive
pump with thin aluminum washers (16) and nuts (17). gear. Both the hydraulic pump and tachometer
Torque nuts 50 to 70 inch-pounds (5.6 to 7.9 Nm). generator must be removed to gain access to the oil
pump.
7. On first ground run-up, check main rotor RPM
indicator to ensure proper functioning. Also check 63-36. OIL PUMP — REMOVAL
transmission oil pressure indicator for normal pressure
indication and that hydraulic pump (18) is providing
1. Drain lubricating oil from transmission.
boost to cyclic and collective control systems.

63-34. TRANSMISSION OIL SYSTEM 2. Remove the hydraulic pump (18, Figure 63-7)
and tachometer generator (20) (paragraph 63-32 and
Lubrication is provided by a system that includes an oil Chapter 29).
pump, pressure regulating valve, oil cooler, filter
element, and spray oil jets No. 1 an No. 2 3. Using a heat lamp, heat the transmission case at
(Figure 63-8). The oil pump is a constant volume type, boss for oil pump (13). After transmission case has
driven by accessory gear that delivers oil under warmed, install slide hammer puller to face of oil pump
pressure externally to oil filter and housing assembly, with two 10-32 bolts or cap screws and remove oil
oil cooler, and then returns oil to the main transmission pump. (Refer to Figure 63-9 for tool application).
and spray jets for lubricating internal parts. An oil level Remove slide hammer puller from oil pump.
sight gauge is located on the right side of the main
transmission lower case where it can be easily 4. Remove and discard packing (12, Figure 63-7)
inspected. A non-vented filler cap is located on the from oil pump (13). Cover ports in oil pump and
main transmission top case. opening in transmission (11) case to prevent entry of
foreign material.
The transmission oil system also provides lubrication
for the freewheel assembly mounted in the engine
accessory gearcase. Oil pressure for lubrication of the 63-37. OIL PUMP — INSPECTION AND REPAIR
freewheel assembly and to transmission oil pressure
gauge on instrument panel is taken from a tee-fitting 1. Rotate shaft of oil pump (13, Figure 63-7) and
installed in the pressure line. check for freedom and smoothness of rotation.

Oil temperature indications are provided by an oil 2. Visually check spline teeth of pump shaft (both
temperature bulb located in the outlet side of the oil ends) for wear, chips, or cracks.
filter housing and a high oil temperature switch, which
is connected to the TRANS OIL TEMP caution
segment. The TRANS OIL PRESS caution segment 3. Visually inspect ports in body of oil pump for
light is connected to the transmission oil pressure damage to gerotor.
switch located in the oil pressure line below and
forward of the instrument panel. 4. Inspect outboard oil seal for excessive leakage.

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 30G/30H
 BHT-206L4-MM-6

63-38. OIL PUMP — INSTALLATION 4. Install tachometer generator (20) and hydraulic
pump (18) (paragraph 63-33 and Chapter 29).

MATERIALS REQUIRED 5. Service transmission to proper level (Chapter 12).

Refer to BHT-ALL-SPM for specifications. 6. On first helicopter ground run-up, check oil pump
for oil leaks and correct indication of oil pressure.
NUMBER NOMENCLATURE Adjust oil pressure as required (paragraph 63-59).
C-030 Lubricating Oil
63-39. OIL PUMP INLET SCREEN
1. Using a heat lamp, heat case of transmission (11,
Figure 63-7) at boss for oil pump (13). The oil pump inlet screen assembly is located in a
boss adjacent to the oil pump of the transmission
lower case, and filters lubricating oil prior to entering
2. Lubricate new packing (12) with lubricating oil
the oil pump. Screen material is 16 x 16 mesh, number
(C-030) and position on oil pump.
23 gauge steel screening that is brazed to an inlet
sleeve and plug.
3. After case of transmission (11) is warm, install oil
pump (13) into case with slot in pump pointing down.
63-40. OIL PUMP INLET SCREEN — REMOVAL
Rotate oil pump slightly if necessary to engage splines
with accessory drive gear. If tachometer generator (20)
and hydraulic pump (18) are not to be installed at this 1. Drain lubricating oil from transmission.
time, install spacers or additional aluminum washers
(14) with nuts (15) to secure oil pump. 2. Remove retaining ring (28, Figure 63-7).

63-00-00
ECCN EAR99 25 FEB 2011 Rev. 13 Page 31
Ell-IT-2061-4-MM-6

THERMOBULB

CLOG FILTER INDICATOR

FILTER BYPASS VALVE

OIL COOLER THERMO

BYPASS VALVE
OIL COOLER

MAST BEARING
MAGNETIC CHIP
DETECTOR

OIL JET NO. 2

BLOWER ASSY

FILTER ELEMENT
-
RESTRICTORS IN FITTING

OIL PUMP
FILTER
4.5TO5GPM
(17 TO 19 IPM)
OIL JET NO. 1

INTERNAL JETS TO SUN GEAR

DRAIN PLUG & MAGNETIC & PLANETARY
CHIP DETECTOR DRAIN PLUG & MAGNETIC
CHIP DETECTOR

NOTE LUBRICATING OIL

1Q To pilot panel oil pressure gage and FLOW OF OIL

low pressure warning switch. UNDER PRESSURE

2061.4-M-63-8

Figure 63-8. Transmission oil system schematic

63-00-00
Page 32
 BHT-206L4-MM-6

1. Bolts or cap screws - 10-32 threads

2. Slide hammer puller
3. Oil pump
206L4-M-63-9

Figure 63-9. Transmission oil pump removal tool application

3. Withdraw screen assembly (26) from 3. Inspect screen assembly (26) for cracks
(")
_.330

transmission (11). Immediately inspect screen and distortion. Inspect retaining ring (28) for
assembly for foreign material. If any particles distortion.
are found, place them in a clean container for
inspection.
63-42. INSTALLATION.
4. Remove and discard packing (27).
((DD

MATERIALS REQUIRED
63-41. INSPECTION.
NUMBER NOMENCLATURE
MATERIALS REQUIRED
C-030
C-030 Turbine Oil

NUMBER NOMENCLATURE
1. Lubricate new packing (27, figure 63-7)
figure 63-7
C-304
C-304 Solvent with turbine oil (C-030)
C-030 and position on
screen assembly (26).
1. If any particles are found, identify and 2. Insert screen assembly (26) into boss in
perform corrective action (paragraph 63-8 and
paragraph 63-8
(<D

lower case of transmission and secure with

'"`

figure 63-3).
figure 63-3 retaining ring (28).
2. Clean screen assembly (26, figure 63-7)
figure 63-7
-.N

3. Service transmission (11) to proper level

with solvent (C-304).
C-304 (Volume 2, Chapter 12).
Chapter 12

4. Inspect for oil leaks on first ground run-

up.

63-00-00
Page 33
13HT-2061-4-MM-6

63-43. ELECTRIC CHIP DETECTORS. 2. Inspect for worn or damaged bayonet pins
on electric chip detectors (7 and 25) and self-
Electric chip detectors consist of a self- closing valves (9 and 23).
locking bayonet type probe with a permanent
ceramic magnet at end. In event metal 63-46. INSTALLATION.
particles should become free in oil, magnet
will attract metal particles. When sufficient
metal is attracted to complete a circuit MATERIALS REQUIRED

E
between pole and ground, applicable yellow
0

>'Q)
caution segment on caution panel will

-r3
illuminate (Volume 10, Chapter 96).
Chapter 96
NUMBER NOMENCLATURE
C-030
C-030 Turbine Oil
63-44. REMOVAL.
C-405
C-405 Lockwi re

Con
1. Install new packings (8, 10, 22, and 24,

3,00
PpN
CAUTION'
%C7

figure 63-7) on electric chip detectors (7 and

figure 63-7
25) and self-closing valves (9 and 23).

BCD
ROUGH HANDLING OF CHIP Lubricate packings with a film of turbine oil
2Z=2=
2t-

DETECTORS AND THE (C-030).

C-030
ELECTRICAL CONNECTOR IS THE
--A

2. Install self-closing valves (9 and 23) in

.O-.
MAJOR CAUSE OF FAILURE AND
FALSE INDICATIONS IN THE upper and lower cases of transmission (11).
OF-

CAUTION LIGHT SYSTEM. Torque self-closing valves 75 to 125 inch-

F->

S])
pounds (8.47 to 14.12 newton-meters) and

(OD
1. Disconnect electrical leads from terminal secure to transmission with lockwire (C-405).
C-405
poi
(CO

studs on end of electric chip detectors (7 and

3. Insert electric chip detectors (7 and 25)
.c>
+--'

25, figure
'C7
63-7).
figure 63-7
into self-closing valves (9 and 23) and turn
2. Press electric chip detector in, turn clockwise to lock in place. Connect electrical
counterclockwise and remove from self- leads to electric chip detectors.
closing valve. Check detector for metal
0N(

particles. If any particles are found, place 4. Service transmission to proper level
.+0

them in a clean container and retain until (Volume 2, Chapter 12).

Chapter 12
inspection is completed.
5. Check for oil leaks on first ground run-up.
3. Inspect self-closing valves (9 and 23) for
leakage after electric chip detectors are 63-47. TRANSMISSION OIL LEVEL SIGHT
removed. GAGE.
4. Drain lubricating oil from component. Transmission oil level sight gage is located on
E

ma)

right side of transmission and provides a

0(D

5. Cut and remove lockwire from self-closing visual indication of oil level.
E

valves (9 and 23), remove valves and discard

Q1)

packings (10 and 22). Discard packings (6

and 24) from electric chip detectors (7 and 63-48. REMOVAL.
25).
1. Drain lubricating oil from transmission.

63-45. INSPECTION. 2. Cut and remove lockwire from eight

-JO

screws (31, figure 63-7, detail A) on sight

figure 63-7
1. Inspect electric chip detectors (7 and 25, gage (29).
((S

figure 63-7) for metal particles. If any particles

figure 63-7
are found, identify (paragraph 63-8). Perform
paragraph 63-8 3. Remove eight screws (31) and washers
(<D

corrective action required by figure 63-3.

figure 63-3 (32) from sight gage (29). Carefully remove
63-00-00
Page 34
 131-IT-2061-4-MM-6

sight gage from transmission case to prevent 63-52. REMOVAL.

damage to bonded gasket, if still serviceable,
with plate (30). 1. Remove screws (8 and 9, figure 63-10)
figure 63-10
and remove oil jet No. 2 (6) from oil filter and

,-«
housing (1) and transmission (27). Remove

°'O
63-49. INSPECTION.
and discard packings (2 through 5) and
sealing washer (7).
1. Inspect sight gage (29, figure 63-7) for
figure 63-7
crazing, discoloration, and cracking. Replace

(0D
2. Remove screws (24 and 25) and remove

Q(n

0^3
sight gage if crazed or discolored to extent it oil jet No. 1 (23) from transmission (27).
will be difficult to see lubricating oil or
Remove and discard packings (19 through

OT.
determine oil level. 22), and sealing washer (26).
2. Inspect plate (30) for cracking and 3. To prevent entry of foreign material, cover
damage. or plug open ports in transmission

63-50. INSTALLATION.
LC)

63-53. INSPECTION.

MATERIALS REQUIRED
MATERIALS REQUIRED

NUMBER NOMENCLATURE
NUMBER NOMENCLATURE
C-304
C-304 Solvent
o

C-304
C-304 Solvent
C-405
C-405 Lockwi re
1. Clean oil jet No. 2 (6, figure 63-10) and
figure 63-10

0TH
1. Clean surface of gasket on sight gage oil jet No. 1 (23) with solvent (C-304)and
C-304 dry
(29, figure 63-7) and mating surface of
figure 63-7 with filtered compressed air.
^a-

transmission (11) with solvent (C-304).

C-304
,-l.

2. Inspect oil jets No. 2 and No. 1 (6 and 23)

for clogged passages, cracks, dents,

ten
2. Position sight gage (29) to transmission
distortion, and corrosion.
O-,

(11) and loosely install lower five screws (31)

30Q

and thin steel washers (32). Position plate

(30) to sight gage (29) and install remaining 63-54. INSTALLATION.
three screws (31) and thin steel washers (32).
+-'

3. Tighten screws (31) evenly and secure MATERIALS REQUIRED

(!1

heads together with lockwire (C-405)

C-405 as
shown in detail A.
NUMBER NOMENCLATURE
4. Service transmission to proper level
(nom

C-030 Turbine Oil

tea)

C-030
(Volume 2, Chapter 12).
Chapter 12
C-405
C-405 Lockwire
5. Inspect for leaks on first ground run-up.
1. Lubricate new packings (2 through 5,
63-51. TRANSMISSION OIL JETS. figure 63-10) with turbine oil (C-030)
C-030 and
.-.-

figure 63-10
position on oil jet No. 2 (6). Install oil jet No. 2
Two oil jets are incorporated in transmission. into oil filter and housing (1) and transmission
CO-0

No. 1 oil jet directs a lubricating oil spray to (27).

bevel gears of transmission and No. 2 oil jet
lubricates planetary pinions and mast bearing. 2. Align tab on oil jet No. 2 (6) and install
0°)
coo

screws (8 and 9) and new sealing washer (7).

ail-

Tighten screws and secure together with

c01

lockwire (C-405).
C-405

63-00-00
Page 35
BHT-2061-4-MM-6

*TORQUE
200 TO 300 IN-LBS
(22.6 TO 33.9 Nm)

27

1. Oil filter and housing 15. Piston

2. Packing 16. Retaining ring
3. Packing 17. Packing
4. Packing 18. Packing
5. Packing 19. Packing
6. Oil jet no. 2 20. Packing
7. Washer - sealing 21. Packing
8. Screw 22. Packing
9. Screw 23. Oil jet no. 1
10. Nut 24. Screw
11. Valve body 25. Screw
12. Adjusting screw 26. Washer - sealing 206L4-M-63-10
13. Packing 27. Transmission
14. Spring

Figure 63-10. Transmission oil jets and relief valve

63-00-00
Page 36
 BHT-206L4-MM-6

3. Lubricate new packings (19 through 22) 63-58. INSTALLATION.

611
-.0
for oil jet No. 1 (23) and install in same
manner as steps 1. and 2.
MATERIALS REQUIRED
4. Inspect for oil leaks on first ground run-
up. NUMBER NOMENCLATURE
C-030
C-030 Turbine Oil
63-55. TRANSMISSION OIL PRESSURE
C-405
C-405 Lockwi re
C'3

REGULATING VALVE.

