S-76B

MAINTENANCE MANUAL, SA 4047-76B-2

CHAPTER

66 POWERTRAIN

WARNING – This document contains technical data subject to the EAR. Authorization is required prior to providing
this technical data to any company, entity, person, or destination. EAR Export Classification: ECCN 9E991, EAR99
COPYRIGHT© 2012 Sikorsky Aircraft
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

WARNING

SPRAYING PRIMER OR SANDING PRIMED SURFACES MAY RESULT IN RELEASE OF HEXAVALENT CHROMIUM.
INHALATION OF HEXAVALENT CHROMIUM DUST MAY CAUSE LUNG CANCER. EXPOSURES ARE DEPENDENT
ON VARIOUS FACTORS INCLUDING WORK PRACTICES AND TASK DURATION. USE APPROPRIATE PERSONAL
PROTECTIVE EQUIPMENT, INCLUDING A RESPIRATOR, WHEN PERFORMING THIS WORK.

66 - WARNING
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

CHAPTER 66

POWERTRAIN

TEMPORARY REVISION RECORD

TEMP ISSUE REISSUE PAGE AFFECTED INCORPORATED IN MANUAL

REV. NO. DATE DATE CHAPTER/SECTION PAGE BY REV. NO. DATE

66-1 APR 10/95 66-30-00 402 15 JUL 31/96

66-2 MAY 15/95 66-10-00 410 15 JUL 31/96

66-3 NOV 10/95 66-20-00 601 15 JUL 31/96

66-4 NOV 10/95 66-30-00 605 15 JUL 31/96

66-5 FEB 15/96 66-40-00 407 15 JUL 31/96

66-6 NOV 30/98 66-10-00 604 18 FEB 15/99

66-7 DEC 15/98 66-30-00 605 18 FEB 15/99

66-8 MAY 7/99 66-50-00 101 19 NOV 15/01

66-9 OCT 25/99 66-10-00 606B 19 NOV 15/01

66-10 MAR 31/00 66-10-00 403 19 NOV 15/01

66-11 NOV 22/02 66-50-01 203 21 OCT 31/03

66-12 OCT 11/02 66-10-00 607 20 OCT 31/02

66-13 FEB 28/03 66-40-00 602 21 OCT 31/03

66-14 APR 17/03 66-50-01 203 21 OCT 31/03

66-15 MAY 25/04 66-10-00 818 22 AUG 31/04

66-16 JUN 30/04 66-10-00 809 22 AUG 31/04

66-17 MAR 17/05 66-10-00 404 23 OCT 31/05

66-18 AUG 24/06 66-10-00 826 24 OCT 31/06

66-19 OCT 23/09 66-10-00 604 29 MAY 31/10

66-20 OCT 23/09 66-10-00 605 29 MAY 31/10

66-21 OCT 23/09 66-10-00 812 31 MAY 31/11

66-22 JUL 27/11 66-11-02 201 32 OCT 31/11

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REV. NO. DATE DATE CHAPTER/SECTION PAGE BY REV. NO. DATE

66-25 DEC 31/17 66-10-00 ALL

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66-29 SEP 17/14 NOV 5/14 66-10-00 ALL 35 OCT 31/14

66-30 SEP 30/15 66-11-02 201-204 36 DEC 15/15

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CHAPTER/ REV. CHAPTER/ REV.

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66-TITLE 417/418 Jul 31/17 37
66-WARNING 1/2 Oct 31/11 32 419/420 Jul 31/17 37
66-LEP 1 Jul 31/17 37 421/422 Jul 31/17 37
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66-CONTENTS 1 Jul 31/17 37 427/428 Jul 31/17 37
2 Jul 31/17 37 429/430 Jul 31/17 37
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CHAPTER 66

POWERTRAIN

TABLE OF CONTENTS

CHAPTER/
SUBJECT SECTION PAGE

POWERTRAIN - GENERAL 66-00-00

General. ........................................................................................................................................... 1
Description and Operation ............................................................................................................... 1

POWERTRAIN - TESTING AND TROUBLESHOOTING 66-00-00

General. ........................................................................................................................................... 101

MAIN GEAR BOX- DESCRIPTION AND OPERATION 66-10-00

General. ........................................................................................................................................... 1
Description and Operation ............................................................................................................... 1

MAIN GEAR BOX - SERVICING 66-10-00

General. ........................................................................................................................................... 301
Draining Main Gear Box. .................................................................................................................. 301
Flushing Main Gear Box. ................................................................................................................... 301

MAIN GEAR BOX - REMOVAL/INSTALLATION 66-10-00

Removal Main Gear Box.................................................................................................................... 401
Installation Main Gear Box. ............................................................................................................... 402
Disassembly/Assembly Main Gear Box. ............................................................................................. 406

MAIN GEAR BOX - ADJUSTMENT/TEST 66-10-00

General. ........................................................................................................................................... 501

MAIN GEAR BOX - INSPECTION/CHECK 66-10-00

Overspeed Inspection Requirements.................................................................................................... 601
Sudden Stoppage Inspection Requirements.......................................................................................... 601
Main Gear Box Torque Limitations. .................................................................................................... 602
Main Gear Box Temperature Limitations. ............................................................................................ 603
Gear Box Run-In. .............................................................................................................................. 604
Allowable Oil Leakage. ..................................................................................................................... 604
Gear Box Contamination. .................................................................................................................. 604
Identification of Metal Particles. .......................................................................................................... 604
SOAP Analysis of Main Gear Box Oil. ............................................................................................... 607
Gear Box Serviceability Check. .......................................................................................................... 609
Gear Box Inspection/Corrosion Protection. ......................................................................................... 609
Main Gear Box Housing Inspection. ................................................................................................... 612
Main Gear Box Lower Housing Jet Bores Inspection............................................................................. 612
Swashplate Guide Area Inspection. .................................................................................................... 614

MAIN GEAR BOX - CLEANING/PAINTING 66-10-00

Cleaning/Painting Main Gear Box. .................................................................................................... 701

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MAIN GEAR BOX - APPROVED REPAIRS 66-10-00

Breather Replacement. ....................................................................................................................... 801
Magnetic Drain Plug Replacement. ..................................................................................................... 801
Main Rotor Shaft Shield Replacement. ................................................................................................ 801
Oil Cooler Blower Drive Seal Replacement.......................................................................................... 802
Hydraulic Pump Seal Replacement...................................................................................................... 805
Engine Input Seal and Packings Replacement. ..................................................................................... 807
Tail Drive Shaft Flange Seal Replacement............................................................................................ 810
Sleeve Replacement. .......................................................................................................................... 812
Unused Center Drive Seal and Packing Replacement. .......................................................................... 814
Hydraulic Manifold Bracket Replacement. ........................................................................................... 815
Main Rotor Shaft Upper Seal Replacement.......................................................................................... 819
Main Rotor Shaft Upper Seal Replacement.......................................................................................... 824
Main Rotor Shaft Lower Housing Seal Replacement. ............................................................................ 827
Unused Blower Drive Assembly Removal/Reinstallation........................................................................ 829

MAIN GEAR BOX LUBRICATION SYSTEM - DESCRIPTION AND OPERATION 66-11-00

Description and Operation ............................................................................................................... 1

OIL PUMPS - DESCRIPTION AND OPERATION 66-11-01

Description and Operation ............................................................................................................... 1

OIL PUMPS - MAINTENANCE PRACTICES 66-11-01

Removal/Installation Oil Pump. .......................................................................................................... 201
Adjustment/Test Oil Pump. ................................................................................................................ 201

OIL FILTER - DESCRIPTION AND OPERATION 66-11-02

Description and Operation ............................................................................................................... 1

OIL FILTER - MAINTENANCE PRACTICES 66-11-02

Removal/Installation Oil Filter. ........................................................................................................... 201
Inspection/Check Oil Filter Housing Mounting Studs............................................................................ 202

OIL STRAINERS - DESCRIPTION AND OPERATION 66-11-03

Description and Operation................................................................................................................. 1

SIGHT WINDOW- DESCRIPTION AND OPERATION 66-11-04

Description and Operation ............................................................................................................... 1

SIGHT WINDOW - MAINTENANCE PRACTICES 66-11-04

Removal/Installation Sight Window. ................................................................................................... 201

OIL FILLER- DESCRIPTION AND OPERATION 66-11-05

Description and Operation ............................................................................................................... 1

OIL FILLER - MAINTENANCE PRACTICES 66-11-05

Removal/Installation Oil Filler. ........................................................................................................... 201

OIL COOLER- DESCRIPTION AND OPERATION 66-11-06

Description and Operation ............................................................................................................... 1

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OIL COOLER - MAINTENANCE PRACTICES 66-11-06

Servicing Oil Cooler. ......................................................................................................................... 201
Removal/Installation Oil Cooler.......................................................................................................... 201
Cleaning Oil Cooler. ......................................................................................................................... 202
Approved Repairs Oil Cooler............................................................................................................. 202

OIL COOLER BLOWER- DESCRIPTION AND OPERATION 66-11-07

Description and Operation................................................................................................................. 1

INTERMEDIATE GEAR BOX- DESCRIPTION AND OPERATION 66-20-00

Description and Operation ............................................................................................................... 1

INTERMEDIATE GEAR BOX - SERVICING 66-20-00

Servicing. ......................................................................................................................................... 301
Draining Intermediate Gear Box......................................................................................................... 301
Flushing Intermediate Gear Box.......................................................................................................... 301

INTERMEDIATE GEAR BOX - REMOVAL/INSTALLATION 66-20-00

Removal/Installation Intermediate Gear Box........................................................................................ 401

INTERMEDIATE GEAR BOX - ADJUSTMENT/TEST 66-20-00

General. ........................................................................................................................................... 501
Operational Check for New or Overhauled Intermediate Gear Boxes. .................................................. 501

INTERMEDIATE GEAR BOX - INSPECTION/CHECK 66-20-00

Allowable Oil Leakage. ..................................................................................................................... 601
Overspeed Inspection Requirements.................................................................................................... 601
Sudden Stoppage Inspection Requirements.......................................................................................... 601
Gear Box Serviceability Check. .......................................................................................................... 601
Gear Box Corrosion Protection........................................................................................................... 601
Intermediate Gear Box Corrosion Inspection........................................................................................ 601

INTERMEDIATE GEAR BOX - CLEANING/PAINTING 66-20-00

Cleaning/Painting Intermediate Gear Box........................................................................................... 701

INTERMEDIATE GEAR BOX - APPROVED REPAIRS 66-20-00

Input Seal Replacement...................................................................................................................... 801
Output Seal Replacement. .................................................................................................................. 803
Oil Level Sight Window Replacement. ................................................................................................ 805
Oil Filler Replacement........................................................................................................................ 805

TAIL GEAR BOX- DESCRIPTION AND OPERATION 66-30-00

Description and Operation ............................................................................................................... 1

TAIL GEAR BOX - SERVICING 66-30-00

Servicing. ......................................................................................................................................... 301
Draining Tail Gear Box...................................................................................................................... 301
Flushing Tail Gear Box. ..................................................................................................................... 301

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TAIL GEAR BOX - REMOVAL/INSTALLATION 66-30-00

Removal/Installation Tail Gear Box. ................................................................................................... 401

TAIL GEAR BOX - ADJUSTMENT/TEST 66-30-00

General. ........................................................................................................................................... 501
Operational Check for New or Overhauled Tail Gear Boxes................................................................ 501

TAIL GEAR BOX - INSPECTION/CHECK 66-30-00

Allowable Oil Leakage. ..................................................................................................................... 601
Overspeed Inspection Requirements.................................................................................................... 601
Sudden Stoppage Inspection Requirements.......................................................................................... 601
Gear Box Serviceability Check. .......................................................................................................... 601
Pitch Change Shaft Assembly Rotational Play Inspection. ..................................................................... 601
Pitch Change Shaft Assembly Axial Play Inspection. ............................................................................ 602
Output Shaft At Flange Axial Play Inspection. ..................................................................................... 604
Output Flange Torque Check.............................................................................................................. 604
Gear Box Corrosion Protection........................................................................................................... 605
Tail Gear Box Corrosion Inspection. ................................................................................................... 606

TAIL GEAR BOX - CLEANING/PAINTING 66-30-00

Cleaning/Painting Tail Gear Box. ...................................................................................................... 701

TAIL GEAR BOX - APPROVED REPAIRS 66-30-00

Input Seal Replacement...................................................................................................................... 801
Output Seal Replacement. .................................................................................................................. 803
Pitch Control Shaft Seal Replacement.................................................................................................. 804
Oil Level Sight Window Replacement. ................................................................................................ 805
Oil Filler Replacement........................................................................................................................ 805
Pressure Pads Replacement. ............................................................................................................... 810

TAIL DRIVE SHAFT- DESCRIPTION AND OPERATION 66-40-00

Description and Operation ............................................................................................................... 1

TAIL DRIVE SHAFT - SERVICING 66-40-00

General. ........................................................................................................................................... 301
Servicing Tail Drive Shaft Bearing Support. ......................................................................................... 301

TAIL DRIVE SHAFT - REMOVAL/INSTALLATION 66-40-00

Removal Tail Drive Shaft. ................................................................................................................... 401
Installation Tail Drive Shaft ................................................................................................................ 402

TAIL DRIVE SHAFT - INSPECTION/CHECK 66-40-00

Overspeed Inspection Requirements.................................................................................................... 601
Sudden Stoppage Inspection Requirements.......................................................................................... 601
Tail Drive Shaft, Bearing and Bearing Support Inspection..................................................................... 601
Section V Tail Drive Shaft Alignment Check. ....................................................................................... 602

TAIL DRIVE SHAFT - CLEANING/PAINTING 66-40-00

Cleaning/Painting Tail Drive Shaft. .................................................................................................... 701

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TAIL DRIVE SHAFT - APPROVED REPAIRS 66-40-00

Scratches. ......................................................................................................................................... 801
Repair Bearing Support Assembly. ..................................................................................................... 801
Viscous Damper Tube Replacement. ................................................................................................... 802

FLEXIBLE COUPLINGS- DESCRIPTION AND OPERATION 66-40-01

Description and Operation ............................................................................................................... 1

FLEXIBLE COUPLINGS - MAINTENANCE PRACTICES 66-40-01

Removal/Installation Flexible Couplings. ............................................................................................. 201
Inspection/Check Flexible Couplings................................................................................................... 201
Approved Repairs Flexible Coupling................................................................................................... 202

ROTOR BRAKE SYSTEM- DESCRIPTION AND OPERATION 66-50-00

General. ........................................................................................................................................... 1
Description ...................................................................................................................................... 1
Operation ........................................................................................................................................ 1

ROTOR BRAKE SYSTEM - TESTING AND TROUBLESHOOTING 66-50-00

Testing and Troubleshooting............................................................................................................... 101

ROTOR BRAKE SYSTEM - MAINTENANCE PRACTICES 66-50-00

Servicing Rotor Brake System. ............................................................................................................ 201
Bleeding Rotor Brake System.............................................................................................................. 201
Flushing Rotor Brake System. ............................................................................................................. 203
Deactivate/Reactivate Rotor Brake System........................................................................................... 204

ROTOR BRAKE- DESCRIPTION AND OPERATION 66-50-01

Description and Operation ............................................................................................................... 1

ROTOR BRAKE - MAINTENANCE PRACTICES 66-50-01

Removal/Installation Rotor Brake........................................................................................................ 201
Inspection/Check Rotor Brake. ........................................................................................................... 203
Approved Repairs Rotor Brake. .......................................................................................................... 206

MASTER CYLINDER (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION 66-50-02

Description and Operation ............................................................................................................... 1

MASTER CYLINDER (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES 66-50-02

Removal/Installation Master Cylinder.................................................................................................. 201

PRESSURE GAGE (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION 66-50-03

Description and Operation ............................................................................................................... 1

PRESSURE GAGE (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES 66-50-03

Removal/Installation Pressure Gage.................................................................................................... 201

ACCUMULATOR/RESERVOIR (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION 66-50-04

Description and Operation ............................................................................................................... 1

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ACCUMULATOR/RESERVOIR (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES 66-50-04

Removal/Installation Accumulator/Reservoir. ...................................................................................... 201

HYDRAULIC LINES (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION 66-50-05

Description and Operation ............................................................................................................... 1

HYDRAULIC LINES (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES 66-50-05

Removal/Installation Hydraulic Lines................................................................................................... 201

GEAR BOX INDICATING SYSTEM- DESCRIPTION AND OPERATION 66-60-00

Description and Operation................................................................................................................. 1

MAIN GEAR BOX OIL TEMPERATURE/PRESSURE INDICATING SYSTEM-DESCRIPTION

AND OPERATION 66-61-00
Description and Operation ............................................................................................................... 1

MAIN GEAR BOX OIL TEMPERATURE/PRESSURE INDICATING SYSTEM - TESTING AND

TROUBLESHOOTING 66-61-00
Testing and Troubleshooting............................................................................................................... 101

MAIN GEAR BOX OIL TEMPERATURE/PRESSURE INDICATING SYSTEM - MAINTENANCE

PRACTICES 66-61-00
Oil Temperature Sensor Replacement.................................................................................................. 201
Oil Pressure Transmitter Replacement.................................................................................................. 201

MAIN GEAR BOX OIL HOT WARNING SYSTEM- DESCRIPTION AND OPERATION 66-62-00
Description and Operation ............................................................................................................... 1

MAIN GEAR BOX OIL HOT WARNING SYSTEM - TESTING AND TROUBLESHOOTING 66-62-00
Testing and Troubleshooting............................................................................................................... 101

MAIN GEAR BOX OIL HOT WARNING SYSTEM - MAINTENANCE PRACTICES 66-62-00
Oil Temperature Warning Switch Replacement.................................................................................... 201

MAIN GEAR BOX OIL LOW PRESSURE WARNING SYSTEM- DESCRIPTION AND OPERA-
TION 66-63-00
Description and Operation ............................................................................................................... 1

MAIN GEAR BOX OIL LOW PRESSURE WARNING SYSTEM - TESTING AND TROUBLE-
SHOOTING 66-63-00
Testing and Troubleshooting............................................................................................................... 101

MAIN GEAR BOX OIL LOW PRESSURE WARNING SYSTEM - MAINTENANCE PRACTICES 66-63-00
Oil Low Pressure Warning Switch Replacement. .................................................................................. 201

GEAR BOX CHIP DETECTOR/OVERTEMP WARNING SYSTEM- DESCRIPTION AND

OPERATION 66-64-00
Description and Operation ............................................................................................................... 1

66 - CONTENTS
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

CHAPTER/
SUBJECT SECTION PAGE

GEAR BOX CHIP DETECTOR/OVERTEMP WARNING SYSTEM - TESTING AND TROUBLE-

SHOOTING 66-64-00
Testing and Troubleshooting............................................................................................................... 101

GEAR BOX CHIP DETECTOR/OVERTEMP WARNING SYSTEM - MAINTENANCE PRAC-

TICES 66-64-00
Main Gear Box Chip Detector/Strainer Replacement. .......................................................................... 201
Intermediate Gear Box Chip Detector Replacement. ............................................................................. 203
Tail Gear Box Chip Detector Replacement........................................................................................... 203

CHIP DETECTOR RELAYS- DESCRIPTION AND OPERATION 66-64-01

Description and Operation................................................................................................................. 1

66 - CONTENTS
Page 7/8
Jul 31/17

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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
POWERTRAIN - GENERAL

1. General.

This chapter provides maintenance information on the system, subsystems, and components of the main gear box,
intermediate gear box, tail gear box, and associated drive shafting.