Transmission oil pressure regulating valve is 1. Lubricate new packings (17 and 18, figure
figure
located on left rear corner of transmission 63-10 with turbine oil (C-030).
63-10) C-030
lower case. Regulating valve is used to adjust
-(o

transmission oil pressure to normal operating

2. Position packing (17) next to head of

o
limits and relieves excess oil pressure back
valve body (11) and packing (18) on end of
into transmission case. valve body.

p<)
63-56. REMOVAL. 3. Carefully thread valve body (11) into boss
on lower case of transmission (27). Torque
valve body 200 to 300 inch-pounds (22.6 to

0
1. Cut and remove lockwire from oil
a)_

33.9 newton-meters) and secure to adjacent

C()
pressure regulating valve body (11, figure 63-
figure 63-
10). oil transfer dowel tube with lockwire (C-405).
C-405
10

4. Inspect for oil leaks and adjust

CO)
2. Use wrench on hexagonal shoulder of
valve body (11) to loosen and remove valve transmission oil pressure on first ground run-
assembly from transmission lower case. up (paragraph 63-59).
paragraph 63-59
Remove and discard packings (17 and 18).
63-59. ADJUSTMENT.
63-57. INSPECTION.

1. Inspect valve body (11, figure 63-10) for

figure 63-10 CAUTION
L..
.................
scored areas and damaged threads. Using a
nonmetallic blunt rod, check piston (15) for
ADJUSTMENT OF TRANSMISSION
freedom of movement by pushing it into valve
0

OIL PRESSURE REGULATING

zoo
body several times.
VALVE MUST BE ACCOMPLISHED
IMMEDIATELY ON GROUND RUN-
................. UP.
CAUTION
1. Transmission oil pressure limits are 30 to
Nn'

70 psi (210 to 480 kPa). Maximum oil

0'°

LOOSENING NUT (10) OR temperature is 110°C (2301F). Do not exceed

TURNING ADJUSTING SCREW (12) these limits.
WILL REQUIRE ADJUSTMENT OF
TRANSMISSION OIL PRESSURE.
--I

2. If transmission oil pressure is not within

specified range, hold adjusting screw (12,
°'o

2. Inspect valve body (11) for evidence of oil figure 63-10) with a flat tip screwdriver and
figure 63-10
cam

leaks and nut (10) for loss of locking tension. loosen nut (10). To obtain correct pressure,
turn adjusting screw (12) clockwise to
3. If evidence of an oil leak is noted around increase pressure and counterclockwise to
C-+.
coo

adjusting screw (12), or piston (15) is binding, decrease pressure. Adjust oil pressure to 50
a`.

repair valve assembly (BHT-206L-CR&O).

BHT-206L-CR&O to 55 psi (345 to 380 kPa) at 100 percent N2

63-00-00
Page 37
BHT-2061-4-MM-6

rpm. Tighten nut (10) after oil pressure is 2. Inspect oil filter housing (13) and housing
adjusted. (16) for security, damage, and oil leaks.

3. When transmission oil temperature has

Eco:
63-63. INSTALLATION.
stabilized, recheck transmission oil pressure
and make additional adjustments, as required.
MATERIALS REQUIRED
TRANSMISSION OIL FILTER AND
63-150.
HOUSING ASSEMBLIES. NUMBER NOMENCLATURE
C-030
C-030 Turbine Oil
Transmission oil filter and housing assembly
3.(?-,w

is mounted to aft side of transmission and

(CO
C-304
C-304 Solvent
incorporates a disposable filter element,
Qom.
c:)

(SD

bypass indicator, bypass valve, thermostat, C-308

C-308 Adhesive
L-0

(_D

(.a
temperature bulb, and a thermoswitch.

1. Clean mating flange surfaces of oil filter

63-61. REMOVAL. housing (13, figure 63-11) and transmission
figure 63-11
(1). Use solvent (C-304).
C-304
1. Drain lubricating oil from transmission and
oil cooler assembly (Volume 2, Chapter 12).
Chapter 12 2. Position oil filter housing (13) on studs of

+O.
transmission top case. Install oil jet No. 2, to
(La=L.

0.c

C)_
2. Remove tube assembly (6, figure 63-11) align housing and top case (paragraph 63-
v`<

figure 63-11
Q-3

paragraph 63-

cam
from two elbows (7) and clamping installation 54). Install an aluminum washer (12), thin
...
E

on transmission (1). If elbows (7) are to be steel washer (11), and nut (10) on each of
Darn

removed, loosen nuts (8) and unscrew elbows three studs. Torque nuts (10) 50 to 70 inch-
from oil filter housing (13) and lower case of pounds (5.65 to 7.91 newton-meters).
transmission (1). Remove and discard
U0)

packings (9). 3. Apply a bead of adhesive (C-308) C-308 to

a)-
mating edge surfaces around oil filter housing

(CD
3. Disconnect oil hose assemblies to inlet (13) and transmission (1).
union (3) and outlet union (4). Install
protective plugs in oil hose assemblies to
C('=
030

4. Apply a film of turbine oil (C-030)

C-030 to new
prevent entry of foreign material. Remove
2.5
^s,

packings (9) and position on two elbows (7)

inlet union (3), outlet union (4), and discard with nuts. Install elbows in oil filter housing
packings (2 and 5). (13) and lower case of transmission (1).
CO-0
C+.

Install tube assembly (6) and torque nuts (8)

4. Remove transmission oil jet No. 2 and nuts on tube assembly. Install electrical
(paragraph 63-52).
paragraph 63-52 clamp installations on tube assembly.

5. Remove three nuts (10) and washers (11)

and washers (12) securing oil filter housing 63-64. TRANSMISSION OIL FILTER.
(13) to transmission (1). Remove complete
tea)

assembly from transmission. Transmission oil filter element is contained in

lower housing of oil filter housing assembly.
Filter element is a micronic, pleated paper
63-62. INSPECTION. type which is disposable.

1. Inspect tube assembly (6, figure 63-11)

figure 63-11
for nicks, scratches, damage, and oil leaks. 63-65. REMOVAL.
UDC=

Check tube nuts for security and clamp

installation for proper mounting. Check 1. Place rags or absorbent material below oil
.,.,

electrical harness, clamped to tube assembly, filter housing (16, figure 63-11) to collect
figure 63-11
CU)

(3)

for chafing and deterioration. residual oil.

63-00-00
Page 38
 BHT-206L4-MM-6

*TORQUE
50 TO 70 IN-LBS
(5.65 TO 7.91 Nm)

**TORQUE
100 TO 140 IN-LBS
(11.30 TO 15.82 Nm)

.-r

1. Transmission 11. Thin steel washer

2. Packing 12. Aluminum washer
3. Union (inlet) 13. Oil filter housing
=`D

4. Union (outlet) 14. Filter element

5. Packing 15. Packing
6. Tube assembly 16. Housing
7. Elbow 17. Steel washer
8. Nut 18. Nut
000

9. Packing 19. Packing

10. Nut
206L4-M-63-11

Figure 63-11. Transmission oil filter and housing

63-00.00
Page 39
131-IT-2061-4-MM-6

2. Disconnect freewheeling oil pressure flex 1. Apply a film of turbine oil (C-030),
C-030 to new
line from transmission reducer (19, figure 63-
figure 63- packings (15 and 19, figure 63-11). Position
figure 63-11
12). Plug line and cap fitting. Move flex line
12 packing (19) on oil journal in lower surface of

m(°
aside sufficifently to provide clearance for oil filter housing (13).
filter removal.
2. Position filter element (14) on oil journal
3. Remove two nuts (18,figure 63-11) with in lower surface of oil filter housing (13).

,-:
figure 63-11
washers (17) and pull housing (16) from oil
filter housing (13). Leave residual oil in 3. Position packing (15) around flange of
housing for inspection. housing (16). Install housing (16) to oil filter
housing (13) and secure with two steel
washers (17) and two nuts (18). Torque nuts

.-.
...
U),_
4. Remove filter element (14) from oil tube
(18) 100 to 140 inch-pounds (11.30 to 15.82
on oil filter housing (13) and place in a clean newton-meters).
container for inspection.
4. Reconnect flex line to reducer (19, figure
figure
5. Remove and discard packings (15 and 63-12).
63-12
19).
5. Inspect for oil leaks and that transmission
(7)

aim
63-66. CLEANING AND INSPECTION. oil pressure and temperature indications are
normal on first ground run-up.

MATERIALS REQUIRED
63-68. TRANSMISSION OIL
TEMPERATURE BULB.
NUMBER NOMENCLATURE
C-304 Solvent Transmission oil temperature bulb is located
o?)°'

C-304
on forward side of oil filter housing and is
electrically connected to oil temperature
1. Immediately upon removal of transmission indicator on instrument panel.
oil filter element (14, figure 63-11) and
figure 63-11
housing (16) inspect residual oil and element
,..,

for foreign particles and contamination. 63-69. REMOVAL.

2. If any particles are found, identify 1. Remove electrical connector from

(paragraph temperature bulb (5, figure 63-12).
L()

63-8). Perform corrective action

paragraph 63-8 figure 63-12
L^)

required (figure 63-3).

figure 63-3
2. Remove temperature bulb (5) from oil
i-+

a_,
70c

3. Clean lower surface of oil filter housing filter housing (16). Remove and discard
(13, figure 63-11) and housing (16) with
figure 63-11 packing (4).
solvent (C-304).
C-304 Dispose of paper filter
element.
63-70. INSPECTION.

63-67. INSTALLATION.
1. Inspect electrical connector and electrical
0-0
Qom

yet

leads to temperature bulb (5, figure 63-12) for

figure 63-12
MATERIALS REQUIRED chafing, damage, and correct clamping.

2. Inspect pins and probe in temperature

m^N

0-0

NUMBER NOMENCLATURE
C

bulb (5) for corrosion and damage. If

C-030
C-030 Turbine Oil installed, check temperature bulb (5) for
external damage, oil leaks, and security.
63-00-00
Page 40
 BHT-206L4-MM-6

*14
15
SEE DETAIL A

*TORQUE
17 TO 19 IN-LBS
(1.92 TO 2.15 Nm)

1. Transmission 14. Screw

2. Thermostat 15. Bypass indicator
3. Packing 16. Oil filter housing
4. Packing 17. Union
5. Temperature bulb 18. Packing
6. Packing 19. Reducer
7. Plug 20. Packing
8. Bypass valve 21. Glyd ring and packing A
9. Spring 22. Lower magnet assembly
10. Packing 23. Spring
11. Retainer 24. Packing
12. Packing 25. Back-up ring
13. Thermoswitch
NOTE
206L4-M-63-12
Not field replaceable.

Figure 63-12. Transmission oil filter housing and fittings

63-00-00
Page 41
 131-IT-2061-4-MM-6

63-71. INSTALLATION. 63-74. INSPECTION.

1. Inspect bypass valve (8, figure 63-12),

figure 63-12
MATERIALS REQUIRED
spring (9), and retainer (11) for visual
evidence of wear or damage.
NUMBER NOMENCLATURE
2. Inspect spring (9) as follows:
C-030
C-030 Turbine Oil
a. Check spring (9) for a free length
C-405
C-405 Lockwire dimension of 2.780 ± 0.010 inches (70.61 ±
0.25 mm).
1. Apply a film of turbine oil (C-030)
C-030 to new
packing (4, figure 63-12) and position on
figure 63-12
b. Apply a measurable amount of weight
temperature bulb (5). to spring (9) and compress length to 1.300 ±
0.010 inches (33.02 ± 0.25 mm). Amount of
weight required shall not exceed 7.6 ± 0.5
2. Install temperature bulb (5) in oil filter pounds (3.4 ± 0.2 kilograms).
housing (16). Secure oil temperature bulb to
hexagon flange and secure thermostat (2)
.O+

3. Visually inspect retainer (11) and port in

with lockwire (C-405).
C-405 oil filter housing (16) for thread damage.
3. Attach electrical lead to oil temperature
bulb (5). 63-75. INSTALLATION.