2. Description and Operation (Figures 1 and 2).

A. Main Gear Box.The main gear box, housed within the main gear box pylon on the transmission deck,
changes the angle of drive from the engines to the main rotor head, and supports it. At 107% Nr it reduces
engine rpm from 6409 rpm to 313.5 rpm at the main rotor shaft and 3491 rpm at the tail takeoff, providing
the means for driving the tail rotor. The main gear box has three stages of reduction from the engine input
shafts to the main rotor shaft accomplished through a series of helical, bevel, and spur gears. Freewheel units
at each engine input permit disengagement of the engines when main rotor rpm goes over relative engine
rpm during autorotation or engine shutdown. Lubrication of the main gear box is done by a self-priming wet
sump system using pressure supplied by two oil pumps driven by the common hydraulic pump drive gear. Oil
is pumped from the sump of the gear box through screened chip detectors to the oil filter, then through an oil
cooler back through jets in the gear box, where it cools and lubricates. Accessories driven by the main gear
box include the two oil pumps, No. 1 and No. 2 engine oil cooler blowers, and first and second stage
hydraulic pumps. Additional accessories installed include a rotor brake, with its accumulator/reservoir. Two
chip detector/strainers are mounted on the main gear box lower housing to detect metal chips in the sump.
The drain plug is magnetic, to collect ferrous particles. Cockpit instruments provide oil temperature and
pressure readings and warning.

B. Intermediate Gear Box.The intermediate gear box, at the base of the vertical stabilizer, transmits torque,
changes the drive angle of the tail drive shaft about 57°, and reduces tail drive shaft rpm from 3491 rpm to
3370 rpm. The input and output housings contain direct drive bevel gears which change the angle of drive
upward along the vertical stabilizer. The center housing contains an oil level sight window, an oil filler, and
a chip detector and temperature sensor which acts as a drain port. The intermediate gear box is splash-
lubricated and air-cooled.

C. Tail Gear Box.The tail gear box, mounted at the upper end of the vertical stabilizer, transmits torque and
changes the angle of drive from the intermediate gear box to the tail rotor. The tail gear box reduces rpm
from 3370 rpm at the input side to 1723 rpm at the tail rotor. It also provides a mount for the tail rotor servo
and a pitch control mechanism for the tail rotor. The output housing contains an oil filler and an oil level sight
window. The input housing contains a magnetic chip detector and temperature sensor which acts as a drain
port. The tail gear box is splash-lubricated and air-cooled.

D. Tail Drive Shaft.The tail drive shaft transmits torque from the main gear box to the tail rotor. It consists of five
sections, and extends from the tail takeoff flange of the main gear box, to the input side of the intermediate
gear box, and from the output side of the intermediate gear box, to the input side of the tail gear box.
Sections I and V consist of two flanges, a shaft, and two flexible couplings each. Sections II, III, and IV each
consists of two flanges, a shaft, a flexible coupling, and a bearing support, and are interchangeable.

66-00-00
Page 1
Jan 31/98
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 TAIL ROTOR
GEAR BOX

(1722.6 RPM)

(3370.3 RPM)

TAIL DRIVE SHAFT

(5 SECTIONS)
INTERMEDIATE
GEAR BOX

Figure 1
NO. 2 ENGINE
S-76B

NO. 1 ENGINE

MAIN GEAR BOX

(313.5 RPM)
(3491.2 RPM)

Powertrain Component Location Diagram

NOTE
MAINTENANCE MANUAL, SA 4047-76B-2

RPM’S GIVEN FOR 107% Nr

ENGINE OUTPUT
DRIVE SHAFT
(6409.3 RPM)

CB0782
SA

66-00-00
Jan 31/98
Page 2

This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 MAIN ROTOR SHAFT
313.5 RPM

NO. 2 ENGINE
OIL COOLER
BLOWER DRIVE
12665 RPM
NOTE

RPM’S GIVEN FOR 107% Nr

NO. 2 ENGINE
INPUT
6409.3 RPM

BEARING TAIL ROTOR GEAR BOX

SUPPORT OUTPUT SHAFT
ASSEMBLY 1722.6 RPM

NO. 1 ENGINE
OIL COOLER

Figure 2
BLOWER DRIVE TAIL ROTOR
12665 RPM DRIVE SHAFT
S-76B

3491.2 RPM

FREE

Powertrain - Simplified Schematic

WHEEL
UNIT NO. 1 ENGINE
INPUT
6409.3 RPM
MAINTENANCE MANUAL, SA 4047-76B-2

MAIN GEAR BOX

LUBRICATION / HYDRAULIC
MAIN GEAR BOX PUMP DRIVE
LUBRICATION / HYDRAULIC 6240.7 RPM
PUMP DRIVE
6240.7 RPM
PYLON DRIVE
SHAFT
3370.3 RPM

This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
CB0783
SA

Jan 31/98
Page 3/4
66-00-00
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
POWERTRAIN - TESTING AND TROUBLESHOOTING

1. General.

Troubleshooting consists of troubleshooting various powertrain components and/or related indicating systems.

A. Vibration Analysis.High frequency vibrations are usually caused by malfunction of gear boxes or misalign-
ment of powertrain system. (Refer to VIBRATION ANALYSIS, CHAPTER 18.)

B. Indicating Systems.For troubles related to main gear box oil temperature and pressure, refer to Testing and
Troubleshooting, 66-61-00. For troubles related to gear box chip indications and intermediate/tail gear box
temperature, refer to Testing and Troubleshooting, 66-64-00.

66-00-00
Page 101/102
Jan 15/92
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX- DESCRIPTION AND OPERATION

1. General.

The main gear box, housed within the main gear box pylon on the transmission deck, changes the angle of drive
from the engines to the main rotor head. It also reduces engine rpm and provides the means for driving the tail
rotor and gear box accessories.

2. Description and Operation (Figure 1).

The main gear box supports and drives the main rotor head, and provides power to the tail takeoff to drive the tail
rotor and gear box accessories. The main gear box has three stages of reduction from the engine input shaft to
the main rotor shaft through a series of helical, bevel, and spur gears. The freewheel units permit disengagement
of the engines when main rotor rpm is higher than relative engine rpm during autorotation or engine shutdown.
Accessories driven by the main gear box include the No. 1 and No. 2 engine oil cooler blowers , two hydraulic
pumps, and two gear box lubrication pumps. Additional accessories installed include a rotor brake, with an
accumulator/reservoir. Lubrication of the gear box is by a self-priming wet sump system. Pressure for lubrication
of the gear box is supplied by two oil pumps mounted on and driven by the gear box accessory drive section. Oil
is pumped from the sump of the gear box through screened chip detectors to an oil filter and then through the oil
cooler. Cooled oil then goes through jets in the gear box where it cools as well as lubricates. Two chip detector/
strainers are mounted on the gear box lower housing to detect metal chips in the sump. For further information on
the main gear box chip detectors, refer to Gear Box Chip Detector/Overtemp Warning System, 66-64-00. The
gear box reduces engine speed of 6409 rpm to 313.5 rpm at the main rotor shaft and 3491 rpm at the tail
takeoff, that drives the tail drive shaft. Instruments provide oil temperature and pressure readings and warn of
high oil temperature or low oil pressure.

66-10-00
Page 1/2
Jan 31/98
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

MAIN ROTOR SHAFT

NO. 2 ENGINE
OIL COOLER BLOWER

OIL PRESSURE
TRANSMITTER
ROTOR BRAKE
ACCUMULATOR / RESERVOIR

OIL TEMPERATURE
WARNING SWITCH D
FW
SHAFT
SHIELD NO. 1 ENGINE
OIL COOLER BLOWER
OIL INLET
PORT
N R SPEED SENSOR
SWASHPLATE (TYPICAL)
GUIDE

BREATHER

FIRST STAGE
HYDRAULIC
PUMP

OIL OUTLET PORT

OIL FILLER

OIL FILTER
NO. 1
ENGINE
D OIL OIL INPUT
FW TEMPERATURE PUMP LOW OIL OIL LEVEL SIGHT WINDOW
SENSOR (TYPICAL) PRESSURE
WARNING
SWITCH
MAGNETIC
DRAIN PLUG NO. 2 ENGINE INPUT
TAIL
CHIP DETECTOR / STRAINER TAKEOFF
(TYPICAL) ROTOR
BRAKE SECOND STAGE
HYDRAULIC
PUMP

CB0784
SA

Main Gear Box Component Location Diagram Main Gear Box Component Location Diagram
Figure 1 (Part 1 of 2) Figure 1 (Part 2)
66-10-00 66-10-00
Page 3/4
Oct 31/02
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX - SERVICING

1. General.

Servicing of the main gear box consists of application of or filling with lubricant. (Refer to SERVICING, CHAPTER
12.) The main gear box is filled with oil through the filler port on the upper right side. Oil level is determined by
88MAINTAIN OIL LEVEL WITHIN BULL’S-EYE’’ marking on oil level sight window below the filler port. Additional
lubrication is done during assembly.

2. Draining Main Gear Box.

A. Prepare for Draining.

(1) General. Draining is removal of lubricating oil from gear box, and should be done with gear box oil
warm, to aid oil flow.

(2) Special Tools and Equipment.

(a) Drain Attachment, D734, Technical Development Corp.

(b) Container, Suitable

B. Drain Main Gear Box.

(1) Open baggage compartment and unscrew and remove overhead access panel to get to magnetic drain
plug on bottom of main gear box sump.

(2) Drain main gear box oil into suitable container, using drain attachment, D734, Technical Development
Corp.

(3) Inspect, clean, install, and lockwire magnetic drain plug. (Refer to SERVICING, CHAPTER 12.)

(4) Install access panel removed in step (1) and secure with screws.

3. Flushing Main Gear Box.

A. Prepare for Flushing.

(1) General. Main gear box should be flushed when changing from any one of the approved oils to
another, when gear box is contaminated with metal chips, when preservation for storage or shipment is
required, or when placing in service after preservation with an oil that is not compatible with the service
oil. (Refer to SERVICING, CHAPTER 12, for approved oils.)

B. Flush Main Gear Box.

(1) Drain gear box.

(2) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(3) With qualified helicopter pilot at controls, start engines and engage main rotor head per Flight Manual,
SA 4047-76B-1. Run up gear box until main gear box oil temperature stabilizes in normal operating
range.

66-10-00
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Jul 31/93
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(4) Drain gear box.

(5) Remove, inspect, clean, and install both chip detector/strainers. (Refer to Removal/Installation, 66-64-
00.)

(6) Remove and replace main gear box oil filter. (Refer to Removal/Installation, 66-11-02.)

(7) Remove, drain, clean, and install main gear box oil cooler. (Refer to Removal/Installation and Cleaning,
66-11-06.)

(8) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

66-10-00
Page 302
Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TEMPORARY REVISION NO. 66-25

FILING INSTRUCTIONS: Replace Chapter/Section 66-10-00, Main Gear Box - Removal/Installation, dated Jul
31/17 in its entirety with Chapter/Section 66-10-00, Main Gear Box - Removal/Installation, dated Dec 31/17.

SUBJECT: MAIN GEAR BOX – ROMOVAL/INSTALLATION

5
This temporary revision updates the Main Gear Box - Removal/Installation, in Powertrain.

-2
MANUAL CHANGES:
Replace Chapter/Section 66-10-00, Main Gear Box - Removal/Installation, dated Jul 31/17 in its entirety with

66
Chapter/Section 66-10-00, Main Gear Box - Removal/Installation, dated Dec 31/17.

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WARNING:
THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF LOCKHEED MARTIN CORPORATION AND/OR ITS SUBSIDIARIES, IS AN
UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, REPRODUCED, IN WHOLE OR IN PART
(INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN LOCKHEED MARTIN CORPORATION AND/OR ITS SUBSIDIARIES WITHOUT ITS WRITTEN
CONSENT, AND THAT NO RIGHT IS GRANTED TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED HEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL
AND CRIMINAL PENALTIES.

66-10-00
Page 1 of 30
Dec 31/17
WARNING ‒ This document contains technical data subject to the EAR. Authorization is required prior to providing
this technical data to any company, entity, person, or destination. EAR Export Classification: ECCN EAR99
 5
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66
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

MAIN GEAR BOX - REMOVAL/INSTALLATION

1. Removal Main Gear Box.

A. Prepare for Removal.

(1) Special Tools and Equipment.

(a) Caps and Plugs (for oil and hydraulic ports, lines and hoses)

(b) Hoist, Suitable

5
(c) Sling, 76700-20008-045

-2
(d) Tags (for line, hose, and electrical connector identification)

66
(e) Transport Cart, 76700-20004-041

B. Remove Main Gear Box.

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NOTE: When replacing main gear box, 76351-09600-041, -042, or -048 with main gear box, 76351-
09600-044, -045, -047, or -049 refer to Table 401 for additional replacement parts.
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NOTE: The main gear box may be removed with the main rotor head installed or removed. Accessory
components are removed from the main gear box after its removal from helicopter and installed
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before installation on helicopter.
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NOTE: As lines are disconnected, drain all liquids into suitable container and cap or plug all ports, fittings,
lines, and hoses to prevent contamination. Tag all lines, hoses, and electrical disconnect plugs to aid
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reinstallation.
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(1) Remove main rotor blades. (Refer to Removal/Installation, 65-11-00.)

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(2) Remove forward fairing and main gear box fairings. Open engine air inlet/bypass cowls and upper
access panels (Figure 401).
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(3) Remove cooler oil in and cooler oil out hoses between main gear box and cooler.
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(4) Remove clamps and disconnect left and right boots between engine oil cooler blowers and ducts (Figure
402).
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(5) Disconnect all No. 1 and No. 2 engine oil lines from oil coolers and plug all lines and fittings.

(6) Remove bolts securing duct assembly to airframe.

(7) Using suitable sling, remove duct assembly (with main gear box oil cooler and engine oil coolers) and
associated frames as a unit. (Refer to Oil Cooler Ducts, 79-10-04.)

(8) Unbolt and remove No. 1 and No. 2 engine drive shafts. (Refer to Removal/Installation, 71-02-00.)

(9) Unbolt and disconnect Section I of tail rotor drive shaft at main gear box tail takeoff flange. (Refer to
Removal/Installation, 66-40-00.)

66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(10) Make certain electrical power is off and disconnect main gear box electrical wiring harness at electrical
connectors (P912 and P913) on forward side of gear box (Figure 403).

(11) Disconnect first and second stage hydraulic pressure and return hoses from hydraulic modules on
forward side of gear box (Figure 404).

(12) Unbolt hydraulic line brackets attached to left and right side on main gear box rear cover.

(13) Remove nuts and washers and remove No. 1 and No. 2 hydraulic pumps. Place pumps and lines intact
on floor of plenum area.

(14) Disconnect pressure and return hoses from pressure and return tubes at upper deck on right side of

5
main gear box. (Refer to Hydraulic Lines (Rotor Brake System), 66-50-05.)

-2
(15) Unbolt and disconnect left lateral servo control rod from aft bellcrank (Figure 405).

(16) Unbolt and remove forward and aft servo controls rods.

66
(17) Disconnect four hoses between damper reservoir and unions at bifilar support, one at a time, and
drain hydraulic fluid into suitable container.

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(18) Unbolt and remove damper reservoir and cap from bifilar support.

(19) Remove bolts securing main gear box to fuselage. si

(20) Using sling, 76700-20008-045 and suitable hoist, remove main gear box/main rotor head assembly
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from helicopter and place in transport cart, 76700-20004-041.

(21) Inspect airframe structure in area of main gear box mounting feet for evidence of a peelable shim. If
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necessary, remove any loose shims.

2. Installation Main Gear Box.

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A. Prepare for Installation.

(1) Special Tools and Equipment.

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(a) Hoist, Suitable

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(b) Sling, 76700-20008-045

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B. Install Main Gear Box.

NOTE: When replacing main gear box, 76351-09600-041, -042, or -048 with main gear box, 76351-
09600-044, -045, -047, or -049 refer to Table 401 for additional replacement parts.

NOTE: The main gear box may be installed with the main rotor head installed or removed. Accessory
components are removed from the main gear box after its removal from helicopter and installed
before installation on helicopter. Ensure proper clearance of accessory components when main gear
box is installed on the airframe.

(1) Attach sling, 76700-20008-045, and suitable hoist, lift main gear box/main rotor head into position on
mounting pads, and line up boltholes.

66-10-00
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Dec 31/17
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(2) With main gear box in position, measure gap, if any, between main gear box mounting feet and
airframe support fitting.

(a) The maximum allowable gap without any shims installed is 0.008 inch.

(b) If gap exceeding 0.008 inch is found, correct gap by bonding a shim, 76209-03001-115, to the
airframe fitting.

(c) Prepare shim and bonding surfaces for bonding. (Refer to Bonding, 51-02-00.)

(d) Bond shim with adhesive, EA9309.3NA, Class II. (Refer to Bonding, 51-02-00.)

5
(e) Adhesive thickness should not exceed 0.004 inch.

-2
NOTE: The number of shims under any one main gear box mounting pad can not exceed the
thickness that would cause the bolt not to allow proper thread protrusion from the barrel-
nut.

66
NOTE: The maximum shim thickness shall be 0.060 inch. The bolt length shall not change to
accommodate more shims. Care should be taken to use the least amount of shims when

on
eliminating the gap.

(3) Apply thin spray coat of lubricant, MIL-C-81309 Type II or molybdenum disulfide, MIL-M-7866, to each
mounting pad on which gear box attachment leg will rest (Figure 405, Detail D). Do not apply lubricant
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to main gear box mounting feet.
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(4) Apply a thin brush coat of sealing compound, MIL-S-81733 Type I or AMS 3265 Class A, to under side
of main gear box housing mounting feet.
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(5) Apply small bead of sealing compound, MIL-S-81733 Type II or AMS 3265 Class B, around the rim of
the bolt hole on the top and bottom side of each mounting hole.
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CAUTION: TO PREVENT POSSIBLE FAILURE OF BARREL- NUT, ONLY RMLH2577 BARREL-NUTS,

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MANUFACTURED BY ESNA OR SPS, SHALL BE USED. RMLH2577 BARREL-NUTS ARE

IDENTIFIED WITH LETTERS 9EN9 OR 9SPS9 STAMPED ON AN END. (ADDITIONAL MARK-
ING MAY ALSO INCLUDE LH2577.)
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(6) Visually inspect mounting bolts and barrel-nuts for damage, wear, and corrosion. Replace if necessary.
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(7) Test all used mounting bolts and barrel-nuts before installation. Using a vise to hold nut, install bolt until
two threads are exposed beyond nut. If breaking torque required to remove bolt is 18 inch-pounds or
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more, bolt and nut are satisfactory for use.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK GEAR BOX MOUNTING BOLTS FOR SPECIFIED TORQUE.

CAUTION: TO PREVENT DAMAGE TO BARREL- NUT RECESS IN MAIN GEAR BOX SUPPORT FIT-
TING, MAKE SURE BARREL-NUTS AND RETAINERS ARE INSTALLED CORRECTLY WHEN
BOLTS ARE TORQUED. BARREL-NUTS MUST BE INSTALLED WITH BARREL (ROUND SIDE)
TOWARDS BOLTHEAD AND RETAINERS BELOW BARREL-NUTS.

66-10-00
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Dec 31/17
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(8) Install barrel-nuts and retainers in main gear box support fitting (Figure 405, Detail C).

CAUTION: VERIFY BOLTHEADS ARE FULLY SEATED WITH NO GAPS FOLLOWING INITIAL INSTAL-
LATION AND TORQUING.

(9) Coat shank, threads, and area under bolthead of main gear box attachment bolts with corrosion
inhibiting sealant, M6856K, and install through gear box mounting feet into fuselage and barrel-nuts.
Handtighten bolts in this sequence: RH FWD, LH AFT, LH FWD, and RH AFT. Torque bolts in same
sequence to 960 inch-pounds (Figure 405). Wipe off excess sealant after installation and torquing.
Apply sealing compound, MIL-S-81733 Type II or AMS 3265 Class B, around main gear box/fuselage
interface.

5
(10) Prior to completing corrosion protection of mounting feet in steps (11) thru (14), a temporary method

-2
of corrosion protection during torque stabilization of the mounting bolts is permitted as follows:

66
(a) Temporary corrosion protect by applying two coats of Fluid Film (non-aerosol spray) 8030-01-
381-6357 or MIL-C-85054 Type I, around boltheads. Reinspect every three days for presence of
coating. Reapply two coats at each torque stabilization check until bolt torque has stabilized.

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(b) After bolt torque has stabilized, remove Fluid Film (non-aerosol spray) 8030-01-381-6357 or
MIL-C-85054 Type I, using safety solvent O-T-620, trichloroethane or equivalent and complete
corrosion protection per steps (11) thru (14).
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(11) Apply small bead of sealing compound, MIL-S-81733 Type II or AMS 3265 Class B, no larger than
1/4 inch diameter, around boltheads and rim of bushings.
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(12) Apply one coat of epoxy primer, MIL-PRF-23377 or MIL-PRF-85582, over sealant. Allow 15 minutes to
dry.
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(13) Apply one coat of polyurethane paint, MIL-C-46168 over primer.

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(14) After all coats are dry, apply two coats of Fluid Film (non-aerosol spray) 8030-01-381-6357 to main
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gear box mounting feet (typical four places) (preferred method) or two coats of AMLGUARD, MIL-C-
85054 Type I, as an alternate.
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(15) When conditional maintenance checks indicate stabilized torque of main gear box attachment bolts,
apply torque stripes. (Refer to Torque Striping Hardware, 20-04-00.)
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(16) Remove sling, 76700-20008-045, from gear box.

(17) Position damper reservoir and cap on top of bifilar and secure with bolts, washers, and nuts. Torque
nuts to 100 inch-pounds.

(18) Connect four hoses or tubes from damper reservoir to unions in bifilar support. Service reservoir with
hydraulic fluid, MIL-PRF-83282 (preferred) or MIL-H-5606 (alternate). (Refer to SERVICING, CHAPTER
12.)

66-10-00
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Dec 31/17
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING

PARTS, SAFETY INSTALLATION, AND PROOF TORQUE OF SELF-RETAINING BOLTS
ARE CRITICAL CHARACTERISTICS. APPLY TORQUE STRIPE. (REFER TO SELF-
RETAINING BOLT INSTALLATION/INSPECTION AND TORQUE STRIPING HARD-
WARE, FLIGHT SAFETY PART PROGRAM, CHAPTER 20.)

(19) Position left lateral servo control rod in bellcrank and secure with bolt, washer, and nut. Torque nut to
30 - 50 inch-pounds and install cotter pin.

(20) Install aft servo control rod (with adjustable rod end facing aft and drain hole on underside) and secure

5
with bolts, washers, and nuts. Torque nuts to 30 - 50 inch-pounds and install cotter pins.

-2
(21) Install forward servo control rod (with adjustable rod end facing aft and drain hole on underside) and
secure bolts, washers, and nuts. Torque nuts to 30 - 50 inch-pounds and install cotter pins.

66
(22) Connect first and second stage hydraulic pressure and return hoses to hydraulic module lines on
forward side of gear box (Figure 404).

(23) Install No. 1 and No. 2 hydraulic pumps with lines attached. (Refer to Removal/Installation, 29-10-01

on
and 29-20-01).

(24) Install hydraulic line brackets on left and right side of main gear box rear cover and secure with bolts,
si
washers, and nuts. Torque nuts to 110 inch-pounds.
i
ev
CAUTION: ENSURE ELBOWS ARE INSTALLED ON LEFT SIDE MAIN GEAR BOX REAR COVER
BRACKET TO PREVENT HYDRAULIC LINE FITTING CONTACT WITH NO. 1 ENGINE OIL
RESERVOIR.
R

(25) Install unions on brackets on left and right side of main gear box rear cover and secure with washers
and nuts. Place washers on either side of brackets as required to obtain unloaded installation of tubes
y

(Figure 408).
ra

(26) Connect pressure and return hoses to pressure and return tubes at upper deck on right side of main
gear box. (Refer to Hydraulic Lines (Rotor Brake System), 66-50-05.)
po

(27) Connect main gear box electrical wiring harness at electrical connectors (P912 and P913) on forward
side of gear box (Figure 403).
m

(28) Connect Section I of tail rotor drive shaft to main gear box tail takeoff flange. (Refer to Removal/
Te

Installation, 66-40-00.)

(29) Conduct main gear box free wheel unit (FWU) functional conformity inspection for both main gear box
input sections as follows:

(a) By hand, turn the input flange in the clockwise direction. Resistance should be felt and the main
rotor shaft will react.

(b) By hand, turn the input flange in the counterclockwise direction. The flange should turn freely with
little resistance and the main rotor shaft should not turn.

(30) Install No. 1 and No. 2 engine drive shafts. (Refer to Removal/Installation, 71-02-00.)

66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

NOTE: When replacing main gear box, 76351-09600-041, -042 or -048 with main gear box,
76351-09600-044, make sure engine drive shafts, 76361-09202-055, are installed. These
drive shafts use a 76361-04008-103 coupling on the forward end and a 76361-04008-104
coupling on the aft end.

(31) Bleed rotor brake. (Refer to Bleeding Rotor Brake, 66-50-00.)

(32) Using suitable sling, install duct assembly (with main gear box oil cooler and engine oil coolers) and
associated frames as a unit (Figure 402). Secure duct assembly to airframe. 79-10-04.)

(33) Connect all No. 1 and No. 2 engine oil lines to fittings on oil coolers. (Refer to Maintenance Practices,
79-10-01 and 79-20-01.)

5
(34) Install left and right boots between oil cooler blowers and ducts and secure with clamps Figure 401.

-2
(35) Install cooler oil in and cooler oil out hoses between main gear box and fittings on oil cooler.

66
(36) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(37) Install main rotor blades. (Refer to Removal/Installation, 65-11-00.)

on
(38) Service and bleed first and second stage hydraulic systems. (Refer to Servicing, 29-00-00.)

Flight Check of Control Rigging, 67-00-00.)

i si
(39) Do a quick rigging check and flight check of main rotor controls. (Refer to Quick Rigging Check and
ev
(40) Install main gear box fairings and forward fairing. Close and secure upper access panels and engine
air inlet/bypass cowls.
R

(41) Do an operational check on new or overhauled gear boxes using instructions in paragraph 5.,
Inspection/Check and Flight Check Procedures Manual, SA 4047-76B-6.
y

3. Disassembly/Assembly Main Gear Box.

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A. Prepare for Disassembly.

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(1) Special Tools and Equipment.

m

(a) Caps and Plugs (plug lines, hoses, and ports)

Te

(b) Tags (for line, hose, and electrical connector identification)

B. Disassemble Main Gear Box.

NOTE: Disassembly and assembly of main gear box are limited to removal and replacement of items as
follows: electrical wiring harness, hydraulic manifolds, No. 1 and No. 2 hydraulic pumps, No. 1
and No. 2 engine oil cooler blowers, rotor brake and accumulator/reservoir.As lines, hoses, and
fittings are removed, drain all liquids into a suitable container and cap or plug all ports, lines, and
fittings to prevent contamination. Note angles of fittings and tag all lines, hoses, and electrical
connectors to aid reinstallation.

(1) Remove bifilar vibration absorber. (Refer to Removal/Installation, 65-13-00.)

66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(2) Remove hub subassembly from main rotor shaft. (Refer to Removal/Installation, 65-12-01.)

(3) Remove swashplate assembly from main rotor shaft. (Refer to Removal/Installation, 65-14-00.)

(4) Remove washers and nuts and remove stationary scissors assembly from main gear box upper housing
(Figure 406).

(5) Remove electrical wiring harness and attachment hardware.

NOTE: Tag all electrical connectors to aid reinstallation.

(6) Unclamp and remove hydraulic manifolds from gear box.

5
NOTE: Tag all four manifold assemblies to aid reinstallation.

-2
(7) Remove washers and nuts securing main rotor servo support assemblies to gear box and unbolt and
disconnect servo pushrods from servos (Figure 407).

66
(8) Remove main rotor servos and support assemblies from gear box as a unit.

(9) Remove washers and nuts and remove aft bellcrank assembly, with servo pushrod attached, from aft left

on
side of gear box.

(10) Remove washers and nuts and remove left lateral bellcrank and support, with servo pushrod attached,
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from left forward side of gear box.
i
ev
(11) Remove washers and nuts and remove forward bellcrank and support, with servo pushrod attached,
from right side of gear box.
R

(12) Remove nuts and remove No. 1 hydraulic pump, with tubing attached, and gasket from gear box rear
cover. Disconnect tubing at bracket on left side of rear cover and remove unions from bracket (Figure
408).
y

(13) Remove nuts and remove No. 2 hydraulic pump, with tubing attached, and gasket from gear box rear
ra

cover. Disconnect tubing at bracket on right side of rear cover and remove unions from bracket.
po

(14) Remove No. 1 and No. 2 engine oil cooler blowers. (Refer to Removal/Installation, 79-10-03.)

(15) Remove rotor brake from main gear box rear cover. (Refer to Removal/Installation, 66-50-01.)
m

(16) Remove rotor brake accumulator/reservoir and associated hydraulic lines from main gear box. (Refer
Te

to Removal/Installation, 66-50-04 and 66-50-05.)

(17) When removing main gear box, 76351-09600-044, do the following:

(a) Remove bracket and cover plate from main gear box pad by removing bolts and washers.

(b) Remove standoffs and cover from main gear box pad.

NOTE: Remove and retain cover, cover plate, bracket, standoffs, bolts, and washers for rein-
stallation on replacement main gear box, 76351-09600-044.

C. Assemble Main Gear Box.

66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(1) When installing main gear box, 76351-09600-044, do the following:

(a) Install cover on main gear box pad studs and secure in place with standoffs. Torque standoffs to
100 inch-pounds. (Refer to Table 401.)

(b) Install cover plate on cover and position bracket on cover plate. Secure bracket and plate to
standoffs with bolts and washers. Torque bolts to 110 inch-pounds. Lockwire bolts using
MS20995NC32.

(c) Apply sealing compound, AMS 3265, Class B2, around entire top and bottom perimeter of cover
where cover mates with gear box pad and cover plate. Also, seal all bolt heads and lockwire.

5
(2) On main gear box, 76351-09600-044, install cover and gasket on left drive pad and temporarily
secure with washers and nuts.

-2
(3) Install rotor brake accumulator/reservoir and associated hydraulic lines on main gear box. (Refer to

66
Removal/Installation, 66-50-04 and 66-50-05.)

(4) Install rotor brake on main gear box rear cover. (Refer to Removal/Installation, 66-50-01.)

on
TABLE 401
KIT PART NUMBER 76070-35010-011
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PART NUMBER NOMENCLATURE QUANTITY
i
76361-09202-055 ENGINE DRIVE SHAFT 2
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76361-04008-103 ENGINE FLEXIBLE COUPLING 2
SS5086-06 Nut 24
R

76351-09671-101 OIL COOLER BLOWER DRIVE 1

COVER (UPPER HOUSING)
76351-09672-101 OIL COOLER BLOWER DRIVE 1
y

COVER PLATE
76650-09006-115 STANDOFF 6
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76650-02001-057 ROTOR BRAKE RESERVOIR 1

BRACKET
po

AN4H3A BOLT 1
AN4H5A BOLT 5
AN960-416 WASHER 6
m

(5) Install No . 1 and No. 2 engine oil cooler blowers. (Refer to Removal/Installation, 79-10-03.)
Te

CAUTION: ENSURE ELBOWS ARE INSTALLED ON LEFT SIDE MAIN GEAR BOX REAR COVER
BRACKET TO PREVENT HYDRAULIC LINE FITTING CONTACT WITH NO. 1 ENGINE OIL
RESERVOIR WHEN GEAR BOX IS INSTALLED.

(6) Install unions on brackets on left and right side of main gear box rear cover and secure with washers
and nuts. Place washers on either side of brackets as required to obtain unloaded installation of tubes
(Figure 408).

(7) Install No. 1 and No. 2 hydraulic pumps. (Refer to Removal/Installation, 29-10-01 and 29-20-01.)

(8) Connect hydraulic lines between hydraulic pumps and unions on gear box rear cover brackets.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(9) Insulate mating surfaces of forward support and gear box with primer, MIL-PRF-23377. Secure forward
support, with pushrod attached, to gear box with washers and nuts. Torque nuts to 100 inch-pounds
(Figure 407, Detail A).

(10) Apply sealing compound, AMS 3265, Class A, around joining area of forward support and gear box.

(11) Insulate mating surfaces of left lateral support and gear box with primer, MIL-PRF-23377. Secure left
lateral support, with pushrod attached, to gear box with washers and nuts. Torque nuts to 100
inch-pounds (Figure 407, Detail D).

(12) Apply sealing compound, AMS 3265, Class A, around joining area of left lateral support and gear
box.

5
(13) Insulate mating surfaces of aft bellcrank and gear box with primer, MIL-PRF-23377. Secure aft bell-

-2
crank, with pushrod attached, to gear box with washers and nuts. Torque nuts to 50 - 100 inch-pounds
and install cotter pin (Figure 407, Detail C).

66
(14) Apply sealing compound, AMS 3265, Class A, around joining area of aft bellcrank and gear box.

WARNING: FLIGHT SAFETY PARTS

on
NICKS, DENTS, SCRATCHES, TOOL OR SCUFF MARKS WITHIN THE CRITICAL CHAR-
ACTERISTIC AREAS (BOTH SIDES AND EDGE OF EITHER SUPPORT LUG) ARE CRITI-
CAL CHARACTERISTICS. INSPECT IN ACCORDANCE WITH FLIGHT SAFETY PARTS
si
PROGRAM, STANDARD PRACTICES, CHAPTER 20.
i
ev
WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF MINIMUM TORQUE IS A CRITICAL CHARACTERISTIC.

R

(15) Insulate mating surfaces of main rotor servo support assemblies and main gear box with primer,
MIL-PRF-23377. Install main rotor servos and support assemblies on gear box as a unit and secure
y

with washers and nuts. Torque MS21043-5 nuts to 155 - 175 inch-pounds and torque MS21043-6
ra

nuts to 260 - 290 inch-pounds (Figure 407, Detail B).

(16) Apply sealing compound, AMS 3265, Class A, around joining area of main rotor servo support
po

assemblies and main gear box.

WARNING: VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING

m

PARTS, SAFETY INSTALLATION, AND PROOF TORQUE OF SELF-RETAINING BOLTS

ARE CRITICAL CHARACTERISTICS. APPLY TORQUE STRIPE. (REFER TO SELF-
Te

RETAINING BOLT INSTALLATION/INSPECTION AND TORQUE STRIPING HARD-

WARE, FLIGHT SAFETY PARTS PROGRAM, CHAPTER 20.)

(17) Position servo pushrods on all three main rotor servos and secure with bolts, washers, and nuts. Torque
nuts to 30 - 50 inch-pounds and install cotter pins. (Refer to Self-Retaining Bolt Installation/Inspection,
20-04-00.)

(18) Position hydraulic manifolds on main gear box and secure with clamps. Connect manifold hydraulic
lines to main rotor servos (Figure 406).

(19) Position main gear box electrical wiring harness on gear box and secure with clamps. Connect
electrical plugs on wiring harness to appropriate receptacles on main gear box.

66-10-00
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Dec 31/17
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(20) Insulate main gear box and stationary scissors mating surface with primer, MIL-PRF-23377.

(21) Install stationary scissors on main gear box and secure with washers and nuts. Install one or two
washers under each nut as required. Torque nuts to 165 inch-pounds.

(22) Apply sealing compound, AMS 3265, Class A, around joining area of stationary scissors and main
gear box.

(23) Install swashplate assembly on main rotor shaft. (Refer to Removal/Installation, 65-14-00.)

(24) Install hub subassembly on main rotor shaft. (Refer to Removal/Installation, 65-12-01.)

5
(25) Install bifilar on top of hub. (Refer to Removal/Installation, 65-13-00.)

-2
66
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66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

A
MAIN GEAR
BOX FAIRING SCREW
FORWARD
FAIRING COOLER
OIL−OUT
HOSE

5
-2
66
SCREW
A

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FORWARD
m
B INLET
FAIRING
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CAMLOC
COOLER
OIL−IN
HOSE
MAIN GEAR
BOX FAIRING
D
SCREW FW CB0106_1
SA

Main Gear Box - Removal/Installation Main Gear Box - Removal/Installation

Figure 401 (Part 1 of 3 ) Figure 401 (Part 2)
66-10-00 66-10-00
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Dec 31/17
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 5
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

5
-2
66
COOLER
DUCT

CLAMP

on
i si BOOT
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R

CLAMP
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D
FW
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OIL COOLER
BLOWER
m
Te

CB0106_2
SA

Main Gear Box - Removal/Installation

Figure 401 (Part 3)
66-10-00
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Dec 31/17
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 5
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
A

DUCT ASSEMBLY,
OIL COOLERS,

5
MOUNTING FRAME

-2
66
B

on
A

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D

R
FW

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m
D
FW
Te

NO. 2 ENGINE
LUBRICATION
LINE

NO. 1 ENGINE
LUBRICATION
LINE CB0785
SA

Main Gear Box - Removal/Installation Main Gear Box - Removal/Installation

Figure 402 (Part 1 of 2) Figure 402 (Part 2)
66-10-00 66-10-00
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Dec 31/17
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 5
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

5
A

-2
66
A

ELECTRICAL
CONNECTOR
(P913)

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ELECTRICAL
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CONNECTOR
(P912)

D
FW

CB0786
SA

Main Gear Box - Removal/Installation

Figure 403
66-10-00
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Dec 31/17
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 5
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

SECOND
STAGE
PRESSURE
HOSE

5
SECOND
STAGE
RETURN

-2
HOSE

66
C
A
D
FW

on
A

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B B

R
C

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HYDRAULIC

ra
LINES (LH)

po BRACKET
m
BOLT, WASHERS,
NUT (TORQUE D
110 IN. LBS) FW
Te

D
FW
NO. 1 HYDRAULIC BOLT, WASHERS,
PUMP NUT (TORQUE
110 IN. LBS)
FIRST STAGE
PRESSURE HOSE
NO. 2 HYDRAULIC
PUMP HYDRAULIC
LINES (RH)
OVERBOARD BRACKET
DRAIN (LH)
FIRST STAGE
RETURN HOSE OVERBOARD CB0787
DRAIN (RH) SA

Main Gear Box - Removal/Installation Main Gear Box - Removal/Installation

Figure 404 (Part 1 of 2) Figure 404 (Part 2)
66-10-00 66-10-00
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Dec 31/17
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

A
B

BOLT, WASHER, NUT,

COTTER PIN (TORQUE
30−50 IN. LBS) BOLT, WASHER, NUT,
COTTER PIN (TORQUE
30−50 IN. LBS)

5
-2
66
on
B FORWARD SERVO
CONTROL ROD

si
A

BOLT,

i
DAMPER WASHERS,

ev
RESERVOIR NUT
(TORQUE
100 IN. LBS)

R
y
CAP

ra
po BOLT, WASHER, NUT,
BARREL−
NUT
COTTER PIN (TORQUE
30−50 IN. LBS)
RETAINER
m
C
ATTACHMENT
BOLT (TORQUE
Te

960 IN. LBS)

D
FW
AFT SERVO
LEFT LATERAL CONTROL ROD
SERVO CONTROL
ROD

DAMPER
CB0788A
SA

Main Gear Box - Removal/Installation Main Gear Box - Removal/Installation

Figure 405 (Part 1 of 4) Figure 405 (Part 2)
66-10-00 66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

BOLT

D
BUSHING

BARREL−NUT

5
-2
66
RETAINER

on
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SA

Main Gear Box - Removal/Installation

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Figure 405 (Part 3)
R
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

MOUNTING BOLT
COAT BOLTS WITH
CORROSION INHIBITING
SEALANT, M6856K. MAIN GEAR BOX
INSTALL AND MOUNTING FOOT
TORQUE WHILE WET.

APPLY SMALL BEAD OF SEALING COMPOUND,

BUSHING MIL−S−81733 TYPE II OR AMS 3265 CLASS B,
AROUND THE RIM OF THE BOLT HOLE ON TOP AND
BOTTOM SIDE OF MOUNTING HOLE.

5
APPLY LUBRICANT, MIL−C−81309

-2
TYPE II OR MOLYBDENUM DISULFIDE,
MIL−M−7866 TO AIRFRAME MOUNT PAD.