4. On first ground run-up, check for oil leaks MATERIALS REQUIRED

C4-

and that transmission oil temperature

increases normally on indicator.
NUMBER NOMENCLATURE
63-72. TRANSMISSION OIL BYPASS C-030
C-030 Turbine Oil
VALVE.
C-405
C-405 Lockwi re
Transmission oil bypass valve assembly will
open when excessive back pressure is 1. Apply a film of turbine oil (C-030)
C-030 to a
(D'

caused by a clogged filter element or extreme new packing (10, figure 63-12) and position
figure 63-12
cold temperatures. Bypass valve will then on retainer (11).
Vi-''

allow lubricating oil to bypass oil filter element

and be directed to thermostat and oil cooler.
SOS

CAUTION
63-73. REMOVAL. .................
BYPASS VALVE MAY FALL LOOSE
.................
INSIDE HOUSING DURING
CAUTION INSTALLATION. INSPECT
i .................
THROUGH CENTER OIL HOLE ON
OBI-

BOTTOM OF OIL FILTER HOUSING

Z17

omz

BYPASS RETAINER IS SPRING

C/)

FOR PROPER SEATING AFTER

LOADED AT 7.6 POUNDS (34 INSTALLATION.
NEWTONS).
2. Insert bypass valve (8) and spring (9) on
slim

1. Cut and remove lockwire from retainer retainer (11) and install in oil filter housing
1:-

(1 , figure 63-12).
figure 63-12
1
(16). Secure retainer (11) to adjacent tang
od'

beside boss with lockwire (C-405).

C-405
2. Remove retainer (11), spring (9), and
N90=

bypass valve (8) from oil filter housing (16).

Remove and discard packing (10).
63-00-00
Page 42
 BHT-206L4-M M-6

3. Inspect for oil leaks on first ground run- 63-79. TRANSMISSION OIL FILTER

((D
up. BYPASS INDICATOR.

Transmission oil filter bypass indicator is

c.-<ao m'-'CD
"((DD
63-76. TRANSMISSION OIL
located on oil filter housing above filter

(j-,
THERMOSTAT.
element. Filter bypass indicator incorporates

o_,. (ate
a spring loaded magnet which is ported to

0
On start up, when transmission thermostat bypass valve. If bypass valve is opened due

3U)
valve is open, lubricating oil does not go to to a clogged filter element or extreme cold

_*.
((DD
cooler but returns to transmission. Thermostat temperature, red indicator button will be
O--

valve begins to close at 150°F (65.6°C). As

Ate)

released to extended position, indicating filter

valve begins to close, some oil flows through element has been bypassed.
cooler. At 178°F (81.1 °C) thermostat valve is
closed on seat, forcing all of oil through
(nO

cooler. 63-80. REMOVAL.

63-77. REMOVAL. 1. Remove screws (14, figure 63-12).

figure 63-12

2. Carefully remove top of bypass indicator

0
1. Cut and remove lockwire between
(15) and lower magnet assembly (22).
thermostat (2, figure 63-12) and temperature
figure 63-12
bulb (5).

2. Remove thermostat (2) from oil filter 'CAUTION'

housing (16). Remove and discard packing
(3).
EXERCISE EXTREME CARE IN
-ono
HANDLING BYPASS INDICATOR
AND LOWER MAGNET ASSEMBLY.
z

NOTE
IF SPRING IS PERMANENTLY
Thermostat Fuctional Test DISTORTED, THE INDICATOR
procedures are located in Chapter
Chapter WILL NOT OPERATE CORRECTLY.
79.
79 BYPASS INDICATOR IS A

Qmo
MATCHED ASSEMBLY, PARTS
63-78. INSTALLATION.
CANNOT BE ORDERED
SEPARATELY AND ARE NOT
INTERCHANGEABLE. DO NOT
MATERIALS REQUIRED REMOVE GLYD RING AND
C'3
PACKING (21).
NUMBER NOMENCLATURE 3. Remove and discard packing (24) and
C-030
C-030 Turbine Oil backup ring (25) from bypass indicator (15)
subassembly.
C-405
C-405 Lockwi re
4. If bypass indicator is found defective,
replace indicator. For repair, contact:
1. Apply a film of turbine oil (C-030)
C-030 to a
new packing (3, figure 63-12) and position on
(r)

figure 63-12
Aircraft Porous Media
thermostat (2).
Ate)

Pinellas Park, FL 34665-5798

2. Install thermostat (2) in oil filter housing
0,1-
c13

(16). Secure thermostat (2) to temperature 63-81. INSPECTION.

-.0

bulb (5) with lockwire (C-405).

C-405
Visually inspect top of bypass indicator
(D`<

1.
0-0

3. Inspect for oil leaks and that oil (15, figure 63-12) for evidence of wear,
figure 63-12
temperature stabilizes on first ground run-up. damage, and security.
63-00-00
Page 43
131-IT-2061-4-MM-6

If top subassembly of bypass indicator to TRANS OIL TEMP caution light segment.

(Dow's
mQm
0.T

:-'
2.
NC-

can
(15) is removed, inspect lower magnet When transmission oil reaches a temperature

-C3

0n)
assembly (22) and lower magnet spring (23) of 110°C (230°F) thermoswitch will illuminate
for damage and distortion. Inspect recess in caution light segment.
O.0

0
oil filter housing (16) for cleanliness and
damage. 63-84. REMOVAL.

63-82. INSTALLATION. 1. Disconnect electrical terminal from

thermoswitch (13, figure 63-12).
figure 63-12
MATERIALS REQUIRED
2. Cut and remove lockwire from
thermoswitch (13) and remove from oil filter
NUMBER NOMENCLATURE housing (16). Remove and discard packing
(12).
C-030
C-030 Turbine Oil
C-405
C-405 Lockwire 63-85. INSPECTION.

1. Inspect electrical terminal post and

.(n+
................. electrical leads to thermoswitch (13, figure
figure
CAUTION 63-12 for chafing, damage, and correct
63-12)
................. clamping.

2. Inspect probe of thermoswitch (13) for

-L)_2_

EXERCISE EXTREME CARE WHEN

HANDLING AND INSTALLING damage. If installed, check for external
SPRING AND LOWER MAGNET damage, oil leaks, and security.
ASSEMBLY TO PREVENT
PERMANENT DISTORTION FROM 63-86. INSTALLATION.
DESTROYING BYPASS INDICATOR
z

CALIBRATION.
MATERIALS REQUIRED
1. Position spring (23, figure 63-12) to lower
figure 63-12
magnet assembly (22) as illustrated in detail NUMBER NOMENCLATURE
A and insert into port of oil filter housing (16).
C-030
C-030 Turbine Oil
2. Position new backup ring (25) and
packing (24) to top subassembly of bypass C-405
C-405 Lockwire
indicator (15). Lubricate packing and ring with
C-030 Carefully insert top unit of
turbine oil (C-030).
1. Apply a film of turbine oil (C-030)
C-030 to new
bypass indicator (15) in oil filter housing (16).
packing (12, figure 63-12) and position on
figure 63-12
thermoswitch (13).
3. Install four screws (14) and torque 17 to
m`0
Ua)
3N:3

19 inch-pounds (1.92 to 2.15 newton-meters),

_.-

using diagonal sequence. Secure heads of

screws in pairs with lockwire (C-405).
C-405 'CAUTION'
4. Inspect for oil leaks and that transmission
oil temperature and pressure increases DO NOT APPLY MORE THAN 6
TAO ¢z-

normally and stabilizes on first ground run-up. INCH-POUNDS (0.68 NEWTON-

METERS) TORQUE TO TERMINAL
STUD OR 12 INCH-POUNDS (1.36
000Q

63-83. TRANSMISSION OIL NEWTON-METERS) TORQUE TO

THERMOSWITCH. HEX NUT OR CALIBRATION MAY
BE DESTROYED.
Transmission oil thermoswitch is located on
0

oil filter housing and is electrically connected

63-00-00
Page 44
(t0
 BHT-206L4-MM-6

2. Install thermoswitch (13) into oil filter housing (16) 63-91. TRANSMISSION OIL SYSTEM HOSES
and secure to adjacent tab with lockwire (C-405). AND TUBE ASSEMBLIES — REMOVAL

63-87. TRANSMISSION OIL FITTINGS 1. Disconnect hose or tube assemblies at

connecting fittings.
Transmission oil fittings consist of unions, plugs, and a
reducer that attach oil hoses or tube assemblies to 2. Remove attaching clamps that secure hose or
transmission and oil filter housing. tube assemblies to structure and remove.

63-88. TRANSMISSION OIL FITTINGS — 3. Remove and discard all packings on fittings.
REMOVAL
4. Install protective caps or plugs to prevent system
1. Remove attaching hose or tube assembly contamination.
connected to fitting.
63-92. TRANSMISSION OIL SYSTEM HOSES
2. Remove fitting and discard packing. AND TUBE ASSEMBLIES — CLEANING
AND INSPECTION
63-89. TRANSMISSION OIL FITTINGS —
INSTALLATION
MATERIALS REQUIRED

MATERIALS REQUIRED Refer to BHT-ALL-SPM for specifications.

Refer to BHT-ALL-SPM for specifications. NUMBER NOMENCLATURE

NUMBER NOMENCLATURE C-304 Drycleaning Solvent

C-030 Lubricating Oil 1. Clean hoses and tube assemblies with

drycleaning solvent (C-304) and dry with filtered
C-304 Drycleaning Solvent compressed air.
C-405 Lockwire
2. Inspect hoses and tube assemblies for evidence
of chafing, crimping, twisting, cracks, damaged
1. Clean threads on fitting and mating port with threads, or obstruction in openings.
drycleaning solvent (C-304). Check fittings and ports
for thread damage.
3. Inspect hose and tube assemblies for leakage.

2. Apply a film of lubricating oil (C-030) to new

63-93. TRANSMISSION OIL SYSTEM HOSES
packings and position packings on fittings.
AND TUBE ASSEMBLIES —
INSTALLATION
3. Install fittings into transmission or oil filter housing
and connect attaching hose on tube assemblies.
Secure fittings, as required, with check nuts or MATERIALS REQUIRED
lockwire (C-405).
Refer to BHT-ALL-SPM for specifications.
63-90. TRANSMISSION OIL SYSTEM HOSES
AND TUBE ASSEMBLIES NUMBER NOMENCLATURE

C-030 Lubricating Oil

Transmission oil system hose and tube assemblies
shown in Figure 63-13, comprise the distribution
system. Tube assemblies have sleeves and fittings, 1. Remove protective caps or plugs from openings
which are retained by flares on tubes. to hoses, tubes, or components.

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 45
BHT-206L4-MM-6

1. Filler cap 12. Drain valve 10

2. Transmission 13. Hose assembly
3. Lanyard 14. Hose assembly
4. Upper electric chip detector 15. Tube assembly
5. Return oil hose 16. Restrictor fitting
6. Outlet oil hose 17. Tube assembly
7. OIl filter and housing 18. Pressure regulating valve 9
8. Union 19. Oil pump 11
9. Packing 20. Electric chip detector
10. Engine and transmission oil cooler 21. Oil screen 8 9
11. Oil cooler blower 22. Restrictor tee 8
23. Union
24. Restrictor fitting
25. Restrictor fitting
6
5 7
4
2
3
OIL RETURN
1
FROM FREEWHEEL
ASSEMBLY
OIL PRESSURE TO
12 FREEWHEEL ASSEMBLY

13
25
14
15
24
22
FORWARD ENGINE
21 23 FIREWALL (REF)
16
20 18 17
19
OIL PRESSURE
FROM FILTER TO
SEE DETAIL A PRESSURE SWITCH 15
AND INDICATOR
3
1

OVERBOARD
DRAIN LINES
VENT LINE

BREATHER

DETAIL A
206L4_MM_63_0013

Figure 63-13. Transmission Oil System

63-00-00
Page 46 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-6

2. Install new packings on all removed fittings. 2. Gain access to rear of instrument panel.
Lubricate new packings with lubricating oil (C-030). Disconnect pressure indicator hose assembly and
When installing restrictor fitting (16, Figure 63-13) connect to a low pressure filler gun or pressure pot
restrictor side of fitting must be installed to tube serviced with lubricating oil (C-030). Apply pressure
assembly (17). When installing restrictor fittings (24 slowly so lines will be filled with lubricating oil,
and 25) in restrictor tee (22), the restrictor side of the displacing air in line. Continue to force lubricating oil
fitting must be installed into the restrictor tee. into lines until a bubble-free steady flow is established
in receptacle at transmission.
3. Position hose or tube assembly to supports,
clamps, and structure as required. Torque fitting, hose, 3. Reconnect hose assemblies at transmission and
or tube assemblies as required by standard torque oil pressure indicator.
chart (BHT-ALL-SPM).
63-95. TRANSMISSION OIL PRESSURE
4. Secure hose or tube assembly with required SWITCH
clamp installation. Make sure that there will be no
chafing between hose or tube assemblies and Transmission oil pressure switch is located below
components. instrument panel and is connected into transmission
oil pressure indicator oil line. During normal operation,
5. Service transmission to proper level (Chapter 12). oil pressure switch contacts open at 38 PSI (262 kPa)
maximum on increasing oil pressure. Contacts close at
6. If oil pressure lines between hose assembly (14) 30 ±2 PSI (207 ±14 kPa) on decreasing oil pressure,
on transmission and oil pressure indicator located on causing TRANS OIL PRESS caution light segment to
pilot instrument panel are disconnected, it is illuminate on pilot instrument panel.
recommended that oil lines be bled (paragraph 63-94).
63-96. TRANSMISSION OIL PRESSURE SWITCH
— REMOVAL
7. Examine for leaks on the first ground run of the
helicopter.
1. Gain access to transmission oil pressure switch
and remove electrical connector.
63-94. BLEEDING — TRANSMISSION OIL
PRESSURE LINES
2. Place rags or absorbent material below oil
pressure switch to collect residual oil.