66
APPLY A THIN BRUSH COAT OF
SEALING COMPOUND, MIL−S−81733 TYPE I OR

on
AMS 3265 CLASS A, TO THE
UNDERSIDE OF THE HOUSING MOUNTING FEET.

MOUNTING BOLT
i si
APPLY SMALL BEAD OF SEALING COMPOUND,
MIL−S−81733 TYPE II OR AMS 3265 CLASS B,
AROUND THE MOUNTING BOLT HEADS AND THE
ev
RIM OF THE BUSHING.
BUSHING
APPLY SMALL BEAD OF
SEALING COMPOUND,
R

MIL−S−81733 TYPE II OR
AMS 3265 CLASS B, AROUND
THE MOUNTING FOOT
AIRFRAME / INTERFACE.
y
ra
po
m

APPLY ONE COAT OF EPOXY

Te

PRIMER, MIL−PRF−23377 OR
MIL−PRF−85582, TO AREA SHOWN.
ALLOW 15 MINUTES TO DRY.

APPLY ONE COAT OF

POLYURETHANE PAINT,
MIL−C−46168 TO AREA SHOWN.
AFTER ALL COATINGS ARE DRY,
APPLY TWO COATS OF FLUID FILM
(NON−AEROSOL SPRAY)
8030−01−381−6357 OR AMLGUARD,
MIL−C−85054 TYPE I TO AREA SHOWN.

CORROSION PROTECTION APPLICATION CC3296_3B

SA

Main Gear Box - Removal/Installation

Figure 405 (Part 4)
66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

SCREW,
WASHER, NUT
HYDRAULIC
MANIFOLD
B CLAMP

D
FW

D SCREW,
FW WASHER

5
-2
CLAMP
C

66
SPACER

on
C

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B D

i
BOLT,

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SCREW, CLAMP (TORQUE
WASHER, SPACER 110 IN. LBS)
BRACKET
NUT

R
CLAMP,
SCREW,
SPACER
(TYPICAL) BOLT, WASHER
(TORQUE

y
110 IN. LBS)
A

ra
BOLT, WASHER WIRING
(TORQUE 500−1150 HARNESS
NUT, WASHER IN. LBS)
(TORQUE 165 po COVER
IN. LBS) PLATE
m
STANDOFF
D
FW (TORQUE
100 IN. LBS)
Te

COVER

D
FW
CLAMP,
SCREW,
WASHER,
STATIONARY NUT
SCISSORS (TYPICAL) EFFECTIVITY
ON MAIN GEAR BOX,
76351−09600−044
CB0228
SA

Main Gear Box - Disassembly/Assembly Main Gear Box - Disassembly/Assembly

Figure 406 (Part 1 of 2) Figure 406 (Part 2)
66-10-00 66-10-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
SERVO
PUSHROD

MAIN ROTOR
SERVO

B C

A
NUT, WASHER
(TORQUE 155−175 IN. LBS

5
FOR MS21043−5 NUT)
(TORQUE 260−290 IN. LBS

-2
FOR MS21043−6 NUT)

66
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100 IN. LBS) CB0590A
SA

Main Gear Box - Disassembly/Assembly Main Gear Box - Disassembly/Assembly

Figure 407 (Part 1 of 2)
66-10-00 Figure 407 (Part 2)
66-10-00
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 S-76B
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D
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Main Gear Box - Disassembly/Assembly

Figure 408
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MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX - ADJUSTMENT/TEST

1. General.

Run-in procedures are not required on main gear boxes that have received a load run-in at the factory or Sikorsky
approved overhaul facility. Examine gear box log card. If an entry: 88Transmission has been full load-tested and
accepted in accordance with current procedures’’ has been made, only operational check procedures in
Inspection/Check are required. If log card does not have this entry, notify the Commercial Product Support
Department, Sikorsky Aircraft.

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MAIN GEAR BOX - INSPECTION/CHECK

1. Overspeed Inspection Requirements.

A. General. Main rotor head overspeed over 366 rpm (121% triple tachometer indicator reading) requires a
serviceability check of main gear box. Inspect main gear box chip detector/strainers and oil filter for metal
particles.

NOTE: For identification of contaminating material, refer to Identification of Metal Particles.

2. Sudden Stoppage Inspection Requirements.

A. General. Sudden stoppage of main rotor blades, tail rotor blades, and associated components can occur in
various degrees of speed and severity. Therefore, this procedure cannot be all-inclusive. However, as a
general rule, the following will require that a sudden stoppage inspection be done:

NOTE: For engine inspection requirements, refer to PT6B-36 Engine Maintenance Manual, 3034442,
Inspection/Check.

(1) An installed main or tail rotor blade is damaged by striking an object.

(2) Dynamic components are brought to an abrupt stop.

(3) Dynamic components are rapidly decelerated by means other than the rotor brake.

(4) If rotor brake stops rotor head in 8 seconds or less at Nr greater than 45%.

B. Main Rotor Drive System.

(1) If damage to main rotor blade is limited to tip cap area and there is no permanent yielding, deforma-
tion, or distortion of spar, inspect as follows:

(a) Inspect main rotor system using sudden stoppage inspection requirements. (Refer to Inspection/
Check, 65-12-00.)

(2) If damage to main rotor blade results in permanent distortion, yielding, or deformation of spar, do this:

NOTE: Clearly tag all components 88DAMAGE INCURRED FROM SUDDEN STOPPAGE’’ with proper
identification and precise relative information concerning nature and severity of damage.
Components are then to undergo complete overhaul and detail inspection.

(a) Inspect and replace components of main rotor system using sudden stoppage inspection require-
ments. (Refer to Inspection/Check, 65-12-00.)

(b) Replace main gear box. (Refer to Removal/Installation.) Inspect airframe attachment points for
deformation and damage.

(c) Inspect engine drive shafts, tail drive shafts, all associated flexible couplings, bearings, and sup-
ports for cracks and distortion.

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C. Tail Rotor Drive System.

(1) If damage to tail rotor blade is minor and there is no permanent distortion, yielding, or deformation of
spar, do this:

(a) Inspect tail rotor system components using sudden stoppage inspection requirements. (Refer to
Inspection/Check, 65-12-00.)

(b) Dye penetrant inspect, per MIL-I-6866, all four tail gear box mounting lugs.

(c) Visually inspect intermediate gear box mounting, all drive shafts and associated flexible couplings,
and drive shaft bearings and supports for cracks and distortion.

(2) If damage to tail rotor blade results in permanent distortion, yielding, or deformation of any section of
the spar, do this:

NOTE: Clearly tag all components 9DAMAGE INCURRED FROM SUDDEN STOPPAGE’’ with proper
identification and precise relative information concerning nature and severity of damage.
Components are then to undergo complete overhaul and detail inspection.

(a) Inspect and replace components of tail rotor system using sudden stoppage inspection require-
ments. (Refer to Inspection/Check, 65-12-00.)

(b) Replace tail gear box. (Refer to Removal/Installation, 66-30-00.)

(c) Replace intermediate gear box. (Refer to Removal/Installation, 66-20-00.)

(d) Replace entire tail drive shaft. (Refer to Removal/Installation, 66-40-00.)

(e) Visually inspect vertical stabilizer for possible structural damage (loose rivets, cracks, etc.).

(f) Do a serviceability check of main gear box.

3. Main Gear Box Torque Limitations.

A. Torque Limitations.

(1) Dual-Engine Operation.

(a) 100% Torque per engine - Takeoff and Maximum Continuous

NOTE: Takeoff torque may exceed 100% on one engine to a maximum of 104% provided that
the torque on the other engine is less than 96% and the sum of the individual torque
values does not exceed 200%

(b) 115% Torque per engine - 10 Second Transient

(2) Single-Engine Operation.

(a) 100% Torque - Maximum Continuous

(b) 127% Torque - 30 Minute Limit

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(c) 136% Torque - 2 1/2 Minute Limit

(d) 150% - 5 Second Transient

(3) Transient Overtorque.

NOTE: Main gear box torque limitations for maximum service life under steady state conditions are
indicated by torquemeter markings. However transient conditions beyond torquemeter red
lines may inadvertently occur.

(a) During single-engine operations, transient overtorque is permissible up to torquemeter readings of

150% output torque for periods of not over 5 seconds for any single instance.

NOTE: The EEC will limit available single-engine torque to 136%.

(b) During dual-engine operations, transient overtorque is permissible up to torquemeter readings of

115% output torque for periods of not over 10 seconds for any single instance.

NOTE: Dual-engine transient limit equals 230% total torque.

NOTE: The EEC will limit available dual-engine torque to a total of 202%.

NOTE: Output torque is defined as:

% No. 1 Engine + % No. 2 Engine

2 2

(c) A main gear box that has operated beyond limits in steps (a) or (b) must be inspected. Contact
Sikorsky Aircraft Commercial Product Support for instructions before further flight.

4. Main Gear Box Temperature Limitations.

A. General. Main gear box temperatures over 120°C (248°F) indicate a malfunction in main gear box or
associated cooling system, or operation in high ambient temperatures. If high temperature was a direct result
of a malfunction in main gear box, gear box should be sent to an overhaul and repair facility for evaluation.
If high temperature was result of a malfunction in the external cooling system, such as a malfunctioning
thermostat or extreme operating conditions, the criteria for acceptance of main gear box are as follows:

(1) Main gear boxes operating from 120° to 135°C (248° to 275°F), for other than a short transient
period, require an inspection of the main gear box systems as to the cause and necessary correction.

(2) Main gear boxes operating from 135° to 140°C (275° to 284°F), for a period of over 30 minutes,
require inspection of oil filter and chip detector/strainers for contamination. (Refer to Gear Box Con-
tamination.) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(3) Main gear boxes operating above 140°C (284°F) for any length of time must be replaced.

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5. Gear Box Run-In.

NOTE: All new, spare, and overhauled gear boxes, overhauled at a Sikorsky Aircraft approved overhaul facility
should receive a full load run-in at the facility before shipment.

A. General. All main, intermediate, and tail gear boxes which have received break-in runs have this entry
recorded on a gear box log card: 88Transmission has been full load-tested and accepted in accordance with
current procedures.’’ However, gear boxes require an operational check and a pilot preflight check.

WARNING: THIS CHECK IS MANDATORY AND MUST BE CONDUCTED FOR SAFETY OF FLIGHT.

B. Operational Check. (Refer to Flight Check Procedures Manual, SA 4047-76B-6.)

6. Allowable Oil Leakage.

A. General. Oil leakage is measured at sight window on right side of gear box. Total leakage from all sources,
during period of ten flight hours, must not be over half the distance from the top to the bottom of the sight
window bull’s-eye.

7. Gear Box Contamination.

A. General. Metal particles found in main gear box oil filter or chip detector/strainers, and metal particles
found on intermediate gear box or tail gear box chip detectors or in oil may indicate malfunction of an
internal component. Refer to applicable troubleshooting charts in Testing and Troubleshooting, 66-64-00.
Quantity, source, form, and type of metal found together with service history of particular gear box, must be
taken into consideration. Time accumulated since gear box was new or overhauled, previous malfunctions,
and type of operation are important factors in determining further serviceability of unit. Particles found may
be steel, silver, cadmium, titanium, aluminum, magnesium, copper, bronze, or phenolic in various shapes
and quantities. For further information concerning gear box contamination, refer to Identification of Metal
Particles, SOAP Analysis of Main Gear Box Oil, and Gear Box Serviceability Check.

CAUTION: WHEN PARTICLES ARE READILY IDENTIFIABLE AS FRAGMENTS OF GEAR BOX PARTS, SUCH
AS GEARS, NUTS, BEARINGS, SNAPRINGS, OR OTHER COMPONENTS, REPLACE GEAR
BOX. IF THE REPLACEMENT OF THE GEAR BOX IS QUESTIONABLE, CONTACT CUSTOMER
SERVICE.

8. Identification of Metal Particles.

A. General. Visual inspection may be enough to determine nature of contaminating material. If identification of
contaminating material is required, the procedures that follow will provide additional identification informa-
tion. For a complete analysis of contaminating material, services of a competent analytical laboratory may be
used.

B. Prepare for Identification of Metal Particles.

(1) Special Tools and Equipment.

(a) Magnet, Permanent

(b) 10X Magnification Glass

(c) 6 Inch Scale

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C. Identify Metal Particles.

NOTE: Identification of contaminating material may be made through visual inspection or a series of tests.

(1) Steel. Isolate steel particles with a permanent magnet.

WARNING: TO PREVENT INJURY, EXERCISE EXTREME CARE WHEN USING ACIDS. CONDUCT
TEST IN A WELL VENTILATED ROOM.

(2) Aluminum. Determine aluminum particles by their reaction to hydrochloric acid, Fed. Spec O-A-86.
Aluminum in hydrochloric acid will fizz with a rapid emission of bubbles. Particles will gradually be
reduced to a black residue (aluminum chloride). Copper, bronze, and phenolic do not noticeably react
to hydrochloric acid.

NOTE: Magnesium reacts similarly to aluminum in hydrochloric acid. When in doubt, go to step (3).

(3) Copper, Bronze, and Magnesium. Differentiate between copper, bronze, and magnesium by their
reactions in nitric acid, Fed. Spec O-A-88. Copper and bronze react rapidly, producing a bright green
cloud in the acid. Magnesium will fizz with a rapid emission of bubbles. Phenolic or aluminum will not
noticeably react to nitric acid.

(4) Titanium. Place chip in test tube, add 10-15 drops of 5% sulfuric acid solution, heat until solution comes
to boil, allow to cool, add 2 drops of 3% hydrogen peroxide. Yellow color indicates titanium.

D. Analysis.

CAUTION: WHEN PARTICLES ARE READILY IDENTIFIABLE AS FRAGMENTS OF GEARS, NUTS, BEAR-
INGS, OR OTHER DYNAMIC COMPONENTS, REPLACE GEAR BOX. IF THE REPLACEMENT
OF THE GEAR BOX IS QUESTIONABLE, CONTACT CUSTOMER SERVICE. QUESTIONABLE
REPLACEMENTS INCLUDE OBJECTS FOREIGN TO GEAR BOX, MACHINING CHIPS ON
BOXES WITH LOW TIME SINCE NEW OR OVERHAUL, ETC. OTHERWISE SEE CRITERIA CON-
TAINED IN TABLE 601 BELOW.

TABLE 601
GEAR BOX CONTAMINATION
Category Quantity and/or Size Action Required

Magnetic Fuzz, fine hairlike particles Acceptable. Return gear box to ser-
vice. No serviceability check is
required.

Thin flakes not over 0.050 inch in Acceptable. Return gear box to ser-
dia. or 1/32 (0.032) inch thick by vice. No serviceability check is
1/8 (0.125) inch. Quantity not to required.
be over three flakes

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TABLE 601 (Cont)

GEAR BOX CONTAMINATION
Category Quantity and/or Size Action Required

*More than three flakes, but not Do serviceability check. Refer to

over 10 flakes Gear Box Serviceability Check. Con-
duct metallurgical evaluation to
determine alloy of debris and
record findings on log card. *Refer
to Table 602.

More than 10 flakes Remove gear box from service.

Any particles of flakes larger than Remove gear box from service. If
0.050 inch dia. or 1/32 (0.032) removal of gear box is question-
inch by 1/8 inch able, contact customer support.

Non-magnetic Thin flakes not over (0.050) inch in Acceptable. Return gear box to ser-
dia. to 1/32 (0.032) inch by 1/8 vice. No serviceability check is
(0.125) inch. Quantity not to be required.
over 10 flakes

*More than 10 flakes, but less than Do serviceability check. Refer to

25 Gear Box Serviceability Check. Con-
duct metallurgical evaluation of
debris to determine material. (Refer
to paragraph 8.) Record findings in
log book. *Refer to Table 602.

More than 25 flakes Remove gear box from service.

Any particles or flakes larger than Remove gear box from service. If
0.050 inch in dia. or 1/32 (0.032) removal of gear box is question-
inch by 1/8 (0.125) inch able, contact customer support.

Wood, Paint, Less than a total area of 1/2 Do serviceability check. Refer to
Paper, Lint, Dust, (0.500) sq. inch Gear Box Serviceability Check.
Phenolic *Refer to Table 602.

More than an area of 1/2 (0.500) Remove gear box from service. If
sq. inch removal of gear box is question-
able, contact customer support.

Rubber More than an area of 1/4 (0.250) Conduct visual leakage inspections
sq. inch of all external oil seal areas and
gear box housing attachment joints.
Evaluate indicator oil pressure read-
ings. Remove gear box if low oil
pressure warning light has been
illuminated and if leakage source
can not be corrected or identified.

NOTE: If continuing chip indications are being found, the following limitations in Table 602 apply:

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TABLE 602
GEAR BOX CONTAMINATION/INDICATIONS
Material Type, Quantity, Size Time Interval No. Indica- Action Required
tions

Steel More than two flakes or 10 hr period three Replace gear box.
granular particles over
0.005 inch thickness or
0.020 inch dia. noted at
each indication
25 hr period five Replace gear box.
50 hr period nine Replace gear box

Non- More than 10 flakes or 10 hr period three Replace gear box.

Magnetic granular particles larger
Metals than 1/32 x 1/8 inch or
larger than 0.050 inch
in diameter

NOTE: To make use of time interval and number of indications, chip light history must be entered on log cards.

9. SOAP Analysis of Main Gear Box Oil.

A. Prepare for SOAP Analysis.

(1) Special Tools and Equipment

(a) Drain Attachment, D734 (Technical Development Corp.), or equivalent.

(b) Container (10 gallon minimum), or equivalent.

(c) Plastic tube, or equivalent.

(d) Screw-top oil sample jar, typical 60 ml (approximately 2 oz.), or equivalent.

B. Oil Sample.

NOTE: Oil sample must be drawn from Main Gear Box (MGB) between 30 minutes and 1 hour after
shutdown.

NOTE: There are two methods for taking oil samples from the MGB; one method is by accessing MGB oil
from the MGB drain plug as shown in step (1), and the alternate method is by accessing MGB oil
from the MGB oil filler as shown in step (2).

(1) Take oil sample from MGB drain plug as follows:

(a) Open baggage compartment and remove screws securing overhead access panel.

(b) Place 10 gallon (minimum) container, or equivalent under MGB magnetic drain plug.

NOTE: The intent of this procedure is not to drain the oil from the MGB, only to take as much oil
as needed to submit for SOAP analysis.

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(c) Remove magnetic drain plug and install Drain Attachment (D734, or equivalent).

(d) Place screw-top oil sample jar, or equivalent into oil stream until oil sample jar is nearly full.

(e) Secure top onto oil sample jar.

(f) Remove Drain Attachment (D734, or equivalent) and install magnetic drain plug into MGB and
lockwire.

(g) Secure overhead access panel with screws and close baggage compartment.

(2) Alternate method of taking oil sample from MGB oil filler is as follows:

(a) Remove right MGB fairing.

CAUTION: MAKE SURE FOD DOES NOT ENTER MGB WHEN REMOVING OIL FILLER AND
STRAINER AND TAKING OIL SAMPLE FROM MGB.

(b) Remove oil filler with strainer. (Refer to Removal/Installation, 66-11-05.)

(c) Extract oil sample using plastic tube, or equivalent and transfer to screw-top oil sample jar.

(d) Secure top onto oil sample jar.

CAUTION: MAKE SURE FOD DOES NOT ENTER MGB WHEN INSTALLING OIL FILLER AND
STRAINER.

(e) Install oil filler with strainer and lockwire fitting. (Refer to Removal/Installation, 66-11-05.)

(f) Install right MGB fairing.

NOTE: A laboratory capable of providing an oil analysis of less than one parts-per-million (ppm)
of titanium is to be used to remain on 300 Hour schedule.

NOTE: Presence of titanium shall be the primary focus of certified laboratory’s oil analysis and
shall be expressed in parts-per-million (ppm).

(3) Forward oil sample with oil usage data and MGB operating data to a certified laboratory for oil
analysis, once results are received back from the lab proceed as follows:

(a) If results of oil analysis show presence of titanium at less than 1.0 ppm, no further action is
required, proceed to step (4).

(b) If results of oil analysis show presence of titanium greater than 1.0 ppm but less than 15 ppm, MGB
oil must be monitored by taking MGB oil sample every 100 flight hours.

(c) If results of oil analysis show presence of titanium at 15 ppm or greater, MGB must be removed
from service. (Refer to Removal Main Gear Box, 66-10-00.)

(4) Service main gear box with lubricating oil. (Refer to SERVICING, CHAPTER 12.)

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10. Gear Box Serviceability Check.

A. Check serviceability.

(1) Drain gear box oil through low lint cloth or filter paper. Inspect debris per Table 601.

CAUTION: MAIN GEAR BOX FILTER NORMALLY KEEPS OIL CLEAN. METALLIC BLACK OIL DIS-
COLORATION FOUND IN MAIN GEAR BOX IS INDICATIVE OF HIGH RATE OF
FRETTING/WEAR. REMOVE GEAR BOX.

NOTE: If removal of gear box is questionable, contact customer support.

NOTE: Intermediate and tail gear boxes do not have oil filters and oil discoloration is possible.

(2) Check filter and chip detector screens.

(3) Reservice gear box.

(4) Run main gear box for one hour at flat pitch, full speed Nr. Inspect oil filter and chip detector/
strainers. Inspect oil by filtering through low lint cloth or filter paper. Refer to Table 601 for criteria. If
number of particles is acceptable, continue gear box in service.

(5) After 3 to 8 hours of normal operation, inspect chip detector/strainers for particles per criteria of Table
601.

(6) Clean and install chip detector and strainers.

11. Gear Box Inspection/Corrosion Protection.

A. General. Maintenance of metallic surfaces requires a comprehensive program of preventive maintenance

for specific helicopter operating conditions. Periodic washing and cleaning, inspection, recognition and
treatment of corrosion, and touchup of surfaces that have lost their protective coatings will reduce the
possibility of corrosion. Corrosion of aluminum, magnesium, and steel may be caused by salts in sea air or
spray, electrolytic action caused by contact of dissimilar metals, engine exhaust, and fretting.

(1) Inspect gear box surfaces (Figure 601).

(a) Inspect surfaces for scratches and other damage or wear.

(b) Inspect surfaces for condition of primer and paint.

(c) Inspect areas of dissimilar metal contacts for evidence of corrosion.

(d) Inspect area around bolts, screws, and other fasteners for corrosion and condition of primer and
sealing compound.

(e) Inspect hidden surfaces whenever removal of any component or equipment exposes area.

(2) Clean affected areas with dry-cleaning solvent, MIL-PRF-680, Type II.

(3) Clean magnesium surfaces of corrosion pits less than 0.030 inch as follows:

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(a) Clean corrosion from magnesium surfaces with 320-400 grit aluminum abrasive cloth, Fed. Spec
P-C-451, or Scotch-Bright abrasive mat, MIL-S-9962, Class 1, or abrasive woven nylon wheel,
MIL-W-81319.

(b) Prepare chromic acid pickle solution of 24 ounces of chromium-trioxide, Fed. Spec O-C-300 per
gallon of distilled water.

NOTE: Chromium-Trioxide, Fed Spec O-C-300, may be purchased in small quantities from
Brand-Nu Laboratories, Inc. 377 research Parkway, Meriden, CT 06450.

(c) With nylon brush, scrub vigorously for one to three minutes, or until corrosion is completely
removed.

(d) Penetrant inspect per MIL-I-6866, Type 1 Method A or B.

(e) Etch unprotected area with Dow 19 (MIL-M-3171, Type VI).

(f) Apply two coats of Amlguard, MIL-C-85054.

(4) Touch up areas, as necessary, with primer, MIL-PRF-23377.

(5) Apply sealing compound, AMS 3265, Class A, around joining areas, as necessary.

(6) Touch up with matching paint.

(7) Periodically apply corrosion-preventive compound, ACF-50, or any other corrosion preventive com-
pound conforming to MIL-C-81309, to surface areas shown in Figure 601.

NOTE: ACF-50 or others approved to MIL-C-81309 provide a protective film, while displacing any
water or moisture that might be present.

B. Main Rotor Shaft Corrosion Protection. This procedure involves the application of water displacing fluid at
the main rotor shaft upper bearing shoulder/bearing interface. This application should prevent corrosion
pitting at the shaft shoulder radius caused by water intrusion.

NOTE: This procedure is not applicable to gear boxes that have had caulking applied at the subject joint
during the initial production or overhaul buildup. The caulking is not to be removed.

(1) Loosen clamp and remove shields from main rotor shaft (Figure 602).

NOTE: Looking at the main rotor shaft upper bearing shoulder, there are four equally spaced flats
machined into shoulder.

(2) Using a clean, low lint cloth, MIL-C-85043 Type II or equivalent, dampened with safety solvent,
MIL-PRF-680 Type II or equivalent, clean the four flats to remove any dirt or surface residue.

CAUTION: TO PREVENT INJURY, WEAR EYE PROTECTION BEFORE PROCEEDING TO NEXT STEP.

NOTE: At the lower midpoint of these shoulder flats, a cavity exists between the shoulder and the
inner race of the bearing.

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(3) Using an aerosol pressure can with the application straw installed, apply a continuous spray of cor-
rosion preventive compound, water displacing fluid, MIL-C-81309, Type III Class 2 (CRC Industrial
3-36 Aerosol or LPS-814-NF) into cavity. Ideally, the fluid will be expelled out the opposite flat cavity,
but is not mandatory.

(4) Continue this procedure until all four cavities have had the water displacing fluid applied.

(5) Wipe off overflow/overspray fluid with a clean, low lint cloth dampened with safety solvent.

(6) Install shields and secure with clamp.

(7) Make a log book entry indicating compliance with this procedure.

C. Main Rotor Shaft/Upper Roller Bearing Seating Gap Inspection. To prevent possible exposure of the upper
roller bearing to atmospheric conditions and water entrapment, this procedure provides an inspection of the
main rotor shaft bearing contact shoulder/upper roller bearing interface for possible gap. Cracking or
tearing of the caulking bead is an indicator of this problem.

(1) Loosen clamp and remove shields from main rotor shaft (Figure 602).

(2) Using a clean, low lint cloth, MIL-C-85043 Type II or equivalent, dampened with safety solvent,
MIL-PRF-680 Type II or equivalent, wipe the caulking bead to remove any dirt, grease, or surface
residue.

(3) Visually inspect the condition of the caulking bead. If the caulking bead contains no evidence of
cracking, tearing or disbonding, no further actions are required. Install shields and secure with clamp.

(4) If a cracked or torn caulking condition is found, the following actions are required:

(a) Using a plastic scraper, remove the existing caulking bead at this joint.

(b) Mask the swashplate guide and the exposed portion of the seal.

CAUTION: TO PREVENT INJURY, WEAR EYE PROTECTION BEFORE PROCEEDING TO NEXT

STEP.

(c) Using an aerosol spray applicator, apply corrosion preventive compound, water displacing fluid,
MIL-C-81309, Type III Class 2 (CRC Industrial 3-36 Aerosol or LPS-814-NF) all around the subject
joint.

(d) Using a clean, low lint cloth, MIL-C-85043 Type II or equivalent, lightly dampened with safety
solvent, MIL-PRF-680 Type II or equivalent, clean all residue of the water displacing fluid in
preparation for caulking application.

(e) Apply a bead of sealing compound (caulk), AMS 3265, Class B or equivalent, all around to the
joint. Remove masking tape.

(f) Install shields and secure with clamp.

D. 300-Hour Main Gear Box/Main Rotor Shaft Seal Liner Inspection. This procedure provides an inspection to
check for the presence of sealant and the integrity of the liner. Do this inspection when required by the
Scheduled Maintenance Checks, 5-20-00.

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NOTE: This inspection will no longer be required after either a new main gear box assembly is installed
with proper sealant application or the main gear box is overhauled with proper sealant installa-
tion.

(1) Loosen clamp and remove main rotor shaft shields from main rotor shaft.

(2) Examine the liner with a 10X magnifying glass for signs of corrosion or cracking, (Figure 610). If there
are any indications of corrosion contact and forward the following information to Sikorsky Service
Engineering.

(a) A description of where the corrosion is visible on the main gear box/main shaft seal liner.

(b) High resolution photographs of the corrosion.

(c) The percentage of the diameter that has corrosion.

(d) Time since last overhaul.

(3) If there are any indications of cracking, remove main gear box and send to an approved overhaul
facility for liner replacement.

(4) If there are no indications of oil leakage, cracking or corrosion, inspection is complete.

(5) Install main rotor shaft shields and secure with clamp.

12. Main Gear Box Housing Inspection.

A. Upper and Lower Housing Inspection for Cracks. Do this inspection if oil leakage is detected.

(1) Inspect housings for cracks, paying particular attention to areas indicated in Figure 603.

13. Main Gear Box Lower Housing Jet Bores Inspection

A. Before First Flight of the Day Inspection. Do this inspection when required by the Scheduled Maintenance
Checks, 5-20-00 Inspect Lower Housing Jet Bores as follows:

(1) Turn off all helicopter electrical and hydraulic power.

(2) Engage rotor brake.

(3) Visually inspect all ten (10) MGB lower housing jet bores. Refer to Figures 604 and 605 for jet bore
locations for the following inspections:

(a) Perform a visual inspection of each jet bore for any sign of the liner protrusion and/or movement.
Refer to Figures 606 and 607. If a jet bore liner appears to be backed out by any amount,
remove gear box. No further flight allowed until a replacement gear box is installed.

(b) Perform a visual inspection for signs of oil leakage from the jet bore. If a leak is present, perform
Section B. No further flight allowed until Section B is performed.

(c) Perform a visual inspection for any sign of bubbling or blistering of paint and/or caulking around
jet bores. Refer to Figure 609. If the paint and/or caulk is bubbling, blistering or cracked,
perform Section B. No further flight allowed until Section B is performed.

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(d) If the anomalies above are not found, return helicopter to service.

B. Inspect/check jet bores.

(1) Remove paint and caulking on and around jet bore with plastic scraper.

(2) Inspect for liner protrusion beyond end face of lower housing surface.

(a) If there is any indication of liner protrusion, replace gear box. (Refer to Figure 607).

(b) If the liner is not protruding, continue with inspection. (Refer to Figure 606).

(3) Inspect liner parting line on end face. (Refer to Figure 606).

(a) If oil is leaking between the liner and the housing, replace gear box.

(b) If oil is not leaking between the liner and the housing, continue with inspection.

CAUTION: TAKE PRECAUTIONARY MEASURES NOT TO INTRODUCE ANY FOREIGN

OBJECTS INTO THE MAIN GEAR BOX ASSEMBLY.

(4) Remove snap ring and jet from housing. Discard packing.

(5) Utilizing a film of gear box oil, install new packing on jet and install jet into housing. Refer to Figure
608 for proper packing size and location.

(6) Perform a minimum of a 30 minute leakage check as follows:

(a) Perform a Ground Run as follows:

1 Operate the main rotor at 107% Nr flat pitch until indications are stable.

2 Ground run the MGB until all fluids have reached normal operating temperatures and then
run for a minimum of 30 minutes.

3 Shutdown and perform a leak check per Step (6)(b) prior to return to service.

(b) Visually inspect jet bores for visible moisture or droplets.

1 If leakage occurs, recheck packing installation, repeat steps (4) and (5). If packing was not
damaged during installation, remove and replace gear box. If the new packing was damaged
during installation, remove and replace with new packing and repeat steps (4) through (6). If
any moisture or droplets of gear box oil are visible, gear box has failed leak check. No further
flight is allowed until gear box is replaced.

2 If no moisture or droplets of gear box oil are visible, MGB has passed leak check.

(7) If the gear box passes the leak check, touch up inspected areas as follows:

(a) Clean surface completely with Acetone per ASTM D329, or Ethyl Alcohol per A-A-53880, or
equivalent.

(b) Apply a bead of caulk (AMS 3265 Class B) to all exposed interfaces.

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(c) Apply two (2) coats of epoxy primer (MIL-P-23377 or alternate MIL-PRF-85582 or equivalent).

(d) Apply two (2) coats touch up paint (MIL-PRF-85285 Color No. 17178 or equivalent).

(e) Apply two (2) coats clear epoxy (MIL-PRF-22750 or alternate MIL-PRF-85285 or equivalent).

(8) Helicopter is returned to service.

14. Swashplate Guide Area Inspection

A. 7 Day Inspection. Do this inspection when required by the Scheduled Maintenance Checks, 5-20-00.
Inspect Swashplate Guide Area as follows:

NOTE: This inspection is not required if the main gear box was deemed compliant with ASB-76-66-54 or
if a non-compliant main gear box was removed and a new or overhauled main gear box was
installed.

(1) Turn off all helicopter electrical and hydraulic power.

(2) Engage rotor brake.

NOTE: This inspection does not require removal of the main rotor shaft shields.

(3) Visually inspect the swashplate guide shield and shield area for indications of oil leakage (Figure
602).

(4) If leak is present, loosen clamp and remove main rotor shaft shields to identify the source of the leak.

(5) If the main rotor shaft upper seal is the split seal, SB8404-103, remove split seal retaining hardware.
(Refer to Approved Repairs.) Removal of the split seal is at the operators discretion.

(6) Remove sealant (caulking) around the main rotor shaft seal liner and examine the liner with a 10X
magnifying glass for signs of corrosion or cracking.

(7) If corrosion is found, contact and forward the following information to Sikorsky Service Engineering:

(a) A description of where the corrosion is visible on the main rotor shaft liner.

(b) High resolution photographs of the corrosion.

(c) The percentage of the diameter that has corrosion.

(d) Time since last overhaul.

(8) If cracking is found, remove the main gear box and send to an approved overhaul facility for liner
replacement.

(9) If there is no corrosion on the main rotor shaft liner and source of the leak is the seal, replace the seal.
(Refer to Approved Repairs.) Re-apply sealant (caulking) around the main rotor shaft liner per the steps
below:

(a) Using low-lint cloth dampened with Acetone, ASTM-D329, clean surfaces that are to have seal-
ant applied.

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(b) Using Alodine, TOUCH-N-PREP COATING, 1132, touch-up the area of the liner to have sealant
applied.

(c) Apply a coat of Epoxy Primer, MIL-PRF-85582 or Epoxy Polyamide Primer, MIL-PRF-23377 to the
areas that are to have sealant applied.

NOTE: The sealant must extend from the main rotor shaft and cover the bearing and liner
chamfer.

(d) Apply a bead of Sealing Compound, AMS3265 to the area shown in (Figure 611).

(10) If the main rotor shaft upper seal is the split seal, SB8404-103, install split seal retaining hardware.
(Refer to Approved Repairs.)

(11) Install main rotor shaft shields and secure with clamp.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

MAIN SHAFT AREA

ABOVE SHIELD

SWASHPLATE GUIDE
ATTACHMENT AREA

SERVO ACTUATOR
MOUNTING PAD STATIONARY
SURFACE SCISSORS
MOUNTING PAD
ACCUMULATOR / RESERVOIR SURFACE
BRACKET MOUNTING EXPOSED SURFACE
EXPOSED SURFACE SURFACE AROUND PRESSURE
AROUND BREATHER TRANSMITTER AND
TEMPERATURE SWITCH

PINION PAD
SURFACE BLOWER PAD
SURFACE
SERVO ACTUATOR
MOUNTING PAD
SERVO ACTUATOR SURFACE
MOUNTING PAD
SURFACE
ALL BOLTED
SURFACES

PINION PAD
SURFACE

SERVO ACTUATOR
MOUNTING PAD OIL PUMP
SURFACE PAD SURFACE GEAR BOX MOUNTING
D SURFACE, SPOT-FACE
FW FLIGHT CONTROLS AREAS, BUSHINGS
MOUNTING PAD
FLIGHT CONTROLS SURFACE
MOUNTING PAD
SURFACE

GEAR BOX MOUNTING D

SURFACE, SPOT-FACE FW
AREAS, BUSHINGS
BLOWER PAD
SURFACE

HYDRAULIC PUMP
PAD SURFACE CB0790
SA

Main Gear Box - Corrosion Inspection Main Gear Box - Corrosion Inspection
Figure 601 (Part 1 of 2) Figure 601 (Part 2)
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MAINTENANCE MANUAL, SA 4047-76B-2

MAIN ROTOR
SHAFT ASSEMBLY

SEAL

CAULKING BEAD
CLAMP

LINER
CAVITY

SEAL SHIELD

SNAP RING
SWASHPLATE
GUIDE
UPPER
ROLLER
BEARING

UPPER ROLLER
BEARING INNER
RACE MAIN
ROTOR
SHAFT
CC3211A
SA

Main Rotor Shaft- Inspection/Corrosion Protection

Figure 602

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D
FW

CHECK FOR CRACKS

IN THIS AREA

LEFT SIDE SECTION VIEW

UPPER HOUSING
AFT RIGHT FOOT

CHECK FOR CRACKS

IN THIS AREA

D
FW

A
CHIP DETECTOR/
STRAINER CB0291
SA

Main Gear Box Upper and Lower Housings - Inspection

Figure 603
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SPUR GEAR
JET BORE
GENERATOR
GEAR JET BORE

FREE WHEEL
UNIT JET BORE

BEVEL GEAR
JET BORE

FREE WHEEL UNIT (FWD)

ROLLER BRG JET BORE
CS0282
SA

Jet Bore Locations, Right Side (LH Side is Opposite of What is Shown) - Inspection
Figure 604

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GENERATOR
GENERATOR
GEAR JET
GEAR JET

SPUR
SPUR GEAR JET
GEAR JET

BEVEL
BEVEL GEAR JET
GEAR JET

FREE WHEEL
FREE WHEEL UNITJET
UNIT JET

FREE WHEEL
UNIT (FWD)
FREE WHEEL ROLLER
UNIT (FWD) BRG JET
ROLLER
BRG JET

LEFT RIGHT
CS0283
SA

Jet Bore Locations - Inspection

Figure 605

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OIL JET

THE PARTING LINE IS THE

INTERFACE BETWEEN THE
LINER AND THE HOUSING

LOWER
HOUSING

JET BORE LINER INSTALLED CORRECTLY:

FLUSH TO 0.010 IN. BELOW HOUSING

OIL JET CROSS SECTIONAL VIEW

CS0284
SA

Jet Bore Liner Installed Correctly - Inspection

Figure 606

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OIL JET

LOWER
HOUSING

JET BORE LINER

PROTRUSION

OIL JET CROSS SECTIONAL VIEW

CS0285
SA

Example of a Jet Bore Liner Backed Out - Inspection

Figure 607

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OUTBOARD PACKING
(LARGER DIAMETER)

INBOARD PACKING
(SMALLER DIAMETER)

LOCATION INBOARD PACKING OUTBOARD PACKING

(SEE FIGURE 606) (SMALLER DIAMETER) (LARGER DIAMETER)
GENERATOR GEAR M83248 / 1−013 M83248 / 1−016

SPUR GEAR M83248 / 1−133 M83248 / 1−226

BEVEL GEAR M83248 / 1−137 M83248 / 1−232

FREE WHEEL UNIT (FWU) JET M83248 / 1−011 M83248 / 1−016

FREE WHEEL UNIT (FWU)

ROLLER BRG JET M83248 / 1−014 M83248 / 1−016
CS0286
SA

Packing Locations on Typical Jet Bore

Figure 608

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INSPECTION AREA FOR

BUBBLING OR BLISTERING
OF PAINT / CAULKING

CS0287
OIL JET CROSS SECTION VIEW SA

Inspection Area
Figure 609

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INSPECTION AREA

SEALANT SEAL

LINER

SPACER

LOCKRING

MAIN ROTOR SHAFT

SWAHSPLATE
GUIDE

BEARING

CC0497
SA

Main Gear Box/Main Rotor Shaft Seal Liner - Inspection

Figure 610
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(SEE NOTE 1)

0.125 IN.
(SEE NOTE 2)

SEAL

LINER

NOTES
1. APPLY SEALANT TO AREA.
2. SEALANT MUST EXTEND 0.125 IN.
BELOW LINER SURFACE. MAKE SURE
SEALANT DOES NOT CONTACT SEAL
OR AREA WHERE SEAL MEETS LINER.
CC0498
SA

Main Gear Box/Main Rotor Shaft Seal Liner - Sealant Application

Figure 611
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MAIN GEAR BOX - CLEANING/PAINTING

1. Cleaning/Painting Main Gear Box.

A. Clean Main Gear Box.

CAUTION: TO PREVENT DAMAGE TO COMPONENTS, DO NOT ALLOW SOLVENT OR KEROSENE TO

SPLASH ON RUBBER COMPONENTS OR BEARINGS. COVER BREATHER AND VENTED OIL
FILLER, TO KEEP SOLVENT OR KEROSENE OUT OF GEAR BOX.