MATERIALS REQUIRED
3. Remove tube assembly from union installed in
forward end of oil pressure switch. Install protective
Refer to BHT-ALL-SPM for specifications.
plugs and caps to prevent entry of foreign material.
NUMBER NOMENCLATURE
4. Remove clamp installation, union, nut, bushing,
C-030 Lubricating Oil and packing from oil pressure switch and remove
switch.
Any time transmission oil pressure line is
disconnected between transmission and transmission 63-97. TRANSMISSION OIL PRESSURE SWITCH
oil pressure indicator, system should be bled. This will — INSPECTION
ensure a positive indication of oil pressure on starts
and eliminate sluggish or erratic operation. 1. Functionally check electrical circuit for
transmission oil pressure indicator and switch
1. Disconnect oil pressure hose assembly (14, (Chapter 95).
Figure 63-13) from reducer at transmission (2) and
place end of hose assembly in a receptacle so that 2. Inspect transmission oil pressure switch for
end will be covered by fluid. Station a person at cracks, wear, leakage and for security of mounting.
receptacle to observe when a bubble-free flow has Check condition of oil pressure lines and electrical
been established. leads.

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BHT-206L4-MM-6

63-98. TRANSMISSION OIL PRESSURE SWITCH 2. It is not necessary to drain engine oil tank unless
— INSTALLATION maintenance is to be performed on tank.

NOTE
MATERIALS REQUIRED
Residual engine and transmission oil will
Refer to BHT-ALL-SPM for specifications. drain from oil cooler and connecting lines
during removal of oil cooler. Position
NUMBER NOMENCLATURE
sufficient absorbent material at oil tubes
C-030 Lubricating Oil and fittings to collect residual oil.

3. Disconnect three engine oil tubes (1, 5, and 9,

1. Apply a film of lubricating oil (C-030) to new Figure 63-14) from oil cooler (2) and engine oil tank.
packing and position on union and install in oil Install protective caps and plugs to prevent oil system
pressure switch. contamination.

2. Position oil pressure switch to clamp installation 4. Disconnect transmission oil inlet and outlet tube
and secure with screws, nuts, and bushing. assemblies (14 and 15) to oil cooler. Install protective
caps and plugs to prevent oil system contamination.
3. Connect oil pressure line to union on oil pressure
switch. 5. Remove bolts (20) and thin aluminum washers
(21) from oil cooler (2) and transition duct (10). Lift oil
4. Bleed transmission oil pressure lines (paragraph cooler from transition duct and oil cooler.
63-94).
6. Remove transition duct (10) by removing screws
5. Inspect for oil leaks on first ground run-up check. (12) and thin aluminum washers (11).

63-99. TRANSMISSION OIL COOLER 7. Remove unions (4, 16, and 18) and elbow (8)
from oil cooler (2). Remove and discard packings (3,
6, 17, and 19). Install protective plugs to prevent oil
Oil cooler assembly contains two separate
system contamination.
independent cores welded together. Aft core is for
engine oil system and forward core is for transmission
oil system. Oil cooler assembly is mounted to oil 63-101. TRANSMISSION OIL COOLER —
cooler blower assembly by a transition duct. Thermal CLEANING AND INSPECTION
bypass valve controlling flow of oil through engine oil
cooler core is located on inlet side of oil cooler and
allows oil to bypass oil cooler core when oil
MATERIALS REQUIRED
temperature is low. Thermal bypass valve for
transmission oil cooler is located on transmission.
Refer to BHT-ALL-SPM for specifications.

63-100. TRANSMISSION OIL COOLER — NUMBER NOMENCLATURE

REMOVAL
C-304 Drycleaning Solvent

1. Open two drain valves (12, Figure 63-13) located

on back wall of baggage compartment and drain 1. Clean exterior surface of oil cooler (2,
transmission oil cooler lines. Allow oil to drain into Figure 63-14) with drycleaning solvent (C-304) and dry
suitable container located below overboard drain lines. with filtered compressed air.

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 BHT-206L4-M M-6

TO ENGINE OIL
TANK- RETURN

APPLY BEAD OF SEALANT (C-353)

C-353 TO AIR SEAL
TRANSITION DUCT, TO OIL COOLER, AND TO
BLOWER ASSEMBLY.

1. Tube assembly
2. Oil cooler
3. Packing

obi
4. Union
5. Tube assembly
6. Packing

13)
7.Nut
8. Elbow
9. Tube assembly
10. Transition duct

.°,
11. Thin aluminum washer
12. Screw
13. Oil cooler blower
33s
14. Tube assembly
15. Tube assembly
16. Union
17. Packing
18. Union
19. Packing
20. Bolt
21. Thin aluminum washer

206L4-M-63-14

Figure 63-14. Transmission oil cooler

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BHT-206L4-MM-6

1. Install oil cooler blower (13, Figure 63-14), if

removed (Chapter 65).
CAUTION
2. Position transition duct (10) to top of oil cooler
blower (13) and secure with screws (12) and thin
IF OIL COOLER HAS BEEN REMOVED aluminum washers (11).
D U E TO M E TA L C O N TA M I N AT I O N ,
IT SHALL BE REPLACED. THE 3. Remove protective plugs from oil cooler (2).
M A N U FA C T U R E R DOES NOT Insert new packings (3, 6, 17 and 19) on unions (4, 16
RECOMMEND REPAIRING DAMAGED and 18) and elbow (8). Lubricate packings with
OR CLEANING CONTAMINATED OIL lubricating oil (C-030). Install unions and elbow with
COOLERS. nut (7) in oil cooler.

OIL SYSTEMS WITH CONTAMINATION 4. Position oil cooler (2) to transition duct (10) and
SHALL HAVE ALL OIL TUBES, HOSES, secure with bolts (20) and thin aluminum washers
VALVES, AND FITTINGS REMOVED AND (21). Seal holes in corners of transition duct with
T H O R O U G H LY C L E A N E D W I T H sealing compound (C-353).
S O LV E N T A N D F L U S H E D W I T H
LUBRICATING OIL.
5. Install engine oil tube assemblies (1, 5, and 9)
and secure to fittings.
2. Inspect oil cooler for damaged core and condition
of threaded parts.
6. Install or connect transmission oil tube
assemblies (14 and 15) and secure to fittings.
3. Inspect all oil tubes for chafing, crimping, wear,
leakage, and condition of threaded fittings. 7. Service engine and transmission oil system to
proper level (Chapter 12)
4. Inspect transition duct (10) for cracks. Check
screws (12) and bolts (20) for security. 8. Inspect for oil leaks on first ground run-up.
Ground run helicopter (BHT-206L4-FM-1) for sufficient
5. Inspect oil cooler blower (Chapter 65). duration to ensure that oil pressure and temperature
stabilize and that thermal bypass valve is operating.

63-102. TRANSMISSION OIL COOLER —

63-103. FREEWHEEL ASSEMBLY
INSTALLATION
Freewheel assembly is mounted on engine accessory
gearbox. The shaft of freewheel assembly is splined
MATERIALS REQUIRED directly to power takeoff gear shaft. Engine power is
transmitted to outer race of freewheel assembly, then
Refer to BHT-ALL-SPM for specifications. through sprag elements of assembly, which couples
engine power to transmission driveshaft. During
NUMBER NOMENCLATURE autorotation, the main rotor drives inner race shaft
assembly. Under this condition, freewheel assembly
C-030 Lubricating Oil provides a disconnect from engine so rotational forces
of main rotor are free to drive transmission, tail rotor,
C-353 Sealing Compound
and all transmission mounted accessories.

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 BHT-206L4-MM-6

3
5

6
7
2
8
9
22 11
10
21

1
4

1. Electrical connector 20
12
2. Drain hose
3. Chip detector housing 19
4. Chip detector
5. Aft bearing seal cap 6
6. Freewheel unit shaft
7. Output adapter
8. Packing 5
9. Washer 13
10. Washer 18
14
11. Cotter pin 17
12. Adapter retaining nut
13. Washer 1 17A
16 15
14. Nut
15. Packing
16. Cone set spacer
17. Cone set
17A. Packing 23
18. Groove
19. Support stud
20. Output support
21. Oil inlet line
22. Elbow fitting 5
23. Seal lip

NOTE
GREASE
1 Packing required if cone set is installed.

206L4_MM_63_0015a

Figure 63-15. Freewheel Assembly (Sheet 1 of 3)

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BHT-206L4-MM-6

24. Output shaft assembly

25. Nut
26. Steel washer
27. Aluminum washer A
28. Forward seal cap
29. Jackscrew
30. Packing
31. Mounting stud
32. Housing assembly
33. Packing
34. Return oil line
35. Elbow fitting
36. Inlet oil line
37. Forward cap fitting
38. Output adapter bolt
39. Packing
40. Pin
41. Output shaft plug assembly
42. Retainer ring
43. Main drive shaft adapter
43A. Packing
44. Threads
45. Splines

206L3_MM_63_0015b

Figure 63-15. Freewheel Assembly (Sheet 2 of 3)

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 BHT-206L4-MM-6

46. Nut
47. Pilot ring
48. Packing
49. Packing
50. Oil transfers tube
51. Housing assembly
52
52. Packing
53. Mounting stud 51
54. Packing
55. Chip detector housing
56. Chip detector
57. Packing
58. Jam nut 47
)U)

59. Elbow fitting 46

Figure 63-15. Freewheeling assembly (Sheet 3)

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BHT-206L4-MM-6

3. Remove electrical connector (1, Figure 63-15)

63-104. FREEWHEEL ASSEMBLY — REMOVAL from chip detector (4).

4. Remove chip detector (4) from chip detector

SPECIAL TOOLS REQUIRED house (3).

5. Install drain hose (2) (H4713) into chip detector

NUMBER NOMENCLATURE
housing (3) and drain oil into suitable container.
406-240-012-101 Spline Wrench
6. When oil is completely drained from freewheel
H4713 Drain Hose unit, remove drain hose and install chip detector (4)
into chip detector housing (3).
T101308 Jackscrew Set

T103306-101 Spanner Adapter 7. Remove and discard cotter pin (11) from adapter
retaining nut (12).

8. Install spanner assembly on output adapter (7)

MATERIALS REQUIRED and secure in place with accompanying hardware.

Refer to BHT-ALL-SPM for specifications.

9. While holding output adapter (7) with spanner
NUMBER NOMENCLATURE assembly, remove nut (12) and washers (10) from
freewheel unit shaft (6).
C-426 Masking Tape

C-427 Barrier Material 10. Using plastic scraper remove sealant from
washer (9) and output adapter (7).

11. Remove washer (9) with packing (8) from

NOTE
freewheel unit shaft (6). Discard packing.
Replacement of freewheel assembly
carbon seal is a critical procedure. Refer to
BHT-206L-CR&O Manual for procedures. NOTE
When adapter (7) is removed, oil will drain
from aft bearing and seal cap (5) to engine
NOTE deck.
For better access to freewheel assembly in
engine compartment from right side, 12. Remove output adapter (7) from aft bearing and
cap (5) and freewheel unit shaft (6).
remove fuel filter bracket (Chapter 28) from
forward firewall with fuel filter attached. Do
not break any fuel lines. Tie complete 13. Disconnect oil inlet line (21) from elbow fitting
(22) on aft bearing and seal cap (5).
assembly with tie-wrap (or other suitable
means) away from area where accessibility
14. Cap oil line and identify for installation location.
is required.

1. Remove forward short tail rotor driveshaft. This 15. Remove nuts (14) and washers (13) from support
studs (19).
shaft connects to aft end of freewheel assembly and
forward end of oil cooling fan shaft (Chapter 65).
16. Remove aft bearing and seal cap (5) with packing
(15) from output support (20) with conduit pliers.
2. Remove main driveshaft (paragraph 63-16). Discard packing.

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 BHT-206L4-MM-6

SHAFT, OR ENGINE ACCESSORY

GEARS WILL RESULT.
CAUTION
26. Install three jackscrews (29) (T101308) in
threaded holes in forward seal cap (28).
CONE SET IS A MATCHED SET.
REMOVE AND INSTALL AS A SET.
27. Remove output shaft assembly (24) with
17. Remove spacer (16), packing (17A) if installed, packings (30 and 33) using jackscrews (29). Discard
and cone set (17) from groove (18) on freewheel unit packings.
shaft (6).
28. Place output shaft assembly (24) on suitable
18. Remove retainer ring (42) from output adapter surface and cover to prevent contamination.
bolt (38).
29. Remove nuts (46) from mounting studs (53).