(1) Wash external surfaces of main gear box and associated components, using dry-cleaning solvent, Fed.
Spec P-D-680, Type II, or kerosene, Fed. Spec VV-K-211.

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MAINTENANCE MANUAL, SA 4047-76B-2

MAIN GEAR BOX - APPROVED REPAIRS

1. Breather Replacement.

A. Replace Breather (Figure 801).

(1) Remove left or right main gear box fairing.

(2) Remove breather and packing.

(3) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing on replacement breather.

(4) Install breather in port on forward side of main gear box and lockwire.

(5) Install main gear box fairing.

2. Magnetic Drain Plug Replacement.

A. Replace Magnetic Drain Plug (Figure 802).

(1) Unscrew and remove overhead access panel in baggage compartment.

(2) Drain main gear box. (Refer to SERVICING, CHAPTER 12.)

(3) Remove magnetic drain plug assembly.

(4) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to outer
packing and install on drain plug assembly.

(5) If necessary, replace inner packing with new packing coated lightly with same type lubricating oil.

(6) Install drain plug assembly in drain port and lockwire.

(7) Install overhead access panel in baggage compartment and secure with screws.

(8) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

3. Main Rotor Shaft Shield Replacement.

A. Replace Main Rotor Shaft Shield (Figure 803).

(1) Remove left or right main gear box fairing.

(2) Remove clamp securing shaft shield to shaft.

(3) Remove shield halves.

(4) Clean old bonding materials from seal on shaft using plastic scraper.

(5) Apply thin coat of adhesive, EC1357, Minnesota Mining and Mfg. Co., to seal and inner mating
surface of shield halves. For instructions, refer to Bonding, 51-02-00.

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D
FW
BREATHER

A PACKING

CB0107
SA

Breather - Replacement
Figure 801
(6) Install replacement shield halves over shaft seal and secure with clamp.

(7) Install main gear box fairing.

4. Oil Cooler Blower Drive Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Lockwasher Installer, 76700-20082-041

(b) Lockwasher Remover, 76700-20066-043

(c) Seal Installer, 76700-20102-107

(d) Wrench and Torque Reactor, 76700-20109-041

B. Replace Oil Cooler Blower Drive Seal (Figure 804).

(1) Remove left and right main gear box fairings.

(2) Turn off all electrical power.

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A PACKING

A
MAGNETIC
DRAIN PLUG

D
FW

CC2662
SA

Magnetic Drain Plug - Replacement

Figure 802
(3) Remove No. 1 or No. 2 oil cooler blower, as applicable. (Refer to Removal/Installation, 79-10-03.)

(4) Remove washers and nuts and remove shield securing drive assembly to gear box housing.

(5) Remove drive assembly.

(6) Remove lockwasher from drive assembly, using lockwasher remover, 76700-20066-043.

(7) Remove nut from gearshaft, using wrench and torque reactor, 76700-20109-041, and remove seal
using suitable puller. Remove packing from drive assembly.

(8) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to lip of
replacement seal and coat OD with primer, MIL-PRF-23377.

(9) Install seal in drive assembly, using seal installer, 76700-20102-107.

(10) Coat threads of nut with anti-seize compound, MIL-A-907, and install nut on gearshaft. Torque nut to
1000 inch-pounds, using wrench and torque reactor, 76700-20109-041.

(11) Brush sealing compound, AMS 3265 Class A, onto threads of gearshaft. Apply a light coat of same
type lubricating oil, as used to service gear box per Servicing, 12-10-00, to internal threads of
lockwasher. Install lockwasher while sealing compound is still wet, using lockwasher installer, 76700-
20082-041.

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CLAMP

MAIN ROTOR
SHAFT
D
FW

MAIN ROTOR
SHAFT SHIELD
(TYPICAL)

CB0108
SA

Main Rotor Shaft Shield - Replacement

Figure 803
NOTE: Lockwasher is positioned to nut so that lockwasher tangs engage and lock into nut slots.

(12) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to
packing and install packing in groove of drive assembly.

(13) Wet install drive assembly in main gear box housing using corrosion inhibiting sealant, M6856K,
applied all around under flange only. Do not allow sealant in packing groove or on packing.

(14) Position shield over drive assembly and secure with washers and nuts. Torque nuts to 100 inch-pounds.

CAUTION: MAKE SURE DRAIN HOLE IN MAIN GEAR BOX MOUNTING BORE REMAINS CLEAR
OF SEALING COMPOUND

(15) Apply sealing compound, MIL-S-29574, Class B-1/2 around edge of drive assembly flange and main
gear box mating surface, around drive assembly attaching nuts and studs, and in jackout holes. Apply
sealing compound so as to be tapered in such away that any liquid will be directed away from
mounting bore and toward drain hole.

NOTE: Sealing compound, AMS 3265, Class B may be used as an alternate. Heat gun may be used
to accelerate cure of AMS 3265.

(16) Install No. 1 or No. 2 oil cooler blower. (Refer to Removal/Installation, 79-10-03).

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(17) Install left and right main gear box fairings.

5. Hydraulic Pump Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment

(a) Lockwasher Installer, 76700-20082-041

(b) Lockwasher Remover, 76700-20066-043

(c) Plate Adapter, OTC 8058, Owatonna Tool Co.

(d) Puller, OTC 1021, Owatonna Tool Co.

(e) Seal Installer, 76700-20102-107

(f) Wrench and Torque Reactor, 76700-20109-041

B. Replace Hydraulic Pump Seal (Figure 805).

NOTE: There are two hydraulic pumps mounted on the main gear box rear cover. Seal replacement
procedures are the same for both.

(1) Hinge open engine air inlet/bypass cowl.

(2) Drain main gear box. (Refer to SERVICING, CHAPTER 12.)

(3) Disconnect hydraulic lines from pump and drain fluid into suitable container.

(4) Remove nuts and remove hydraulic pump and gasket from main gear box rear cover.

(5) Remove lockwasher, using lockwasher remover, 76700-20066-043.

(6) Remove nut from gearshaft, using wrench and torque reactor, 76700-20109-041.

(7) Pull flinger and seal from gearshaft, using puller, OTC 1021, and plate adapter, OTC 8058.

(8) Remove seal from flinger using suitable puller.

(9) Install flinger on gearshaft.

(10) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to lip of
seal and coat OD with primer, MIL-PRF-23377.

(11) Install replacement seal on flinger, using seal installer, 76700-20102-107.

(12) Install nut on gearshaft. Torque nut to 1000 inch-pounds, using wrench and torque reactor, 76700-
20109-041.

(13) Install lockwasher, using lockwasher installer, 76700-20082-041.

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GEAR SHAFT SHIELD

LOCKWASHER

D
FW
NUT NUT

SEAL WASHER

PACKING

C
A

NUT

WASHER
OIL
COOLER
SHIELD BLOWER

LOCKWASHER

NUT
NUT

SEAL

B A
DRIVER QAD
ASSEMBLY CLAMP

PACKING

CB0781
SA

Oil Cooler Blower Drive Seal - Replacement

Figure 804
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NOTE: Lockwasher is positioned to nut so that lockwasher tangs engage and lock into nut slots.

CAUTION: v IF INSTALLING HYDRAULIC PUMP, 76650-09808-101, WITH MODIFICATION C

IDENTIFICATION PLATE, OR HYDRAULIC PUMP, 76650-09808-102, DISREGARD
STEPS (14) AND (15).
v DO NOT INSTALL PACKING OR LUBRICATE EXTERNAL DRIVE SHAFT NON-METALLIC
SPLINED ADAPTER.
v MAKE SURE INTERNAL SPLINES OF HELICAL GEAR IN MAIN GEAR BOX ARE CLEAN
AND FREE OF GREASE.

(14) Coat hydraulic pump external drive shaft packing with grease, MIL-G-81827, and install packing in
packing groove.

CAUTION: DO NOT PUT ANY GREASE ON PUMP EXTERNAL DRIVE SHAFT.

(15) Coat mating internal splines of helical gear, in main gear box rear cover, with grease, MIL-G-81827.
Coat full depth of spline for full length of cavity.

CAUTION: DO NOT PACK CAVITY BEHIND SPLINED TEETH OF HELICAL GEAR FULL WITH
GREASE. TOO MUCH GREASE COULD CAUSE HYDRAULIC LOCK.

(16) Install pump on main gear box rear cover and secure in place with washers and nuts. Torque nuts to
180 inch-pounds. Seal joining area of pump and gear box with sealing compound, AMS 3265, Class
A.

(17) Connect hydraulic lines and overboard drain to pump and service hydraulic system with hydraulic
fluid, Specification MIL-H-5606. (Refer to SERVICING, CHAPTER 12.)

(18) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(19) Do an operational check of hydraulic system. (Refer to HYDRAULIC POWER, CHAPTER 29.)

(20) Hinge close and secure engine air inlet/bypass cowl.

6. Engine Input Seal and Packings Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Lockwasher Installer, 76700-20082-044

(b) Lockwasher Remover, 76700-20066-043

(c) Seal Installer, 76700-20102-106

(d) Torque Reactor, 76700-20103-041 (used on 76351-09600-044 main gear box)

(e) Torque Reactor, 76700-20177-041 (used on 76351-09600-041/-042 main gear box)

(f) Wrench, 76700-20101-045

(g) Sleeve Installer (Included in sleeve replacement kit)

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

MAIN
D GEAR BOX
FW REAR SUPPORT
PUMP CASE COVER
DRAIN TUBE
D
FW PUMP
PRESSURE TUBE

NUT
(TORQUE
180 IN. LBS)
WASHER

B
GASKET
C
PACKING

ADAPTER

PUMP SUPPLY
A TUBE HYDRAULIC OVERBOARD
PUMP DRAIN TUBE

C B

SEAL NUT

GEAR SHAFT

FLINGER

SEAL

NUT (TORQUE
1000 IN. LBS)
LOCKWASHER LOCKWASHER
GEAR SHAFT FLINGER
CB0109A
SA

Hydraulic Pump Seal - Replacement

Figure 805
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MAINTENANCE MANUAL, SA 4047-76B-2

B. Replace Engine Input Seal and Packings (Figure 806).

NOTE: There are two engine input seals in the main gear box rear cover. Replacement procedures are the
same for both.

(1) Hinge open engine air inlet/bypass cowl.

(2) Remove engine drive shafts. (Refer to Removal/Installation, 71-02-00.) Make certain coupling shims are
identified and retained for proper reinstallation.

(3) Remove retaining ring and locking plate.

(4) Remove retaining nut, using wrench, 76700-20101-045, and applicable torque reactor, 76700-
20103-041 or 76700-20177-041. Remove packing from retaining nut.

(5) Remove flange from gearshaft on freewheel assembly.

(6) Remove seal from gear box rear cover input housing using suitable puller and remove packing from
gearshaft.

(7) Replace sleeve. (Refer to Paragraph 8.)

(8) If necessary, remove nuts and washers and remove input housing from main gear box rear cover.
Remove packing from input housing.

(9) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to replace-
ment packing and install packing in groove of input housing.

(10) Install input housing on gear box rear cover and secure with washers and nuts. Torque nuts to 100
inch-pounds.

(11) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to new
packing and install packing in groove of gearshaft.

(12) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to lip of
seal and sleeve and coat OD with primer, MIL-PRF-23377.

(13) Install replacement seal in gear box rear cover, using seal installer, 76700-20102-106.

CAUTION: PRIOR TO FLANGE INSTALLATION, AXIAL MOTION OF CAMSHAFT ASSEMBLY IS

POSSIBLE BUT MUST BE AVOIDED SINCE ORIENTATION AND FUNCTION OF FREE
WHEEL UNIT (FWU) COMPONENTS COULD BE EFFECTED. FLANGE IS TO BE DRAWN
ONTO CAMSHAFT ASSEMBLY (GEAR SHAFT) BY TORQUING RETAINING NUT.

(14) Install flange on freewheel assembly gearshaft.

(15) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to
replacement pacing and install packing in groove of retaining nut.

(16) Install retaining nut on gearshaft. Torque nut to 1500 inch-pounds using wrench, 76700-20101-045,
and applicable torque reactor, 76700-20103-041 or 76700-20177-041.

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MAINTENANCE MANUAL, SA 4047-76B-2

(17) Install locking plate and retaining ring. Conduct free wheel unit (FWU) functional conformity inspection
as follows:

(a) By hand, turn the input flange in the clockwise direction. Resistance should be felt and the main
rotor shaft will react.

(b) By hand, turn the input flange in the counterclockwise direction. The flange should turn freely with
little resistance and the main rotor shaft should not turn.

(18) Install engine drive shaft. (Refer to Removal/Installation, 71-02-00.)

(19) Hinge down and secure engine air inlet cowl.

7. Tail Drive Shaft Flange Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Seal Installer, 76700-20102-106

(b) Torque Reactor, 76700-20103-041

(c) Wrench, DMYNO-78286A712

(d) Sleeve Installer (included in sleeve replacement kit)

B. Replace Tail Drive Shaft Flange Seal (Figure 807).

(1) Hinge open engine air inlet/bypass cowl and open upper access panel.

(2) Remove Section I of tail rotor drive shaft. (Refer to Removal/Installation, 66-40-00.)

(3) Remove rotor brake and disc, if installed. (Refer to Removal/Installation, 66-50-02.)

(4) Remove retaining nut from gearshaft by removing retaining ring and locking plate, using wrench,
DMYNO-78286A712, and torque reactor, 76700-20103-041.

(5) Remove flange from gearshaft.

(6) Remove snapring and remove seal, using suitable puller.

(7) Replace sleeve. (Refer to paragraph 8.)

(8) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to lip of
seal and sleeve and coat OD with primer, MIL-PRF-23377.

(9) Install seal, with primer wet, in gear box rear cover, using seal installer, 76700-20102-106, and install
snapring.

(10) Install flange on gearshaft.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

GEAR SHAFT

D PACKING
FW
INPUT
HOUSING

NUT,
WASHER,
(TORQUE
PACKING 100 IN. LBS)

SLEEVE
A
SEAL
B
FLANGE

RETAINING RING
RETAINING NUT
(TORQUE 1500 PACKING
IN. LBS) (SEE NOTE)
LOCKING
PLATE

FLANGE A

0.070 TO 0.100
INCH
LOCKING PLATE
SEAL

C
C
PACKING
(SEE NOTE)

PACKING
SLEEVE
GEAR SHAFT
RETAINING
SLEEVE LOCATION RING

RETAINING
NUT

FLANGE
NOTE SLEEVE

PACKING INSTALLED WITH

76351-09614-104 RETAINING
NUT ONLY. CB0791
SA

Engine Input Seal and Packings - Replacement

Figure 806
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MAINTENANCE MANUAL, SA 4047-76B-2

(11) Install retaining nut on gearshaft. Torque nut to 1500 inch-pounds, using wrench, DMYNO-
78286A712, and torque reactor, 76700-20103-041. Install locking plate and retaining ring.

(12) Install rotor brake and disc, if applicable. (Refer to Removal/Installation, 66-50-02.)

(13) Install Section I of tail rotor drive shaft. (Refer to Removal/Installation, 66-40-00.)

(14) Close upper access panel and engine air inlet/bypass cowl.

8. Sleeve Replacement.

A. Replace Sleeve. Inspect and replace sleeve as required whenever seals are replaced. Sleeves are installed in
main gear box at oil cooler blower drive seal, engine input seals, and tail drive shaft flange seal. Sleeves are
also installed in intermediate and tail gear boxes at input and output seals.

CAUTION: TO PREVENT DAMAGE TO FLANGE, USE CARE DURING SLEEVE REMOVAL.

(1) Using a sharp-edged phenolic cutter, or scribe, make two lines 180° apart across width of sleeve, to
serve as breakpoint. Lines should be inside edges of width of sleeve.

(2) Remove sleeve by light peening across breaklines in a circular motion, over an area 3/4 to 1 inch wide.
Sleeve will expand enough or crack to allow removal from flange with wire cutter.

(3) Remove any primer from flange using paint remover, MIL-R-8633. Rinse flange with water and air-dry.

(4) Chill gear box flange in dry ice for 15 minutes.

(5) To aid in later removal of sleeve flange, saw through flange of sleeve, using a hacksaw, to precut
groove in sleeve.

NOTE: Removal of sleeve flange at engine input and intermediate gear box input is optional.

(6) Heat sleeve to 121°C (250°F) for 15 minutes.

(7) Remove flange from dry ice and brush sealant on flange OD or under sleeve upon installation using
AMS 3265, Class B sealant. Ensure that no sealant comes in contact with seal lip.

(8) While sealant is wet, place sleeve in sleeve installation tool and install on flange. Using arbor press with
wooden block or large-face mallet, gently press or tap sleeve onto flange as shown in sleeve detail on
applicable seal replacement figure.

NOTE: Installation tool is included with sleeve replacement kit.

(9) Remove installation tool and wipe off extra sealant from flange.

(10) Remove sleeve flange, starting at saw line, by using sidecutters to pry flange from sleeve surface,
twisting into coil. Sleeve flange will peel off along precut line.

NOTE: Removal of sleeve flange at engine input and intermediate gear box input is optional.

(11) Check sleeve for burrs, which might cut seal lip. Remove any burrs with crocus cloth, a fine sandstone,
and oil. Wipe clean.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

D
FW

A SNAPRING
GEAR
B SHAFT SLEEVE

RETAINING
NUT
(TORQUE
1500
IN. LBS)

RETAINING
RING
SEAL

FLANGE

LOCKING
PLATE
A
C B

SNAPRING
0.160 INCH

C
LOCKING FLANGE
FLANGE PLATE
SLEEVE SEAL

RETAINING
RING

GEAR
SHAFT

SLEEVE LOCATION
RETAINING
NUT

SLEEVE

CC0180A
SA

Tail Drive Shaft Flange Seal - Replacement

Figure 807
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

9. Unused Center Drive Seal and Packing Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Seal Installer, 76700-20102-107.

(b) Torque Reactor, 76700-20084-041

(c) Wrench, 76700-20083-041

(d) Sleeve Installer (included in sleeve replacement kit)

B. Replace Unused Center Drive Seal and Packing (Figure 808).

(1) Remove left or right main gear box fairing.

(2) Remove rotor brake accumulator/reservoir. (Refer to Removal/Installation, 66-50-04.)

(3) Remove nuts securing blower drive assembly to main gear box upper housing and remove drive assem-
bly.

(4) Remove packing from upper end of drive assembly.

(5) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to replace-
ment packing and install on drive assembly.

(6) Remove cotter pin securing nut to gearshaft.

(7) Remove nut securing flange to gearshaft, using wrench, 76700-20083-041, and torque reactor,
76700-20084-041.

(8) Remove flange from gearshaft and remove seal from drive assembly housing using suitable puller.

(9) Replace sleeve (Refer to paragraph 8.)

(10) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to lip of
replacement seal and sleeve and coat OD with primer, MIL-PRF-23377.

(11) Install seal in drive assembly housing, using seal installer, 76700-20102-107.

(12) Coat spline of flange with grease, MIL-G-81322, and install on gearshaft.

(13) Install nut on gearshaft. Torque nut to 720 inch-pounds using wrench, 76700-20083-041, and torque
reactor, 76700-20084-041.