NOTE
30. Remove housing assembly (51) and pilot ring
A single jackscrew (29) (T101308) can be (47) with packing (52). Discard packing.
used as a tool to remove output shaft plug
assembly (41) by threading jackscrew into 31. Remove pilot ring (47) and packings (48) from
plug assembly. housing assembly (51). Discard packing.
19. Remove output shaft plug assembly (41) with
packing (39). Discard packing. 32. Cover openings in engine accessory gear case
with barrier material (C-427) and secure with masking
tape (C-426).
20. Install input adapter spanner (T103306-101) on
main driveshaft adapter (43) and secure in place.
33. Remove elbow fitting (59) from housing assembly
(51) by loosening jamnut (58) and turning elbow fitting.
21. While holding main driveshaft adapter (43) in Remove and discard packing (57).
place, remove output adapter bolt (38), using external
spline wrench (406-240-012-101).
34. Cut lockwire and remove chip detector (56) and
housing (55) with packing (54) from housing (51).
22. Remove main driveshaft adapter (43) from Discard packing.
freewheel unit output shaft assembly (24).
35. Remove packing (49) from housing assembly oil
23. Disconnect inlet oil line (36) from forward cap transfer tube (50). Discard packing.
fitting (37).
63-105. FREEWHEEL ASSEMBLY — CLEANING
24. Disconnect return oil line (34) from elbow
fitting (35).
MATERIALS REQUIRED
25. Remove nuts (25), steel washers (26), and
aluminum washers (27) securing output shaft Refer to BHT-ALL-SPM for specifications.
assembly (24) to housing assembly (32).
NUMBER NOMENCLATURE

C-304 Drycleaning Solvent

CAUTION
1. Clean all components with wiping rag dampened
JACKSCREW MUST BE TURNED with drycleaning solvent (C-304).
EVENLY WHILE REMOVING OUTPUT
SHAFT, OR DAMAGE TO OUTPUT 2. Dry all components with wiping rag.

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BHT-206L4-MM-6

63-106. FREEWHEEL ASSEMBLY — INSPECTION MATERIALS REQUIRED (Cont)

AND REPAIR
Refer to BHT-ALL-SPM for specifications.
1. Deleted.
NUMBER NOMENCLATURE
2. Examine all components for condition. Refer to C-030 Lubricating Oil
BHT-206L-CR&O for the damage limits.
C-308 Sealant
3. Examine splines (1, Figure 63-16) for chipped,
worn, or broken teeth. C-405 Lockwire

4. If removed, examine forward seal cap (4) for NOTE

corrosion, scratches, nicks, and cracks.
If engine assembly is removed, install
freewheel assembly before installing
5. Examine the visible portions of the inner and
engine assembly in helicopter, for ease of
outer shafts for corrosion, wear, and cracks.
maintenance.

6. Turn the main driveshaft adapter (43) or output 1. Install packing (49, Figure 63-15) on housing
shaft assembly (24) by hand. Do a check of the clutch assembly oil transfer tube (50). Lubricate packing with
and bearing for smoothness and freedom of rotation in lubricating oil (C-030).
the freewheel direction and lockup in the drive
direction.
2. Install packing (54) on chip detector housing (55)
and install in housing assembly (51).
7. Repair all damage (BHT-206L-CR&O,
Chapter 63).
3. Torque chip detector housing (55) 75 to
100 inch-pounds (8.5 to 11.3 Nm).
8. If necessary, replace forward or aft seals
(BHT-206L-CR&O, Chapter 63).
4. Secure chip detector housing (55) to housing
assembly (51) with lockwire (C-405). Install chip
9. Touch up all damaged surface protection detector (56).
(BHT-206L-CR&O, Chapter 63).
5. Install packing (57) on elbow fitting (59) and
63-107. FREEWHEEL ASSEMBLY — install elbow fitting in housing assembly (51).
INSTALLATION
6. Torque jamnut (58) 75 to 125 inch-pounds (8.5 to
14 Nm).
SPECIAL TOOLS REQUIRED
7. Install packing (52) on housing assembly (51) and
NUMBER NOMENCLATURE install housing assembly on mounting studs (53).

T103216-101 Spanner Assembly 8. Install packings (48) on mounting studs (53).

9. Install pilot ring (47) in housing assembly (51) and

MATERIALS REQUIRED on mounting studs (53).

Refer to BHT-ALL-SPM for specifications. 10. Install nuts (46) on mounting studs (53) inside
housing assembly.
NUMBER NOMENCLATURE
11. Torque nuts (46) 50 to 70 inch-pounds (5.65 to
C-001 Grease
7.91 Nm).

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 BHT-206L4-MM-6

Figure 63-16. Seal Cap, Clutch, and Shaft Assembly Inspection

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BHT-206L4-MM-6

12. Lubricate packings (30 and 33) with lubricating oil 23. Install washers (13) and nuts (14) on support
(C-030). studs (19). Torque nuts 50 to 70 inch-pounds (5.65 to
7.91 Nm).
13. Install packing (30) in groove of forward seal cap
(28) and packing (33) in groove on aft end of output 24. Connect oil inlet line (21) to elbow fitting (22).
shaft assembly (24).

14. Install output shaft assembly (24) into housing

assembly (32) and on mounting studs (31). CAUTION

15. Install aluminum washers (27) on mounting studs

(31) and against forward seal cap (28). DO NOT REMOVE OUTPUT ADAPTER
O N C E I T H A S B E E N I N S TA L L E D .
MOVEMENT (IN OR OUT) OF OUTPUT
16. Install steel washer (26) and nuts (25) on ADAPTER MAY CAUSE CONE SET TO
mounting studs (31). BE U N S E AT E D . DAMAGE TO
ACCESSORY DRIVE GEARS AND
17. Torque nuts (25) 50 to 70 inch-pounds (5.65 to OUTPUT SHAFT MAY RESULT.
7.91 Nm).

NOTE
If output adapter is moved, check cone set
CAUTION for seated condition. Check of cone set
may require removal of aft bearing and seal
cap.
MAKE SURE THAT BOTH HALVES OF
CONE SET ARE PROPERLY SEATED IN
G R O O V E O F TA I L R O T O R D R I V E 25. Install output adapter (7) on aft end of freewheel
O U T P U T S H A F T A N D T H AT T H E shaft (6).
SPACER IS FULLY SEATED ON CONE
SET. DAMAGE TO ACCESSORY DRIVE 26. Install packing (8) on washer (9) and install
GEARS AND OUTPUT SHAFT COULD washer with packing on freewheel shaft (6). Apply
R E S U LT I F C O N E S E T B E C O M E S sealant (C-308) to mating edges of output adapter (7)
UNSEATED. CONE SET IS A MATCHED and washer (9).
SET. REMOVE AND INSTALL AS A SET.

18. Install cone set (17) in groove (18) on aft end of 27. Install washers (10) and retaining nut (12).
freewheel shaft (6). If cone set (17) has a groove on
conical surface, install packing (17A). 28. Install spanner assembly (T103216-101) on
output adapter (7).
19. Install spacer (16) on freewheel shaft (6) and
mate with cone set (17). 29. Torque retaining nut (12) 225 to 500 inch-pounds
(25.4 to 56.5 Nm) and install cotter pin (11).
20. Install packing (15) on aft bearing and seal cap
(5) and lubricate packing (15) with lubricating oil
30. Install forward short tail rotor driveshaft
(C-030).
(Chapter 65).

21. Fill area between lips of seal (23) with grease

(C-001). 31. Install main driveshaft (paragraph 63-19).

22. Install aft bearing and seal cap (5) on support 32. If a new, overhauled, or internally repaired
studs (19). Use hand pressure to seat aft bearing and freewheel assembly has been installed, perform run-in
seal cap in output support (20). checks and inspection (paragraph 63-108).

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 BHT-206L4-MM-6

63-108. FREEWHEEL ASSEMBLY — 63-110. TRANSMISSION MOUNTS — CLEANING

OPERATIONAL CHECK

MATERIALS REQUIRED
NOTE
Perform this operational check after each Refer to BHT-ALL-SPM for specifications.
freewheel assembly installation.
NUMBER NOMENCLATURE
1. Perform ground run-in cycle for 20 minutes
(BHT-206L4-FM-1). C-304 Drycleaning Solvent

2. After shutdown, accomplish the following NOTE

requirements:
Although elastomeric bearing and bushing
members in transmission mount support
a. Remove and inspect electric chip detector for assemblies and transmission restraint are
metal particles. If metal particles are found, investigate fuel and oil resistan,t it is recommended
to determine cause (Figure 63-3). that they be kept clean and free of solvents,
fuels, and oil.
b. Inspect freewheel assembly for oil leaks.
1. Clean components of transmission mounts and
63-109. TRANSMISSION MOUNTS — NODAL transmission restraint with drycleaning solvent (C-304)
BEAM
2. Dry with filtered compressed air.
Transmission with mast and main rotor hub and blade
assembly is supported by, and isolated from fuselage 63-111. LINK ATTACHMENTS
by transmission mounts (Nodal Beam) and
transmission restraint. This is accomplished by use of Four Nodal Beam link attachments are steel forgings
four link attachments and two stop mounts bolted to and are attached to transmission top case. Spindles
transmission. Attached to these are four link provide a mounting point for transmission to Nodal
assemblies incorporating elastomeric bearings, which Beam mounting installation.
are secured to four support assemblies and flexure
assemblies. Support assemblies are bolted to cabin 63-112. LINK ATTACHMENTS — REMOVAL
roof shell and cabin roof beam, and contain
elastomeric bearing and bushing members to isolate
and balance vibration inputs from rotor into flexure SPECIAL TOOLS REQUIRED
assemblies. Flexure assemblies are primary vibration
isolating components, that provide for a vibration free
ride throughout helicopter speed range. NUMBER NOMENCLATURE

206-240-001-101 Lift and Cover Plate

Transmission restraint restrains movement of
transmission through use of an elastomeric bearing T100220 Main Rotor Hoisting
and bushing member which is secured to transmission Sling
restraint support. Support is bolted to cabin roof shell
and cabin roof beam along with two drag pins. Two T103141 Hoisting Ring
stop mounts, that are bolted to transmission, are
installed over drag pins. Up stops mounted on drag Commercial Hoist, 600 Pound
pins restrict up movement of transmission and all (272 kg) Capacity,
oscillatory movement. Minimum

Commercial Hoisting Cable,

Tuning weights are bolted to arm and flexure
600 Pound (272 kg)
assemblies and provide for fine tuning and balance of
Capacity, Minimum
transmission mounting system.

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BHT-206L4-MM-6

206-240-001-101 lift and cover plate when mast

MATERIALS REQUIRED assembly is removed.

Refer to BHT-ALL-SPM for specifications. 3. Disconnect link assemblies (7, Figure 63-17)
from link attachment (2) by removing nut (10), support
NUMBER NOMENCLATURE washer (9), and bearing washer (5).
C-309 MEK
4. Remove nuts (4) and washers (3), remove link
attachment (2) from transmission (1). It may be
1. Remove transmission fairing (Chapter 71). necessary to use a plastic mallet to free link
attachment from transmission case due to sealing
2. Support transmission in helicopter with suitable compound between mating surfaces.
hoist and hoisting device. This may be accomplished
by use of a clevis attached to main rotor mast nut, 5. Remove old sealant with a plastic scraper and
main rotor hoisting sling (T100220), or MEK (C-309).

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 BHT-206L4-MM-6

1 2

3
4 T 3
8
7
5
6
2

13

T 1
10

1
12

14 12
11 T 2
15

206L3_MM_63_0018a+

Figure 63-17. Transmission Link Assembly and Attachment (Sheet 1 of 2)

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BHT-206L4-MM-6

1. Transmission 6. Bearing 11. Nut

2. Link attachment 7. Link assembly 12. Thin aluminum washer
3. Steel washer 8. Bearing 13. Bolt
4. Nut 9. Support washer 14. Aft arm assembly
5. Bearing washer 10. Nut 15. Forward arm assembly

36 TO 204 IN-LBS
T 1 (4.1 TO 23 Nm)
120 TO 780 IN-LBS
T 2 (13.6 TO 88.1 Nm)
160 TO 190 IN-LBS
T 3 (18.1 TO 21.4 Nm)

NOTES
1 Apply film of sealing compound (C-328) between mating flanges.

2 After installation of parts, apply bead of sealant (C-308) to mating edge of parts and transmission.

206L3_MM_63_0018b+

Figure 63-17. Transmission Link Assembly and Attachment (Sheet 2 of 2)

63-00-00
Page 60B Rev. 11 31 AUG 2010 ECCN EAR99
 131-IT-2061-4-MM-6

63-113. INSPECTION AND REPAIR. 36 to 204 inch-pounds (4.1 to 23.0 newton-

meters).
1. Visually inspect link attachments (2, figure
figure

>,L

Q-'
63-17)
63-17 for nicks, scratches, dents, and 6. Disconnect and remove hoist and hoisting

0
corrosion damage. device.

a. Maximum depth of nicks, scratches, 7. Install transmission fairing (Volume 9,

E
(0-D

0
1-00

(/)
and dents is 0.005 inch (0.127 mm) in bolt Chapter 71).
Chapter 71
holes, 0.02 inch (0.51 mm) at spot face for
bolt holes, and 0.05 inch (1.3 mm) all other
areas. 63-115. LINK ASSEMBLIES.

b. Maximum depth of corrosion is 0.003 Four Nodal Beam link assemblies are
Ox.

--_-
6-0
35,33

0
inch (0.076 mm) in bolt holes, 0.01 inch (0.25 aluminum alloy forgings and contain two

(t)
mm) at spot face for bolt holes, and 0.025 elastomeric bearings. Link assemblies attach

C)-
(1)0
0

inch (0.635 mm) all other areas. transmission to arm assemblies and flexure of
((0

(TS

O``
Nodal Beam mounting installation.