(14) Install new cotter pin.

(15) Wet install blower drive assembly in main gear box upper housing using corrosion inhibiting sealant,
M6856K, applied all around under flange only. Do not allow sealant in packing groove or on packing.

NOTE: It may be necessary to turn flange on drive assembly to engage gears.

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MAINTENANCE MANUAL, SA 4047-76B-2

(16) Install nuts securing drive assembly to gear box housing. Torque nuts to 100 inch-pounds.

CAUTION: MAKE SURE DRAIN HOLE IN MAIN GEAR BOX MOUNTING BORE REMAINS CLEAR
OF SEALING COMPOUND

(17) Apply sealing compound, MIL-S-29574, Class B-1/2, around edge of drive assembly flange and main
gear box mating surface and around drive assembly attaching nuts and studs.

NOTE: Sealing compound, AMS 3265, Class B, may be used as an alternate. Heat gun may be used
to accelerate cure of AMS 3265.

(18) Install rotor brake accumulator/reservoir. (Refer to Removal/Installation, 66-50-04.)

(19) Install main gear box fairing.

10. Hydraulic Manifold Bracket Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Bracket Installation Tool, 76650-09004-012T046.

B. Replace Hydraulic Manifold Bracket (Figure 809).

(1) Turn off all electrical power.

(2) Remove left or right main gear box fairing.

(3) Remove loose bracket or bracket that is to be replaced. If there is soft sealant on the housing or bracket,
mask the adjacent areas with tape to preclude contamination. Rub the soft sealant with clean cloth or
paper to remove uncured sealant.

(4) Scrape the cured sealant with plastic scraper to remove as much as possible.

(5) Clean the housing surfaces as follows:

CAUTION: DO NOT ABRADE THROUGH THE ROCKHARD COATING OR PRIMER/PAINT COAT-

ING.

NOTE: Some housings may have Dow 17 coating only.

(a) Wet abrade the bond area with very fine Scotchbrite pad and clean tap water to remove all
silicone sealant. Sand just enough to break the glaze of paint.

(b) If the bare magnesium is exposed, touchup the exposed surface with chemical conversion coating
AMS-M-3171, Type VI (Dow 19).

(c) Check for water breaks on the bonding area using distilled or deionized water. If water breaks
occur within 30 seconds, repeat steps (a) and (b) and repeat water break check.

NOTE: The abrasion/water break procedures substitute for the precleaning steps in the coating
procedure.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

COTTER PIN

NUT
D (TORQUE
FW 720 IN. LBS)
A FLANGE
B

SLEEVE

NUT
(TORQUE SEAL
100 IN. LBS)

GEAR
SHAFT

OIL COOLER
BLOWER DRIVE
ASSEMBLY

PACKING

C B

FLANGE NUT COTTER PIN

FLANGE

GEAR
SLEEVE SHAFT

SEAL

SLEEVE

SLEEVE LOCATION
C CB4127
SA

Unused Center Drive Seal and Packing - Replacement

Figure 808
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

D F
E
F

R IB
A
T
B
RI

D
RI
B

G
D

C G
RIB Q
G RIB
C

L
A RI
B

NOTE
CC3276_1
ALL DIMENSIONS ARE IN INCHES. SA

Hydraulic Manifold Bracket - Replacement

Figure 809 (Part 1 of 2)
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

76650−02001−049 76650−02001−044

FLUSH TO + 0.25

5.00−5.26
VIEW A−A

4.37−4.63 VIEW C−C

76650−02001−048

FOR
76650−09004−013
INSTALL ONLY
76650−02001−047 (FOR 76650−09004−012 INSTALL)
76650−02001−061 (FOR 76650−09004−013 INSTALL)
VIEW G−G FLUSH TO + 0.25

VIEW D−D

76650−02001−045 (FOR 76650−09004−012 INSTALL)

76650−02001−059 (FOR 76650−09004−013 INSTALL)

76650−09004−013
0.12−0.38 INSTALL ONLY

FOR
76650−09004−013
INSTALL ONLY
FLUSH TO + 0.25
76650−02001−046 (FOR 76650−09004−012 INSTALL)
76650−02001−060 (FOR 76650−09004−013 INSTALL)
VIEW E−E CC3276_2
VIEW F−F SA

Hydraulic Manifold Bracket - Replacement

Figure 809 (Part 2)
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(d) Dry the bond area of visible moisture at 140°F maximum using hot air gun.

(6) Wet abrade the bond area of the bracket with very fine Scotchbrite pad and clean tap water to remove
all silicone sealant. Sand just enough to break the glaze of paint.

(7) Check for water breaks on the bonding area using distilled or deionized water. If water breaks occur
within 30 seconds, repeat step (6) and repeat water break check.

(8) Touchup the bracket exposed surface with chemical conversion coating MIL-C-5541 (Alodine1200S).

(9) Dry the bond area of visible moisture at 140°F maximum using hot air gun.

CAUTION: TO PREVENT HYDRAULIC LINE PRELOADING, KEEP TOP SURFACE OF BRACKET AS

PARALLEL TO HYDRAULIC LINES AS POSSIBLE.

(10) Bond bracket to housing with sealant, AMS 3269, Class B (PR-1770). Sealant, MIL-S-8802 or AMS
3265, Class B may be used as an alternate. Locate and install brackets using bracket installation tool,
76650-09004-012T046, (Figure 809). Keep top surface of bracket parallel to the hydraulic lines as
much as possible to minimize any preloading of hydraulic manifold lines.

(11) After sealant has cured, attach hydraulic manifold lines to bracket using clamps. (Refer to
Disassembly/Assembly, 66-10-00). Check for any preloading of hydraulic lines.

(12) Install main gear box fairing.

11. Main Rotor Shaft Upper Seal Replacement.

This procedure is applicable to helicopters with main gear boxes equipped with seal, SB8404-101/-102. (Refer
to paragraph 12 for helicopters with main gear boxes equipped with seal, SB8404-103, installed at time of
overhaul.)

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Seal Modification Kit, 76070-35016-011

(b) Pry Bar, Snap-On 18 inch, P/N SPB18A or equivalent

(c) Metal Shears (Cutting Tool), suitable

(d) Angle Drill, Dotco P/N 15LF283-62 or equivalent

(e) Vacuum, suitable

(2) Consumable Materials.

(a) Sealing Compound, AMS 3265 Class B

(b) ULTRCHEM Assembly Fluid #1

(c) Cotton Swabs

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(d) Isopropyl Alcohol, Fed. Spec TT-I-735

(e) Low-Link Cloth, MIL-C-85043 Type II or equivalent

(f) Scotchbrite Pad

(g) Grease, MIL-PRF-81322 or equivalent

(h) Acetone, Fed. Spec O-A-51 or equivalent

(i) Loctite Adhesive 416

(j) Locquic Primer Type T, MIL-R-22473

(k) Loctite 640, MIL-R-46082 Type II

(l) Dry Ice

B. Remove Main Rotor Shaft Upper Seal, SB8404-101/-102 (Figure 810).

(1) Turn off all electrical and hydraulic power.

(2) Remove the left and right main gear box fairings.

(3) Loosen and remove clamp. Remove shields from main rotor shaft.

NOTE: Located between the swashplate guide and the main rotor shaft liner is the seal, SB8404-
101/-102, that is going to be replaced by the new split seal, SB8404-103.

(4) Apply protective masking to all adjacent components in the rework area, to prevent possible chemical
or impact damage.

(5) Using clean, low-lint cloths and isopropyl alcohol, clean the exposed surface of the seal to remove any
oil, dirt or other surface residue. Use the vacuum to remove any large particles that are not removed
during wiping. Using Scotchbrite pad, roughen up the surface of the exposed seal and wipe with
alcohol and clean cloths until the cloth remains clean after rubbing the surface. Apply excess alcohol to
wipe the top of the seal, if necessary.

(6) Using clean, low-lint cloths and isopropyl alcohol, clean the bottom of the seal removal tool, 76070-
35016-101, which comes in contact with the seal.

NOTE: There are four of the removal tools, 76070-35016-101, required.

(7) Mask along the inside of the swashplate guide so the bottom of the masking is in contact with the seal.
Make sure that it is flush with the top surface of the seal to prevent accidental bonding of the seal to the
swashplate.

(8) After the seal removal tool, 76070-35016-101, and the seal have fully dried, wipe the top surface of
the seal with acetone, Fed. Spec O-A-51 or equivalent. Apply a long thin bead of Loctite adhesive 416
or equivalent, to the center of the recently cleaned surface of the seal removal tool, 76070-35016-101.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

MAIN
ROTOR
SHAFT

MAIN SHAFT
ROTOR SEAL
SHAFT

SHIELD
SHIELD SHAFT
SEAL
HOSE CLAMP

SCREW
CAULK
ATTACHMENT
CLAMP RING
SEAL
REMOVAL PRESSURE
TOOL SET
RING
SCREW
CLAMP
LINER

BEARING
SEAL
LOCK SEAL
RING
LINER
LOCK
RING SPACER
BEARING RING

SWASHPLATE
GUIDE
SWASHPLATE
GUIDE

BEFORE INSTALLATION OF MODIFICATION KIT AFTER INSTALLATION OF MODIFICATION KIT

CC3590
SA

Main Rotor Shaft Upper Seal - Replacement

Figure 810
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MAINTENANCE MANUAL, SA 4047-76B-2

Immediately press the tool to the surface of the seal, centering the tool between the swashplate guide
and the liner, while not coming in contact with either of them. Press the tool down firmly so the bead
of Loctite adhesive 416 or equivalent is spread uniformly along the contact surface between the
removal tool and seal.

(9) Repeat step (8) for the remaining three seal removal tools, 76070-35016-101. Install each of the tools
approximately 90 degrees apart. Allow the seal removal tools to cure for a minimum of 30 minutes.

(10) Pack drill bit with grease, MIL-PRF-81322 or equivalent before drilling. Using the angle drill, Dotco
15LF283-62 or equivalent, and the drill bit, 76070-35016-041, drill two holes in seal using the pilot
holes at the ends of the removal tool as a guide. The holes should be drilled to the maximum depth of
0.765 inches, according to the stop on the drill bit, with minimum amount of force required. After
each hole is drilled, remove exposed chips from top surface of seal removal tool, 76070-35016-101,
and clean and repack drill bit with grease before and after each use.

(11) Install screws, MS51850-48, tightly into the newly drilled holes.

(12) Repeat steps (10) and (11) for the remaining seal removal tools, mounting all four seal removal tools
to the seal.

(13) After all four seal removal tools have been secured to the seal, make sure surrounding dynamic
components are protected with a suitable cloth cover secured in place.

CAUTION: TO PREVENT DAMAGE TO THE SWASHPLATE GUIDE, THE USE OF THE NYLON
BLOCKS IS ESSENTIAL.

(14) Place the pry guard, 76070-35016-102, on the top edge of the swashplate guide directly in front of
the slot in the removal tool. After the nylon block is positioned so it lays length wise and flat, insert the
pry bar, SPB18A or equivalent, into the center of the slot until it comes in contact with the back surface
of the slot.

(15) Position the pry bar so it lies firmly against the nylon block while still inserted in the slot.

(16) Place a downward force on the handle of the pry bar to create a prying motion. Increase the force
until the seal raises slightly.

(17) Repeat steps (14), (15) and (16) in a circular pattern around each of the seal removal tools, 76070-
35016-101, to raise the seal. Once the seal reaches a height where the nylon block becomes
ineffective, add another pry guard, 76070-35016-102 or 103 or 104 in different combinations, as
required, to the existing nylon block positioned on the swashplate guide to create a higher prying
surface. Continue the three previous steps in a circular pattern around the seal until the seal is fully
dislodged from the swashplate guide.

(18) Once the seal is released, make sure that no debris falls into the main gear box internal cavity, where
the seal was just removed.

(19) Raise the seal so it is equally spaced from any other parts, above and below it.

(20) Remove any debris that may have fallen in the internal cavity by collecting the debris using a cotton
swab along with ULTRACHEM Assembly Fluid #1.

(21) Mask the clean open cavity to prevent any further debris ingestion.

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(22) Pull the seal to one side of the main rotor shaft, so that the seal is pressed against the main rotor shaft
on one side and has a gap on the opposite side. Using the metal shears, cut the seal where the gap
between the seal and the main rotor shaft is the greatest.

(23) Bend/spread the seal to create an opening large enough for the seal to fit past the main rotor shaft
and remove it from around the main rotor shaft.

(24) Remove the bonded seal removal tool, 76070-35016-101, from the seal using the dry ice soak
procedure and discard the seal.

C. Install Main Rotor Shaft Upper Seal, SB8404-103 (Figure 810).

(1) Remove any masking or low-lint cloths from cavity and the surrounding components, if necessary.

(2) Using a mirror, inspect the cavity between the swashplate guide and the main rotor shaft for any
debris. If any debris is found, remove it using a cotton swab along with ULTRACHEM Assembly Fluid
#1.

(3) Place the split spacer ring, 76070-35016-042, on top of the lock ring. Make sure that the edges of the
spacer ring are not overlapping, but are lying flush to the lock ring. Arrange the assembly so the
breaks are located approximately 45 degrees off of the drain holes on the swashplate guide.

(4) Assemble the spring of the split seal around the main rotor shaft and squeeze the hook and eye to
secure the joint. Place the split seal around the main rotor shaft above the swashplate guide. Press the
seal over the spring so that the spring latch is 180 degrees from the split in the seal.

(5) Apply a light coat of grease, MIL-PRF-81322 or equivalent, between the dust lip and the primary lip of
the split seal.

(6) Firmly seat the assembled seal against the spacer ring so that the split in the seal is 90 degrees from
the split in the spacer ring.

(7) Place the pressure ring, 76070-35016-043, on top of the split seal so that the breaks in the pressure
ring are located 90 degrees away from the split in the seal and directly over the splits in the spacer
ring. The pressure ring should be lying flush against the seal.

(8) Caulk inside groove of the two split attachment rings, that come in contact with the swashplate guide,
with a thin bead of sealing compound, AMS 3265 Class B, along the center of the contact groove.

(9) Position the two parts of the attachment ring around the main rotor shaft and insert the pins of the one
half into the respective holes located in the other half.

(10) Vertically align the two threaded holes of the attachment ring with the two drain holes of the swash-
plate guide and press the assembly onto the swashplate guide. Insert the two setscrews into the
attachment ring, so the points of the setscrews are inserted into the drain holes of the swashplate
guide. Realign the attachment ring on the swashplate guide, if necessary, to insert the setscrews.
When installing the setscrew, make sure that when it is fully inserted, it should be flush to 0.05 inch
below, with the outside surface of the attachment ring.

(11) To fully secure the attachment ring, install the hose clamp around the attachment ring.

(12) Install screws in attachment ring as follows:

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(a) Clean screws with isopropyl alcohol.

(b) Apply Locquic Primer Type T, MIL-R-22473, to screws and allow to dry.

(c) Apply a light coat of Loctite 640, MIL-R-46082 Type II, on the first three or four threads on the
screw tip only.

(d) Install and tighten screws immediately so the distance between the base of the screw head and
the top surface of the attachment ring is 0.070 6 0.005 inches.

(13) Repeat the previous step eight times in a star pattern around the attachment ring.

(14) Install the shields and secure with clamp.

(15) Install left and right main gear box fairings.

(16) Make an appropriate log card entry to reflect the modification to the main gear box.

12. Main Rotor Shaft Upper Seal Replacement.

This procedure is applicable to helicopters with main gear boxes equipped with seal, SB8404-103, installed at
time of overhaul.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) 10-32 Thread 3-piece tap set

(b) Vacuum, suitable

(2) Consumable Materials.

(a) ULTRACHEM Assembly Fluid #1

(b) Cotton Swabs

(c) Isopropyl Alcohol, Fed. Spec TT-I-735

(d) Grease, MIL-PRF-81322 or equivalent

(e) Locquic Primer Type T, MIL-R-22473

(f) Loctite 222, MIL-R-46082 Type II

(g) Low-Link Cloth, MIL-C-85043 Type II or equivalent

B. Replace Main Rotor Shaft Upper Seal, SB8404-103 (Figure 811).

(1) Turn off all electrical and hydraulic power.

(2) Remove the left and right main gear box fairings.

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(3) Loosen and remove clamp. Remove shields from main rotor shaft.

(4) Using clean, low-lint cloths and isopropyl alcohol, clean the exposed surface of the seal to remove any
oil, dirt or other surface residue. Use the vacuum to remove any large particles that are not removed
during wiping.

(5) Mark the orientation of the retaining ring in relation to the swashplate guide with an index mark using
indelible ink.

(6) Remove and discard the screws securing the four retaining clips.

(7) Remove the four retaining clips by sliding them radially outboard from the swashplate guide.

(8) Using a feeler gage, measure the gap under the head of each of the eight screws securing the retaining
ring.

(a) If the gap measures .035 6 .005 inches, do not perform steps (9) and (10).

(b) If the gap does not measure .035 6 .005 inches, carefully remove the applicable screws and
complete steps (9) and (10) at the specific screw locations.

(9) Slide the retaining ring up the shaft. Mask the open cavity using a clean cloth, MIL-C-85043 Type II or
equivalent. Tap the applicable holes that contained the removed screws using a 10-32 thread 3-piece
tap set and the following procedure:

CAUTION: BE CAREFUL NOT TO STRIP THE THREADS IN THE RETAINING RING.

(a) Tap the holes using the most course tap to slightly clean up any debris that is bonded to the
internal threads. Apply the minimum force necessary to run the entire tap through the hole and
back out, to remove the Loctite that has cured in the thread when the screws were originally
installed.

(b) Tap the holes using the medium tap. Be sure to run the tap through the entire hole to clean the
threads up to the largest diameter of the tap.

(c) Tap the holes using the third and finest tap out of the set. Once again, run the entire tap through
the full length of the hole to remove any excess Loctite that was present in the threads, from the
original installation.

(d) Remove the cloth from the open cavity.

(10) Any debris that has fallen onto the existing pressure ring is to be removed with cotton swabs, lightly
soaked with ULTRACHEM Assembly Fluid #1.

(11) Raise the retaining ring and the pressure ring and temporarily secure both rings as high as possible
to the main rotor shaft.

(12) Remove seal, SB8404-103, along with the garter spring, by locating the split in the seal and prying
it up using a sharp tool, being careful not to damage any of the surrounding parts. The garter spring
may be cut if it can not be unlatched.

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HOSE CLAMP SHAFT SEAL

RETAINING RING
SHIELD

SCREW PRESSURE RING

RETAINING CLIP
LINER

LOCK RING

SPLIT SEAL

SPACER RING BEARING

MAIN ROTOR SHAFT

SWASHPLATE GUIDE

CC3594
SA

Main Rotor Shaft Upper Seal - Replacement

Figure 811
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(13) Using a mirror, inspect the cavity between the swashplate guide and the main rotor shaft for any
debris. If any debris is found, remove it using a cotton swab along with ULTRACHEM Assembly Fluid
#1.

(14) Check and make sure the spacer ring is sitting flush on top of the lock ring.

(15) Assemble the new seal spring of the split seal, SB8404-103, around the main rotor shaft and squeeze
the hook and eye to secure the joint. Place the split seal around the main rotor shaft above the
swashplate guide. Press the spring up into the seal so that the spring latch is 180 degrees from the
split in the seal.

(16) Apply a light coat of grease, MIL-PRF-81322 or equivalent, between the dust lip and the primary lip
of the split seal.

(17) Firmly seat the assembled seal against the spacer ring so that the split in the seal is 90 degrees from
the .125 inch diameter drainage holes in the forward and aft direction of the swashplate guide.

(18) Install the pressure ring on top of the split seal. The pressure ring should be lying flush against the
seal.

(19) Install the retaining ring flush against the pressure ring, while aligning it with the orientation marking
on the swashplate guide.

(20) Align the four raised threaded holes of the pressure ring with the four .209 inch diameter holes of the
swashplate guide. Insert the four retaining clips into the swashplate guide so the clip is flush against
the swashplate guide.