=`.
2. Blend out acceptable damage with 320 or
400 grit abrasive cloth or paper (C-423).
C-423 SPECIAL TOOLS REQUIRED
Touchup repaired areas with primer (C-204).
C-204
Do not apply primer to spindle portion of link
attachment. NUMBER NOMENCLATURE
Commercial Hoist, 600 Lb (272 kg)
3. Inspect bearing surfaces on spindles of
link attachments (2) for removal or loss of
Capacity, Minimum
6(D

solid film lubricant. Touchup with solid film Hoisting Cable, 600 Lb
600

Commercial
C-005 per (BHT-ALL-SPM).
lubricant (C-005) BHT-ALL-SPM (272 kg) Capacity,
Minimum
63-114. INSTALLATION.
206-240-001-101 Hoisting Ring
1. Clean mating surfaces of transmission (1, Main Rotor Hoist Sling
0
0

T100220
figure 63-17) and link attachment (2) with
00)

figure 63-17
MEK (C-309).
C-309 Ensure all old sealing
compound has been removed.
(On

63-116. REMOVAL.
2. Apply a film of sealing compound (C-328)
C-328
to mounting area of transmission (1) and link 1. Remove transmission fairing (volume 9,
E
cony

attachment (2). chapter 71).

chapter 71

Support transmission (1, figure 63-17) in

...

3. Position link attachment (2) on studs of 2. figure 63-17

,ti
CTS

helicopter with suitable hoist and hoisting

3°o0<cD

O)"
(J)

transmission (1) and secure with washers (3)

O-0
.-.

and nuts (4). Torque nuts (4) 160 to 190 inch- device. This may be accomplished by use of
a clevis attached to main rotor mast nut, or
2o0

pounds (18.08 to 21.47 newton-meters).

U_-

T100220 main rotor hoisting sling or 206-240-

001-101 hoisting ring after mast assembly is
4. Apply a bead of sealing compound (C-
C-
removed.
328 to mating edge surfaces of link
328)
E+.

attachment (2) and transmission (1). Remove

excess sealing compound and sealant. 3. Remove nuts (10), support washers (9),
0

and bearing washers (5).

Position bearing washers (5) on spindles
_C^±.

5.
C)1

of link attachments (2). Then position link 4. Remove nuts (11), washers (12), and
assemblies (7), support washers (9), and nuts bolts (13). Lift link assemblies (7) from arm
...

(10) on link attachments (2). Torque nuts (10) assemblies (14 and 15).
63-00-00
Page 61
1311-IT-20611-4-MM-6

63-117. INSPECTION AND REPAIR. OF C O M P O N E N T F O R

SEPARATION OF STRUCTURAL
1. Visually inspect link assemblies (7, figure
figure DETERIORATION.
63-17 for nicks, scratches, dents, and
63-17)
corrosion damage.
NOTE
a. Maximum depth of nicks, scratches,
(n0
Many elastomeric components will

.3,

0
and dents is 0.005 inch (0.127 mm) on be severely damaged if they are

3
contoured surfaces surrounding elastomeric allowed to remain in contact with oil.
_(a

;QC)

0
bearings (6 and 8) and 0.01 inch (0.25 mm) Oil contaminants should be removed

:3.0
on all other surfaces. Full depth repairs are on regular basis, using detergent (C-
C-

a-.
not allowed on same or opposite sides of 355 and warm water.
355)

(!I

E
flanges within 1.0 inch (25 mm) spacing.
Elastomer in component is covered

0
Maximum depth of corrosion damage is
b. with a thin, oil resistant rubber

+.r
(DD
0.003 inch (0.076 mm) on contoured surfaces coating. If this coating cracks, peels
surrounding elastomeric bearings (6 and 8) or becomes loose on elastomer, it
and 0.005 inch (0.127 mm) on all other should be replaced per steps 1.
surfaces. through 4.
2. Blend out acceptable damage with 320 1. Scrub elastomeric components used in
and 400 grit abrasive cloth or paper (C-423).
C-423 main rotor, swashplate, nodal beam pylon
Apply chemical film material (C-100)to
C-100 support, and airframe with detergent (C-355)
a-0 C-355
repaired areas and touchup with primer (C- C- and water. Rinse with water and dry with
204 per (BHT-ALL-SPM).
204) BHT-ALL-SPM clean cloths.
2. Rinse both metal and rubber elastomeric
(on

63-118. ELASTOMERIC BEARINGS

INSPECTION. component surfaces with aliphatic naphtha
C-305 Wipe dry with clean cloths.
(C-305).
Inspection of elastomeric bearings is feasible
a)>N

3. Apply adhesive (C-307)

C-307 to prepared
only with link assembly removed from surface in uniform thickness '/sa to '/,s inch
helicopter. Once link assembly has been (0.39 to 1.58 mm). To obtain full contact use
removed, inspect for following:
a stiff brush or spatula. Silicone adhesive
(Do

forms a trackfree skin within twenty minutes.

1. Elastomer degradation. Use a 0.005 inch Discontinue use of tools and remove any
(0.127 mm) feeler gage and a magnifying masking tape, approximately ten minutes,
07W

glass. Note maximum depth and arc in

a)(0

before adhesive begins to harden.

degrees of damage (figure 63-17).
figure 63-17
4. Allow component to cure undisturbed at
2. Inspect lower bearing for cracked shims. room temperature for 24 hours.
(CD

Confirm cracks by running firm thin object

.fl

(fingernail) along shim edge. Replace link

assembly if shim crack is detected. 63-120. INSTALLATION.
1. Insert end of link assemblies (7, figure 63-
figure 63-
E

63-119. SEALING OF ELASTOMERIC 17) with large elastomeric bearing (8) into
17
`"°

((DD(
0
E

COMPONENTS. forward and aft arm assemblies (14 and 15).

3._

).C

Align bearings with bushings in arm

Cr.

................. assemblies and install bolts (13), thin

CAUTION aluminum washers (12), and nuts (11). Install
E+,

bolts (13) with heads inboard and torque nuts

(TO

120 to 780 inch-pounds (13.56 to 88.13

REPLACEMENT COATING newton-meters).
2-{

THICKNESS SHOULD NOT

PREVENT PROPER INSPECTION
63-00-00
c(0

Page 62
 131-IT-2061-4-MM-6

2. Position bearing washers (5) with SPECIAL TOOLS REQUIRED (CONT)

chamfered I.D. against spindle shoulder of
link attachment (2), then position link
NUMBER NOMENCLATURE

c
assemblies (7), support washer (9), and nut
(j)
(10). Torque nuts (10) 36 to 204 inch-pounds 206-240-001-101 Hoisting Ring
(4.1 to 23.0 newton-meters).

E
T100220 Main Rotor Hoist Sling
3. Disconnect and remove hoist and hoisting
0

device.
63-122. REMOVAL.
4. Install transmission fairing (Volume 9,
Chapter 71).
Chapter 71 1. Remove transmission fairing (Volume 9,
Chapter 71).
Chapter 71
63-121. ARM AND FLEXURE
';N

ASSEMBLY. 2. Support transmission in helicopter with

suitable hoist and hoisting device. This may

OT! >-o
'"6(n
(Dc 0000

LOCO

00<.CD
Arm and flexure assembly is primary Nodal be accomplished by use of a clevis attached
NOD

to main rotor mast nut, or T100220 main rotor

j00
Beam component that isolates main rotor and
transmission vibrations from fuselage. Nodal hoisting sling or equivalent, or206-240-001-
0Q-
0-wa3o(n0mc

Beam installation develops a standing wave 0)0 101 hoisting ring when mast assembly is
form to reduce fuselage vibrations throughout removed.
helicopter speed range to below level of
3. Remove link assemblies (7, figure 63-17)
figure 63-17

E
perception. Arm assemblies are manufactured
(OD

from aluminum alloy forgings and are bushing from transmission (1) and forward and aft
mounted to forward and aft support arms (24 and 5, figure 63-18 and paragraph
figure 63-18 paragraph
assemblies. Flexure assembly, located 63-116).
63-116
between two arm assemblies, consists of a
laminated elastomer flexure, shims, and shear 4. From aft arm (5) and aft support (16),
E°a0)

pads bonded into metal brackets. Tellurium remove bolt (1), washer (2), up stop (3),
0,0-a

lead tuning weights are located on end of arm spacer (4) and down stop (17).
assemblies adjacent to flexure and provide a
5. From forward arm (24) and forward
"0>a
E

method for tuning Nodal Beam installation.

support assembly (20), remove bolt (1),
washer (2), up stop (3), spacer (4) and down
NOTE stop (17).
Arm and flexure assembly should be
3i03

6. Remove nuts (10), washers (9) and bolts

disassembled in accordance with (21) from forward and aft arms (24 and 5) and
procedure in BHT-206L-CR&O
BHT-206L-CR&O from forward and aft supports (20 and 16) .
manual. Tuning weight adjustments
are not authorized. 7. Remove nuts (11), washers (12), washers
a3.
(<D

0-.-g

(23) and bolts (22) from forward and aft

SPECIAL TOOLS REQUIRED supports (20 and 16). Lift forward and aft arm
and flexures from supports.
NUMBER NOMENCLATURE
m

63-123. INSPECTION AND REPAIR.

Commercial Hoist, 600 Lb (272 kg)
Capacity, Minimum
NOTE
Commercial Hoisting Cable, 600 Lb For detained inspection, refer to
(272 kg) Capacity, BHT-206L-CR&O
BHT-206L-CR&O manual.
Minimum
1. Visually inspect forward and aft arms (24
-1,
Q.0)

w°-.'

and 5, figure 63-18) for nicks, scratches,

C1)

figure 63-18
dents, and corrosion damage.
63-00-00
Page 63
BHT-206L4-MM-6

1 T 3

2
21 3 5

9 4

7
22
8

23
9
T 3
1 10 T 1

2 25
3
4
17
24 18
22
INB 16
23
D 12
17 13 11 T 2
15
F WD
14
14 15 SEE VIEW B
21 12
9
20
19
SEE VIEW A 9
10 T 1
11 T 2

LEFT-HAND SIDE SHOWN

(RIGHT-HAND SIDE OPPOSITE)

206L3_MM_63_0019a+

Figure 63-18. Transmission Arm and Flexure (Sheet 1 of 2)

63-00-00
Page 64 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-6

28 26

27 27
26 INB
D

27
D 1. Bolt
FW
2. Washer
3. Up stop
4. Spacer
5. Aft arm
MOUNTING SURFACE 6. Bushing
7. Bushing
8. Bushing
9. Aluminum washer
20 10. Nut
11. Nut
9 12. Aluminum washer
13. Elastomeric bearing and
T 1 10 bushing member
10 9 14. Barrel nut
T 1 15. Retainer
9 16. Aft support
10 T 1
VIEW A 17. Down stop
(LEFT-HAND SIDE SHOWN) 18. Flexure
19. Elastomeric bearing and
28 28 bushing member
20. Forward support
21. Bolt
27 22. Bolt
27 23. Aluminum washer
28 27 24. Forward arm
25. Tuning weight
27 28 26. External wrenching bolt
27. Special washer
INB 28. External wrenching bolt
D
27

D
MOUNTING FW
SURFACE
75 TO 95 IN-LBS
16 9 T 1 (8.5 TO 10.7 Nm)
240 TO 1500 IN-LBS
9
10 T 1 T 2 (27.1 TO 169.4 Nm)
9
T 1 10 468 TO 516 IN-LBS
9 T 3 (52.8 TO 58.3 Nm)
10 T 1
MOUNTING SURFACES
T 1
10
VIEW B
(LEFT-HAND SIDE SHOWN)
206L4_MM_63_0018b

Figure 63-18. Transmission Arm and Flexure (Sheet 2 of 2)

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 65
B HT-206 L4-M MI-6

a. Maximum acceptable depth of nicks, b. Nicks, scratches, and dents in bore of

cam
QA)

0
scratches, and dents is 0.008 inch (0.203 down stop (17) of 0.01 inch (0.25 mm) depth
mm) and maximum acceptable length is 0.04 or less may be repaired by deepening

0.o
(D^¢)

inch (1.0 mm). Full depth repairs are not counterbore a maximum of 0.010 inch (0.254
E

=11
allowed on same or opposite sides of flanges mm).
within 1.0 inch (25.4 mm) spacing.
c. Maximum acceptable area of bond
b. Maximum acceptable depth of separation for elastomeric material on down
corrosion damage is 0.004 inch (0.102 mm). and up stops (17 and 3) is 0.6 sq. in. (400 sq.
mm). Maximum acceptable depth of flex

-ti
c. Maximum acceptable depth of cracks is 0.1 inch (2.5 mm).

°00
3_3

scratches in bushings (6 through 8) is 0.008

0)E^3
inch (0.203 mm) or maximum acceptable d. Blend out acceptable damage (step 2.).
width is 0.05 inch (1.3 mm). Cracks or
corrosion in bushings require bushing INSTALLATION.
replacement. 63-124.

2. Blend out acceptable damage with 320 or 1. Position forward and aft arms (24 and 5,
63-18) and flexure (18) into forward
.-..

400 grit abrasive cloth or paper (C-423).

C-423
figure
figure 63-18
Apply chemical film material (C-100)to
C-100 and aft supports (20 and 16).
repaired areas and touch up with primer (C-
C-
2. Align bushings (7) in forward and aft arms

^O,
204).
204
(24 and 5) with elastomeric bearing and
3. Check tuning weights (25) for security to bushing members (13 and 19). Loosely install
a)-

n>'
aft and forward arms (5 and 24). bolts (22), aluminum washers (12), thin
aluminum washer (23), and nuts (11). Install
(09

c
4. Inspect flexure (18) for security to forward bolts with heads inboard.
and aft arms (24 and 5) and damage to
elastomeric material covering. 3. Align tangs on elastomeric bearing and
(3D

bushing members (13 and 19) with bushings

5. Visually inspect flexure assembly end (6) in forward and aft arms (24 and 5). Install
housings for nicks, scratches, dents, bond bolts (21), heads inboard, with thin aluminum
separation, and corrosion damage. washers (9) and nuts (10).
4. Check that barrel nuts (14) and retainers

(CD
Maximum acceptable depth of nicks,
a.
330

scratches, and dents is 0.008 inch (0.203 (15) are installed and aligned with bolt holes
.U,

mm) and maximum acceptable length is 0.040 in aft support assembly (16) and support
0+,
-.-a

inch (1.02 mm) on housings bolted to either located inside cabin and below forward
end of flexure (18). support (20).

b. Maximum acceptable depth of NOTE

corrosion damage is 0.004 inch (0.102 mm).
Washer (2) is optional, as required,
c. Blend out acceptable damage (step 2.). to obtain thread engagement.
Maximum permissible exposed
6. Visually inspect down stops (17) and up threads through barrel nut is two.
.m+

stops (3) for nicks, scratches, dents, and

OT,

corrosion damage. a. Through aft arm (5) and aft support

(16) loosely install bolt (1), washer (2), up
a. Maximum acceptable depth of nicks, stop (3), spacer (4), and down stop (17),
^L`

scratches, and dents on cadmium plated engaging barrel nut (14) in aft support
i.irfaces is 0.05 inch (1.3 mm). Nicks, assembly (16).
scratches, and dents less than 0.01 inch (0.25
mm) in depth need not be repaired. b. Through forward arm (24) and forward
support (20) loosely install bolt (1), washer
(2), up stop (3), spacer (4), and down stop
63-00-00
Page 66
 BHT-206L4-MM-6

(17), engaging barrel nut (14). Down stop (17) is 2. Support transmission in helicopter with suitable
inserted between forward arm (24) and structure hoist and hoisting device. This may be accomplished
aligning spacer (4) with counterbore in down stop. by the use of a clevis attached to the main rotor mast
nut, or main rotor hoisting sling (T100220). When mast
assembly is removed, use lift and cover plate
c. Torque bolts (1) 468 to 516 inch-pounds (52.8
(206-240-001-101).
to 58.3 Nm).

d. Torque nuts (11) 240 to 1500 inch-pounds 3. Remove link assemblies (7, Figure 63-17) from
(27.1 to 169.4 Nm). transmission (paragraph 63-116).

4. Remove forward and aft arms (24 and 5,

NOTE Figure 63-18) with flexure (18) from forward and aft
supports (20 and 16) (paragraph 63-122).
It is permissible to use a maximum of seven
additional thin aluminum washers to obtain 5. Remove forward and aft supports (20 and 16) by
torque range. removing bolts (26 and 28), washers (9), washers
(27), and nuts (10). It may be necessary to trim sealant
5. Install link assemblies (7, Figure 63-17 and
from the mating edges of support and structure to
paragraph 63-120).
remove part.

6. Disconnect and remove hoist and hoisting device. 63-127. SUPPORT ASSEMBLIES — INSPECTION
AND REPAIR
7. Install transmission fairing (Chapter 71).

63-125. SUPPORT ASSEMBLIES MATERIALS REQUIRED

The forward and aft support assemblies contain Refer to BHT-ALL-SPM for specifications.
bonded elastomeric bearing and bushing members to NUMBER NOMENCLATURE
isolate the arm and flexure assemblies from the
fuselage. Support assemblies are manufactured from C-204 Epoxy Polyamide
aluminum alloy forgings. Primer

63-126. SUPPORT ASSEMBLIES — REMOVAL C-309 MEK

C-423 Abrasive Paper

SPECIAL TOOLS REQUIRED

1. Inspect cabin roof shell and cabin roof beam for
evidence of damage in area of forward and aft
NUMBER NOMENCLATURE supports (20 and 16, Figure 63-18). Remove aged
sealant or sealing compound with MEK (C-309) and
206-240-001-101 Lift and Cover Plate plastic scraper.
(206L3+ IGW Upgrade)
T100220 Main Rotor Hoisting 2. Visually inspect forward and aft supports (20 and
Sling 16) for nicks, scratches, dents, and corrosion damage.

Commercial Hoist, 600 Pound a. Maximum acceptable depth of nicks,

(272 kg) Capacity, scratches, and dents is 0.005 inch (0.127 mm) in bolt
Minimum holes. Maximum acceptable damage in all other areas
is 0.008 inch (0.203 mm) in depth and 0.040 inch
Commercial Hoisting Cable,
(1.01 mm) in length.
600 Pound (272 kg)
Capacity, Minimum b. Maximum acceptable depth of corrosion
damage is 0.003 inch (0.076 mm) in bolt holes and
1. Remove transmission fairing (Chapter 71). 0.004 inch (0.102 mm) in all other areas.

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 67
BHT-206L4-MM-6

1 2 TIGHTEN NUT UNTIL CONTACT IS MADE

WITH STOP, THEN TIGHTEN NUT
3 AN ADDITIONAL 90 TO 120°.
4 SEE DETAIL A

5 7
6 8
9 2 7
(ALTERNATE)
11
12 10

14 13 T 6 20 T 2
1 6
AREAS NOTED MUST BE
15 T 1 21 23
FREE OF ADHESIVE 18 22
12 24
16 19
0.12 IN.
(3.0 mm) 17
34
BOND PACKING
USING ADHESIVE 33
(C-311) 35
25 T 3
0.10 IN. 32 21
(2.5 mm) 4 29
28
32 26 T
DETAIL A 30 27 5
T 31
4
1. Transmission
31 T 4
32
2. Nut
3. Up stop
4. Packing 14. Steel washer 25. Nut
5. Bolt 15. Nut 26. Nut
6. Aluminum washer 16. Bolt 27. Steel washer
7. Transmission restraint 17. Special washer 28. Bolt
8. Restraint spring 18. Torsional (elastomeric) bearing 29. Torsional (elastomeric) bushing
9. Special washer 19. Torsional (elastomeric) bushing 30. Torsional (elastomeric) bearing
(140-009H25S40) 20. Nut 31. Nut
10. Bearing 21. Thin aluminum washer 32. Thin aluminum washer
11. Bushing 22. Isolation support 33. Bolt
12. Stop mount 23. Bolt 34. Drag pin
13. Nut 24. Thin aluminum washer 35. Bolt

NOTES
1 Permissible to use a maximum of four 15 TO 90 IN-LBS 120 TO 160 IN-LBS
additional washers (6), as required, to obtain
T 1 (1.7 TO 10.1 Nm) T 4 (13.5 TO 18.0 Nm)
torque range for cotter pin installation. 30 TO 40 IN-LBS 260 TO 390 IN-LBS
T 2 (3.4 TO 4.5 Nm) T 5 (29.3 TO 44.0 Nm)
2 Permissible to use a maximum of three
washers (9) between isolation support 75 TO 95 IN-LBS 444 TO 502 IN-LBS
and transmission restraint.
T 3 (8.5 TO 10.7 Nm) T 6 (50.1 TO 56.7 Nm)

206L3_MM_63_0020+

Figure 63-19. Transmission Restraint

63-00-00
Page 68 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-6

3. Blend out acceptable damage with No. 320 or washers (9), and nuts (10). Locate washers as shown
400 grit abrasive paper (C-423). Touch up repaired in View A. Torque nuts 75 to 95 inch-pounds (8.5 to
areas with epoxy polyamide primer (C-204). 10.7 Nm).

4. Visually inspect elastomeric bearing and bushing 4. Position aft support (16) in place. Secure with ten
members (13 and 19) for evidence of cuts, flex cracks, MS21250-04012 12-point external wrenching bolts
and bond separation. (28), special washers (27), aluminum washers (9), and
nuts (10). Locate washers as shown in View B. Torque
a. Maximum area of metal-to-rubber bond nuts 75 to 95 inch-pounds (8.5 to 10.7 Nm).
separation not to exceed a total of 0.6 square inch
(400 mm2).
5. After sealant (C-308) has cured, torque check all
b. Maximum acceptable depth of flex cracks or attaching nuts.
surface failure of rubber due to flexing not to exceed
0.1 inch (2 mm). 6. Install forward and aft arms (24 and 5) and flexure
(18) (paragraph 63-124).
c. Inspect bore of elastomeric bearing and
bushing for evidence of scratches, cracks, or 7. Install four link assemblies (7, Figure 63-17)
corrosion. Maximum acceptable depth of scratches is (paragraph 63-120).
0.008 inch (0.203 mm) or maximum acceptable length
is 0.05 inch (1.27 mm). Cracks or corrosion are not
8. Disconnect and remove hoist and hoisting device.
permitted in bushing.

5. Inspect barrel nuts (14) and retainers (15) for 9. Install transmission fairing (Chapter 71).
cracks, distortion, and thread damage.
63-129. TRANSMISSION RESTRAINT
63-128. SUPPORT ASSEMBLIES —
INSTALLATION Transmission restraint is an elastomeric spring
assembly enclosed in a steel housing. Restraint is
secured in an isolation support that is mounted to
MATERIALS REQUIRED cabin roof beam and restrains transmission movement
both fore and aft and laterally. Forward arms of
Refer to BHT-ALL-SPM for specifications. restraint contain Teflon lined spherical bearings that
are attached to stop mounts which are secured to
NUMBER NOMENCLATURE transmission. Transmission is further restrained
through stop mounts by up stops and drag pins.
C-308 Sealant

1. Install barrel nuts (14, Figure 63-18) and retainers SPECIAL TOOLS REQUIRED
(15) in aft support (16) and in support structure inside
cabin for forward support (20), if removed.
NUMBER NOMENCLATURE
2. Apply sealant (C-308) to faying surfaces of cabin 206-240-001-101 Hoisting Ring
roof shell and aft and forward support assemblies (16
and 20). T100220 Main Rotor Hoist Sling

3. Position forward support (20) in place. Secure Commercial Hoist, 600 Pound
inboard side with two 12-point external wrenching (272 kg) Capacity,
bolts (26) (MS21250-04014), special washers (27), Minimum
aluminum washers (9), and nuts (10). Locate washers
Commercial Hoisting Cable,
as shown in View A. Secure center and outboard side
600 Pound (272 kg)
with three 12-point external wrenching bolts (28)
Capacity, Minimum
(MS21250-04012), special washers (27), aluminum

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 69
BHT-206L4-MM-6

63-130. TRANSMISSION RESTRAINT — b. Maximum acceptable depth of corrosion is

REMOVAL 0.004 inch (0.102 mm).

1. Remove transmission fairing (Chapter 71). 2. Blend out acceptable damage with 320 or 400 grit
abrasive paper (C-423). Touch up repaired areas and
bare spots with epoxy polyamide primer (C-204).
2. Support transmission in helicopter with suitable
hoist and hoisting device. This may be accomplished
by use of a clevis attached to main rotor mast nut or 3. Inspect bearings (10) in arms of transmission
main rotor mast hoist sling (T100220) or hoisting ring restraint (7) for smoothness of movement, looseness,
(206-240-001-101) when mast assembly is removed. and general condition.
Hoist transmission sufficiently to allow removal of
hardware from transmission restraint. a. Maximum acceptable depth of scratches is
0.008 inch (0.203 mm) and maximum acceptable
3. Remove main driveshaft (paragraph 63-16). width is 0.05 inch (1.3 mm). Cracks or corrosion on
bearing (10) will require bearing replacement.

4. Disconnect hose clamps on left arm of b. Maximum allowable axial wear of bearing (10)
transmission restraint (7, Figure 63-19) for freewheel is 0.007 inch (0.178 mm).
oil return hose.
c. Check both sides of bearing (10) for evidence
5. Disconnect transmission restraint (7) from of Teflon fabric liner deterioration that would require
isolation support (22) by removing nut (26), washers bearing replacement (BHT-206L-CR&O).
(27), bolt (16), and washers (9 and 17). Adjust hoist
tension to allow free removal of bolt. 4. Visually inspect restraint spring (8) in
transmission restraint (7) for evidence of cuts, flex
6. Remove nuts (15), washers (6), and bolts (5). cracks, or bond separation.
Remove transmission restraint (7) from helicopter.
a. Maximum acceptable area of metal to rubber
bond separation is a total of 0.6 square inch
63-131. TRANSMISSION RESTRAINT —
(400 mm2).
INSPECTION AND REPAIR
b. Maximum acceptable area of flex cracks or
surface failure of rubber due to flexing is 0.1 square
MATERIALS REQUIRED inch (60 mm2).

Refer to BHT-ALL-SPM for specifications. c. Inspect bore of torsional bushings (19 and 29)
for evidence of scratches, cracks, or corrosion.
NUMBER NOMENCLATURE
Maximum acceptable depth of scratches is 0.008 inch
C-204 Epoxy Polyamide (0.203 mm) and maximum acceptable width is 0.05
Primer inch (1.3 mm). Cracks or corrosion are not permitted in
bushing.
C-423 Abrasive Paper
63-132. TRANSMISSION RESTRAINT —
INSTALLATION
1. Visually inspect transmission restraint (7,
Figure 63-19) for nicks, scratches, dents, and 1. Position transmission restraint (7, Figure 63-19)
corrosion damage. into stop mount (12) and isolation support (22). Install
bolt (16) with special washers (9 and 17) through
a. Maximum acceptable depth of nicks and isolation support and through transmission restraint
scratches is 0.008 inch (0.203 mm) and dents (7), using steel washers (27) as necessary to fill gap
0.040 inch (1.02 mm). Full depth repairs are not between isolation support and transmission restraint.
allowed on same or opposite sides of transmission Install nut (26). Torque nut 260 to 390 inch-pounds
restraint (7) within 1.0 inch (25.4 mm) spacing. (29.4 to 44.0 Nm).

63-00-00
Page 70 Rev. 11 31 AUG 2010 ECCN EAR99
 BHT-206L4-MM-6

3. Disconnect and remove hoist and hoisting device.

NOTE
It is permissible to use maximum of four
additional washers to obtain torque range 4. Install main driveshaft (paragraph 63-19).
and install cotter pins.
5. Secure hose clamp installation to left arm of
2. Adjust hoist tension and position transmission transmission restraint (7).
assembly to allow installation of bolts (5), washers (6)
and nuts (15). Torque nuts 15 to 90 inch-pounds (1.69
to 10.17 Nm). 6. Install transmission fairing (Chapter 71).

63-00-00
ECCN EAR99 31 AUG 2010 Rev. 11 Page 70A/70B
 B HT-206 L4-M M-6

to exceed 0.008 inch (0.203 mm) or 0.05 inch

('O
63-133. ISOLATION SUPPORT.
(1.3 mm) in length. Cracks or corrosion are
Isolation support is an aluminum alloy forging not permitted in bushing (BHT-206L-CR&O).
BHT-206L-CR&O
and is secured to upper cabin roof shell and

)-0
'-0
cabin roof beam. Isolation support provides a 63-136. INSTALLATION.
fixed structure support for transmission
0
restraint, limiting transmission movement

^0)
E
1. Position isolation support (22, figure 63-
figure 63-

0--o
through elastomeric bearings. 19) on cabin roof shell and align bolt holes.
19

63-134. REMOVAL. 2. Insert bolts (28) from bottom and bolts

('7

(23) from top with thin aluminum washers (21

._.
and 24) through isolation support (22), cabin

=).

-0i
co-
1. Remove transmission fairing (Volume 9,

([!
c

Chapter 71).
Chapter 71 roof shell, and cabin roof beam. Bolts (28) are
rte

longest and are installed in four forward

2. Remove transmission restraint (7, figure
figure locations. If necessary, install additional thin
^0`

aluminum washers on each bolt and secure

000
(i3
63-19 and paragraph
63-19 63-130).
paragraph 63-130
with nuts (20 and 25). Torque nuts (20) 30 to

`-'
0)-O
3. Remove isolation support (22) from 40 inch-pounds (3.39 to 4.52 newton-meters).
0'(n

structure by removing bolts (23 and 28), Torque nuts (25) 75 to 95 inch-pounds (8.47
washers (24 and 21), and nuts (25 and 20). to 10.73 newton-meters).

3. Install transmission restraint (7)

63-135. INSPECTION AND REPAIR. (paragraph 63-132).
paragraph 63-132

1. Inspect cabin roof shell and cabin roof 4. Install transmission fairing (Volume 9,
0.,.

beam for evidence of damage in area of Chapter 71).

Chapter 71
isolation support (22, figure 63-19).
figure 63-19
C')

2. Visually inspect isolation support (22) for 63-137. STOP MOUNTS.

-'a

nicks, scratches, dents, and corrosion

Two stop mounts are steel forgings attached

-..
damage.
(DD

to lower aft portion of transmission lower

case. Stop mounts limit vertical and

E
E
0

a.Maximum acceptable depth of nicks,

scratches, and dents is 0.003 inch (0.076 oscillatory movement of transmission.
mm) in bolt holes, 0.005 inch (0.127 mm) in
E

bushing area, and 0.02 inch (0.51 mm) on SPECIAL TOOLS REQUIRED
3v)3"

other surfaces. Full depth repairs are not

Nina

allowed on same or opposi to sides of

0

isolation support within 1.0 inch (25 mm) NUMBER NOMENCLATURE

spacing. Commercial Hoist, 600 Lb (272 kg)
-f.

Capacity, Minimum
b. Maximum acceptable depth of
j30-

corrosion is 0.002 inch (0.051 mm) in bolt Commercial Hoisting Cable, 600 Lb
holes, 0.003 inch (0.076 mm) in bushing area, (272 kg) Capacity,
and 0.01 inch (0.25 mm) on other surfaces. Minimum
3. Blend out acceptable damage with 320 or 206-240-001-101 Hoisting Ring
c

400 grit abrasive cloth or paper (C-423).

C-423
a'>'-

Apply chemical film material (C-100)to

C-100 T100220 Main Rotor Hoist Sling
repaired areas and touch up with primer (C-
C-
004).
004
63-138. REMOVAL.
4. Inspect bore of bushings (19 and 29) for
evidence of scratches, cracks, or corrosion. 1. Remove transmission fairing (Volume 9,
0

Maximum acceptable depth of scratches not Chapter 71).

Chapter 71

63-00-00
Page 71
 BHT-2061-4-M M-6

2. Remove main driveshaft (paragraph 63-

paragraph 63- opposite sides of lugs within a 0.50 inch (13
16).
16 mm) spacing.

Support transmission in helicopter with c. Inspect bushings (11) for scratches,

0'-.
a:.
3.
suitable hoist and hoisting device. This may cracks, corrosion, and security. Maximum

`)I<

?03
be accomplished by use of a clevis attached acceptable depth of scratches is 0.008 inch
to main rotor mast nut, or T100220 main rotor (0.203 mm) and 0.05 inch (1.3 mm) in length.
'""
.,_.

NN)
O-r

hoist sling or 206-240-001-101 hoisting ring No cracks or corrosion are allowed in

when mast assembly is removed. bushings.

2. Blend out acceptable damage with 320 or

3(D
4. Remove transmission restraint (7, figure
figure
3'(n

400 grit abrasive cloth or paper (C-423).

.-r
63-19 (paragraph
63-19) 63-130).
paragraph 63-130 C-423
Touchup repaired areas with primer (C-204).
C-204
5. Disconnect four link assemblies
(paragraph 63-116), and hoist transmission 63-140. INSTALLATION.
3-1

paragraph 63-116
(1) only enough to allow removal of bolts (33)
0

after stop mounts (12) and drag pins (34) 1. Clean mating surfaces of transmission (1,
.O+

have been disconnected. Use extreme figure 63-19) and stop mount (12) with MEK
figure 63-19
caution during hoisting not to apply tension to (C-309).
C-309 Ensure all aged sealant has been
:.QC

connected control tubes, hose assemblies, removed.

and electrical cabling.
2. Ensure packing (4) is serviceable or new

7'-

c)>1
6. Remove nuts (2) and up stops (3) from packing is properly bonded to stop mount (12)
drag pins (34) and stop mounts (12). Remove with adhesive (C-311)
C-311 (detail A).
>'.'

bolts (33 and 35), washers (32), nuts

(31),nuts (13) and washers (14). Remove stop 3. Apply a film of sealing compound (C-328)
C-328
mounts (12) and drag pins (34). It may be to mounting area on transmission (1) for stop
a(D3

necessary to use a plastic mallet to free stop mount (12).

0

mounts from transmission lower case due to

E

4. Insert drag pin (34) into stop mount (12)

...
sealing compound applied between mating
surfaces. and position assembly to studs on
transmission (1) and structure of helicopter.
stn

a)-
Ensure that spindle of drag pin (34) is tilted
Ill

amC

7. Remove aged sealant with a plastic

-0U

scraper and MEK (C-309).

C-309 forward then secure to structure with bolts (33 r..
(t)

and 35), thin aluminum washers (32), and

E

nuts (31). Torque nuts (31) 120 to 160 inch-

63-139. INSPECTION AND REPAIR. pounds (13.50 to 18.08 newton-meters).

1. Visually inspect stop mounts (12, figure 5. Secure stop mount (12) to transmission
3N?

figure
63-19)
63-19 for nicks, scratches, dents and (1) with steel washers (14) and nuts (13).
corrosion damage. Torque nuts (13) 444 to 502 inch-pounds
(50.1 to 56.7 newton-meters).
a. Maximum acceptable depth of nicks,
E

6. Apply a bead of adhesive (C-308)

C-308 to
v0)-C)

scratches, and dents is 0.005 inch (0.127

mating edge surfaces of stop mount (12) and
33.

0).-

mm) on lugs for bushings (11) and bolt holes,

0.02 inch (0.51 mm) in radius groove for transmission (1). Remove excess sealing
packings (4), and 0.05 inch (1.3 mm) on other compound.
(n-0

surfaces.
7. Reconnect link assemblies (paragraph 63-
paragraph 63-
0

114).
114
b. Maximum acceptable depth of
0-"

-orrosion is 0.003 inch (0.076 mm) on lugs for

0
0
0
C

uushings (11) and bolt holes, 0.01 inch (0.25

8. Install transmission restraint (7)
mm) in radius groove for packings (4), and
(paragraph 63-132).
paragraph 63-132
a03

0.025 inch (0.635 mm) on other surfaces. Full

depth repairs are not allowed on same or
63-00-00
Page 72
 131-IT-2061-4-MM-6

9. Remove all tension from transmission and b. Maximum acceptable depth of

.t2
install up stops (3, figure 63-19) on spindle
figure 63-19 corrosion is 0.025 inch (0.635 mm) on top
drag pins (34) and secure with nuts (2). surface and 0.002 inch (0.051 mm) on lower

,-.
Tighten nuts (2) until contact is made with up (disc) surface.
stops, then tighten nuts an additional 90 to

.C+
120 degrees. 2. Blend out acceptable damage with 320 or
400 grit abrasive cloth or paper (C-423).
C-423
10. Disconnect and remove hoist and Touchup repaired areas and bare spots with
hoisting device. primer (C-204).
C-204

11. Install main driveshaft (paragraph 63-

paragraph 63- 3. Visually inspect drag pins (34) for nicks,
19).
19 scratches, dents, and corrosion damage.
12. Install transmission fairing (Volume 9, a. Maximum acceptable depth of nicks,
Chapter 71).
Chapter 71 scratches, and dents is 0.005 inch (0.127
mm) in bolt holes and 0.05 inch (1.27 mm) on
63-141. DRAG PINS AND UP STOPS. all other surfaces. Nicks, scratches, and dents
'fl

on drag pins less than 0.01 inch (0.25 mm) in

E
depth need not be repaired.
Two drag pins are steel forgings attached to
0.0

upper cabin roof shell and cabin roof beam. b. Maximum acceptable depth of

E°o
Drag pins limit oscillatory movement of corrosion is 0.003 inch (0.076 mm) in bolt
transmission through stop mounts. Vertical holes and 0.025 inch (0.635 mm) on all other

c
restraint is limited by up stops which consist surfaces.
of bonded upper and lower discs in contact
3-a

with stop mounts.

c. Blend out acceptable damage (step 2.).
63-142. REMOVAL.
63-144. INSTALLATION.
1. Remove transmission fairing (Volume 9,
1. For installation of drag pins (34, figure 63-
figure 63-

Caw
.(Q
Chapter 71).
Chapter 71
19) with transmission (1) installed (paragraph
19 E-a' paragraph

-(D
2. Remove nuts (2, figure 63-19) from up
figure 63-19 63-140 it will be necessary to install drag
63-140)
pins (34) and stop mounts (12) together with
stops (3), and drag pins (34). Lift up stops (3)
transmission (1) partially hoisted.
from spindle of drag pins (34).

3. For removal of drag pins (34) with 2. Install drag pins (34) with spindle tilted
forward, and secure with bolts (33 and 35),
transmission (1) installed (paragraph 63-138)
paragraph 63-138 thin aluminum washers (32), and nuts (31).
it will be necessary to remove stop mounts
Torque nuts (31) 120 to 160 inch-pounds
(12) with drag pins and transmission partially
hoisted. (13.56 to 18.08 newton-meters).

3. With stop mounts (12) installed and all

63-143. INSPECTION AND REPAIR. tension removed from transmission, insert up
stops (3) on spindle of drag pins (34) and
-'0 ...

-^0)

1. Visually inspect up stops (3, figure 63-19)

figure 63-19 install nuts (2). Tighten nuts (2) until contact
3+.

for nicks, scratches, dents, and corrosion is made with up stop (3), then tighten nuts an
damage. additional 90 to 120 degrees.

a. Maximum acceptable depth of nicks, 4. Install transmission fairing (Volume 9,

E-0

SD-0
M.-

scratches, and dents is 0.05 inch (1.3 mm) on Chapter 71).

Chapter 71
top surface and 0.004 inch (0.102 mm) on
lower (disc) surface. Nicks, scratches, and
D))

dents on top surfaces less than 0.01 inch

(0.25 mm) in depth need not be repaired.

63-00-00
Page 73/74