(21) Install four new screws, NAS1351-3LL6P, through the top of the clips into the pressure ring to a
torque of 15 - 20 inch-pounds. Realign the pressure ring, if necessary, to install the screws.

(22) Install remaining eight new screws NAS1351-3LL6P in a star pattern. Tighten screws until gap
between the base of the head of screw and the top surface of the retaining ring is .035 +/- .005
inches.

(23) Apply torque stripe to all replacement screws. (Refer to Torque Striping Hardware, 20-04-00.)

(24) Install the shields and secure with clamp.

(25) Install left and right main gear box fairings.

13. Main Rotor Shaft Lower Housing Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Alignment Tool, 76351-09000-047T098 or equivalent

(b) Seal Installation Tool, 76351-09600-044T046 or equivalent

(c) Rollover Stand, 76700-20002-041 or equivalent

(d) Jacking Bolts, AN4 or 1/4-28

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(e) Wooden Dowel, suitable

B. Remove Main Rotor Shaft Lower Housing Seal, SB8209-103 (Figure 812).

(1) Turn off all electrical and hydraulic power.

CAUTION: MAKE SURE THAT ROLLOVER STAND OR EQUIVALENT IS LOCKED IN PLACE.

(2) Remove main gear box and place on a suitable rollover stand, 76700-20002-041 or equivalent.
(Refer to Removal/Installation.)

(3) Remove nuts and washers securing lower bearing housing assembly to main gear box lower housing
assembly.

(4) Clean inserts of any sealing compound and jack lower bearing housing assembly from lower housing
using jacking bolts, AN4 or 1/4-28. Turn bolts until lower bearing housing is removed breaking seal
of packing. Remove packing from lower bearing housing assembly.

(5) Remove transfer tube from lower bearing housing assembly. Remove packings from transfer tube.
Discard packings.

(6) Remove bolts at the base of the main rotor shaft that secure retainer to retainer nut.

(7) Lower retainer and allow it to rest on bearing retainer ring in base of bull gear assembly.

CAUTION: CARE SHOULD BE TAKEN NOT TO CONTACT INSIDE DIAMETER OF THE MAIN
ROTOR SHAFT DURING SEAL REMOVAL.

(8) Using a wooden dowel or equivalent inserted through top of main rotor shaft, lightly tap dowel while
alternating contact point on surface of seal until seal is removed from main rotor shaft assembly.

C. Install Main Rotor Shaft Lower Housing Seal, SB8209-103 (Figure 812).

NOTE: Make sure spring side of the seal open end is facing upward.

(1) Pack seal void between primary seal lip and dirt lip with grease, MIL-PRF-81322. Coat tube surface,
where the seal contacts, with main gear box lubricating oil.

(2) Install seal using installation tool, 76351-09600-044T046 or equivalent, with spring side (open side)
facing upwards. Align seal in main rotor shaft using tool, then press in until fully seated.

(3) Install retainer using two bolts. Torque bolts to 125 inch-pounds.

(4) Coat large packing with main gear box lubricating oil. Install packing on lower bearing housing
assembly.

(5) Install two packings on transfer tube lubricated with main gear box lubricating oil.

(6) Using alignment tool, 76351-09000-047T098 or equivalent, guide tube on lower bearing housing
assembly into main rotor shaft seal inside diameter. Coat studs on lower housing with epoxy primer,
MIL-PRF-85582. Install lower bearing housing assembly into lower housing assembly and secure with
eight new nuts and washers. Torque nuts to 165 inch-pounds.

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 S-76B
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(7) Remove alignment tool through top of main rotor shaft.

(8) Apply sealing compound, AMS 3265, Class A2 or equivalent, to seal lower bearing housing assem-
bly, studs, nuts and inserts.

(9) Touch up main gear box with matching paint (epoxy coating), MIL-PRF-22750.

(10) Install main gear box. (Refer to Removal/Installation.)

(11) Perform ground run leak check. (Refer to Flight Check Procedures Manual, SA 4047-76B-6.)

14. Unused Blower Drive Assembly Removal/Reinstallation

A. Remove Unused Drive Assembly (Figure 813), (Figure 814).

(1) For helicopters equipped with 76351-09600-044 main gear box assembly, remove unused blower
drive assembly (76351-09041-043 or -044) from main gear box as follows:

(2) Make sure rotor brake is off, then turn off all electrical power to helicopter.

(3) Hinge open left engine air inlet cowl.

(4) Temporarily remove rotor brake accumulator/reservoir and mounting bracket from main gear box.
(Refer to Removal/Installation 66-50-04.)

(5) Remove four nuts securing blower drive assembly and packing to main gear box. (Refer to Figure
814).

CAUTION: BE CAREFUL NOT TO ALLOW ANY FOREIGN MATTER TO ENTER MAIN GEAR BOX
WHILE ACCESSORY DRIVE OPENING IS EXPOSED.

(6) Remove blower drive assembly.

(7) Blower drive assembly should be preserved, tagged and stored. (Refer to Storage Maintenance Prac-
tices, 10-11-00 Paragraph 3.F.)

(8) Apply same type lubricating oil, as used to service gear box, Servicing, 12-10-00, lightly to packing
and install packing in groove of plug.

(9) Install packing and plug into blower drive bore and secure with four washers and four nuts. (Refer to
Figure 814, Detail C).

(10) Torque nuts to 100 inch-pounds.

(11) Seal all around plug edges and attaching hardware with sealant, MIL-S-8802, Class B-2, or equiva-
lent.

NOTE: Do not remove or alter main gear box data plate.

(12) After modification, reidentify main gear box assembly 76351-09600-044 to 76070-35012-045 at
location shown. (Refer to Figure 814, Detail C). Using rubber stamp and indelible ink. Apply a coat
of clear urethane (M85285-12-CLEAR), or equivalent over identified area.

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MAIN ROTOR SHAFT

(76351−09630)

LOWER HOUSING ASSEMBLY

PACKING
(76351−09073−104)

SEAL
(SB8209−103)

RETAINER NUT PACKING

(76351−09117−101) (M83248 / 1−012)
TUBE
(76351−09150)

TRANSFER TUBE
RETAINER (76351−09056−102)
(76351−09115−102 / −103)

PACKING
(M83248 / 1−012)

RETAINER RING BOLT

(76351−09095−105) (TPL1304−1M)
LOWER BEARING
HOUSING ASSEMBLY
NUT
(MS21043−5)
WASHER
(NAS1149F0563P)

BULL GEAR ASSEMBLY

(76351−09032 / −09632 / −09732)

CC3765
SA

Main Rotor Shaft Lower Housing Seal - Replacement

Figure 812
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NOTE: Lockwire accumulator/reservoir bracket mounting bolts. (Refer to Figure 814, Detail D).

(13) Reinstall rotor brake accumulator/reservoir mounting bracket. (Refer to Removal/Installation 66-50-
04.)

(14) Perform an operational check as follows: With a qualified operator, ground run helicopter for
approximately 20 minutes at 107% Nr in accordance with approved aircraft operating procedures
and until temperature stabilizes. Power shall be a minimum at flat pitch of the rotor blades. Shut
down and check for leaks and the chip detectors/strainers for debris.

(15) Make appropriate entry on the Main Gear Box component log card to document alterations to main
gear box.

B. Reinstallation of Unused Blower Drive Assembly (Figure 813), (Figure 814).

(1) If blower drive assembly is to be reinstalled for reuse, reinstall as follows:

(2) Depreserve blower drive assembly unit to be reinstalled.

(3) Gain access to plug by temporarily removing rotor brake accumulator/reservoir and rotor brake
accumulator/reservoir mounting bracket. (Refer to Removal/Installation 66-50-04.)

(4) Remove sealant, nuts and four washers retaining plug to gear box housing.

CAUTION: BE CAREFUL NOT TO ALLOW ANY FOREIGN MATTER TO ENTER MAIN GEAR BOX
WHILE ACCESSORY DRIVE IS EXPOSED.

(5) If required, use a 1/4 - 28 threaded rod or equivalent to remove plug by pulling straight up while
being careful not to drop any foreign matter into the exposed gear box drive opening.

(6) Apply same type lubricating oil, as used to service gear box, Servicing, 12-10-00, lightly to packing
and install packing in groove of blower drive assembly (Refer to Figure 814, Detail B).

(7) Carefully install the blower drive assembly unit into main gear box.

NOTE: It may be necessary to turn flange on the drive assembly to engage the gears.

(8) Install four nuts securing blower drive assembly to main gear box housing and torque nuts to 100
inch-pounds.

(9) Apply sealant, MIL-S-8802, Class B-2, or equivalent around edge of drive assembly flange and main
gear box mating surface and around drive assembly attaching nuts and studs.

(10) Reinstall rotor brake accumulator/reservoir mounting bracket. (Refer to Removal/Installation 66-50-
04.)

(11) Perform an operational check as follows: With a qualified operator, ground run helicopter for
approximately 20 minutes at 107% Nr in accordance with approved aircraft operating procedures
and until temperature stabilizes. Power shall be a minimum at flat pitch of the rotor blades. Shut down
and check for leaks and the chip detectors/strainers for debris.

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(12) Reidentify main gear box assembly with the correct part number, or if main gear box assembly has
been returned to its original configuration, make sure all modification part numbers are removed.
(Refer to Figure 813).

(13) Make appropriate entry on the Main Gear Box component log card to document alterations to main
gear box.

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MGB MGB

USE ONE 76070−35012−013 KIT 2

76351−09600−044 ..................................... REIDENTIFIED TO ..................................... 76070−35012−045

LEGEND

DRIVE INSTALLED
DRIVE REMOVED CB0285
SA

Unused Blower Drive Assembly Removal/Reinstallation

Figure 813

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

B C

NOTES
1. AFTER REWORK, REIDENTIFY MGB
ASSEMBLY AT LOCATION SHOWN.
2. LOCKWIRE AS SHOWN USING
(MS20995NC32).
CB0286_1
SA

Unused Blower Drive Assembly Removal/Reinstallation

Figure 814 (Sheet 1 of 2)
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 S-76B
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BOLT
D (TORQUE TO
BOLT
110 IN. LBS)

WASHER WASHER

BRACKET BRACKET
ASSEMBLY ASSEMBLY

BOLT
BOLT (TORQUE TO
110 IN. LBS)

COVER PLATE WASHER COVER PLATE WASHER

STANDOFF STANDOFF

COVER COVER

NUT
(TORQUE TO
100 IN. LBS) (SEE NOTE 1)
NUT
WASHER

PLUG
BLOWER
DRIVE
ASSEMBLY EXTRACTION HOLE

PACKING

FW FW
D D

PACKING

B C
D
BOLT,
WASHER
(TORQUE TO
110 IN. LBS) BRACKET
ASSEMBLY
COVER
PLATE

BOLT,
WASHER
(TORQUE TO
110 IN. LBS)

(SEE NOTE 2)

FWD
CB0286_2
SA

Unused Blower Drive Assembly Removal/Reinstallation

Figure 814 (Sheet 2)
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX LUBRICATION SYSTEM - DESCRIPTION AND OPERATION

1. Description and Operation (Figure 1).

Lubrication of the main gear box is by a self-priming wet sump system. Pressure for lubrication of the main gear
box is supplied by two vane-type lubrication pumps mounted on the gear box lower housing and driven by the
accessory section. Oil is pumped from the sump of the gear box through the oil filter to the oil cooler. The oil is
directed through the cooler core or bypassed directly to the gear box by the thermostatic bypass valve at the top
of the cooler. The oil is bypassed if the oil temperature is below 68° to 74°C (155° to 165°F), or if the core
differential pressure is greater than 40 psid. Oil flow is 15.8 gpm and oil pressure at the manifold is 80 6 5 psi
with both pumps operating and 11.6 gpm at 40 - 45 psi with one pump inoperative. An oil cooler blower is
mounted on the top aft of the gear box. A sight window and oil filler are on the aft right side of the gear box.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL COOLER

CAUTION PANEL

MAIN XMSN
OIL PRESSURE
OIL HOT
TRANSMITTER

OIL TEMPERATURE COCKPIT

WARNING SWITCH PRESSURE
121.5O 2.8OC GAGE
(250O 5OF)

OIL COOLER BREATHER

BYPASS VALVE
OPENS BELOW
60O − 71OC
DIFFERENTIAL (140O − 160OF)
PRESSURE INDICATOR OPENS AT
(12 3 PSI 35 PSI

OIL
FILTER COOLER
BLOWER

OIL FILLER FILTER

BYPASS
VALVE
20 4
PSI

OIL LEVEL
SIGHT WINDOW

CHECK CHECK
VALVE VALVE LOW OIL PRESSURE
LUBRICATION WARNING SWITCH
PUMP (14 2 PSI)

PUMP
PUMP

RELIEF RELIEF +28 VDC FWD

VALVE VALVE

MAIN XMSN
OIL PRESS

CHIP DETECTOR / CAUTION PANEL

STRAINER
OIL
TEMPERATURE MAIN XMSN
SENSOR CHIP
CHIP DETECTOR /
STRAINER

COCKPIT
TEMPERATURE MAGNETIC
GAGE DRAIN PLUG
S76B_87306 (C7)
SA

Main Gear Box Lubrication System - Simplified Schematic Diagram Main Gear Box Lubrication System - Simplified Schematic Diagram
Figure 1 (Part 1 of 2) Figure 1 (Part 2)
66-11-00 66-11-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
OIL PUMPS - DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

The two oil pumps, on the lower left and right sides of the main gear box lower housing, are accessory-driven,
vane-type, gear box lubrication pumps. Each pump consists of a vane-type pumping element, a relief valve, and
an anti-static leakage check valve. The pumping element consists of a rotor and four vanes revolving within the
bore of the liner. The relief valve is a screw-adjustable, spring-loaded poppet in the fluid passage between the
inlet and discharge sides of the pump. The anti-static leak valve consists of a spring-loaded ball that seats against
an opening into the discharge port. Torque is transmitted from the accessory drive gears to a quill shaft which
drives the pump rotor. As the rotor turns, the vanes shift radially in the rotor slots while their tips remain in contact
with the liner wall. As the sliding vanes pass the inlet port, the area between them increases and forms a suction
that draws oil into the pumping section. At the discharge port, the area between the vanes decreases and oil is
forced from the pump. The inlet and discharge cycles occur at the same time, which results in non-pulsating flow.
Should the pump develop too much discharge pressure, the relief valve unseats and returns oil to the inlet side.
While the pump is operating, discharge pressure unseats and holds the check valve ball in an open position.
When the pump is shut down, the valve closes and prevents oil from draining through the pump.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
OIL PUMPS - MAINTENANCE PRACTICES

1. Removal/Installation Oil Pump.

A. Remove Oil Pump (Figure 201).

NOTE: There are two oil pumps on the main gear box. Removal procedures are the same for both.

(1) Drain main gear box. (Refer to Draining Main Gear Box, 66-10-00.)

(2) Remove left or right main gear box fairing.

(3) Remove washers and nuts and remove oil pump from main gear box lower housing.

B. Install Oil Pump (Figure 201).

NOTE: There are two oil pumps on the main gear box. Installation procedures are the same for both.

(1) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to three
packings and position packings in proper grooves on pump.

(2) Install pump in gear box lower housing and secure with washers and nuts. Torque nuts to 100 inch-
pounds. Seal joining area of pump and gear box with sealing compound, MIL-S-8802, Class A.

(3) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(4) Do an operational test of oil pressure indicating system. (Refer to Testing and Troubleshooting, 66-61-
00.)

(5) Install left or right main gear box fairing.

2. Adjustment/Test Oil Pump.

A. Adjust Oil Pump Pressure. The following alternate method to establish discharge pressure symmetry between
the two lubrication oil pumps may be used if one of the pumps require replacement with anew or overhauled
pump.

(1) Prior to any main gear box oil pump replacement efforts the normal cockpit transmission oil pressure
and oil temperature gauge readings are to be documented at normal flight conditions.

(2) On the pump being replaced, measure the distance from the top of the pressure adjustment screw to the
top of the associated jamnut using a depth micrometer. The measurement is to be within 6 .010 inches.

(3) On the replacement pump, adjust the pressure adjustment screw to match the measurement of the pump
being replaced within 6 .010 inches.

(4) During installation of the replacement pump, care must be taken to ensure the pump splined shaft is
engaged into the internal spline of the drive gear. Hand rotation of the main rotor head or main gear
box input during installation of the pump will assist in the proper seating of the spline.

(5) After installation of the pump is completed the main rotor head should be free to rotate by hand. If
rotation difficulty is encountered, the pump is to be backed out and installation tried again.

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D
FW

PACKING
(M83248 / 1−039)

PACKING
(M83248 / 1−040)

PACKING
(M83248 / 1−041)

OIL
PUMP

NUT
(TORQUE
100 IN. LBS)

WASHER CB0110
SA

Oil Pumps - Removal/Installation

Figure 201
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CAUTION: DO NOT ATTEMPT TO APPLY ENGINE POWER TO THE MAIN GEAR BOX UNTIL THE
PUMP IS PROPERLY ENGAGED AS QUILL SHAFT DAMAGE WILL LIKELY OCCUR.

(6) Conduct a main gear box serviceability test. (Refer to Gear Box Serviceability Check, 66-10-00.) During
this test, carefully monitor both the main gear box oil pressure and oil temperature gauges. The read-
ings must be comparable to the original readings taken prior to the pump replacement effort.

(7) If the readings are not comparable, contact Sikorsky Aircraft Customer Service for standard oil pump
adjustment instructions.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
OIL FILTER - DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

A filter for the main gear box lubrication system is mounted on the aft right side of the gear box. The filter consists
of 12-micron disposable element, a 200-micron permanently attached screen, a filter bypass button and an outer
housing. Oil from the gear box sump is pumped to the filter at 80 psi under normal operating conditions. When
a pressure drop of 12 6 3 psi occurs, due to clogging of the filter, the filter bypass indicator button will extend
indicating an impending bypass condition. Actual bypassing will not occur until clogging produces a pressure
drop of 20 6 4 psi. A thermal lockout feature is provided to prevent the bypass indicator button from extending
until the oil being filtered reaches 29° to 46°C (85° - 115°F). Once extended, the filter bypass indicator button
can be reset only by removing the filter housing from the gear box and replacing the clogged element.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL FILTER - MAINTENANCE PRACTICES

1. Removal/Installation Oil Filter.

A. Remove Oil Filter (Figure 201).

(1) Remove right main gear box fairing.

NOTE: Make sure nuts are discarded after removal. Do not reuse nuts.

(2) Remove washers and nuts securing oil filter to gear box. Discard nuts.

(3) Place suitable container under filter, raise spring-loaded handle on filter housing and pull filter from
gear box.

(4) Remove oil filter element from filter housing and discard.

(5) Remove retaining ring and remove inlet plug and packing from main gear box.

(6) Inspect oil filter housing mounting studs. (Refer to Inspection/Check Oil Filter Housing Mounting Studs.)

B. Install Oil Filter (Figure 201).

(1) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing,
install packing on inlet plug, and install inlet plug in main gear box. Install retaining ring to secure inlet
plug in place.

(2) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packings
at both ends of new filter element and position element on inlet plug in gear box.

(3) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing in groove of filter housing.

(4) Reset filter bypass indicator button.

CAUTION: TO PREVENT DAMAGE TO FILTER HOUSING MOUNTING STUDS AND/OR NUTS, DO

NOT USE STUDS AND NUTS TO DRAW AND SEAT FILTER HOUSING ASSEMBLY ON
TO BASE OF MAIN GEAR BOX.

(5) Using hand pressure, position filter housing on main gear box. Secure filter housing with washers and
new nuts.

(6) Using torque wrench, measure run-on torque of each nut. Run-on torque shall not exceed 30 inch-
pounds. If run-on torque exceeds 30 inch-pounds, do as follows:

(a) Remove nut.

(b) Using a magnifying glass (10X) and mirror, visually inspect stud threads for signs of damage such
as galling and missing or flattened threads. None allowed. If damage is found, contact Sikorsky
Customer Service Engineering.

(c) If no damage is found, repeat step (6) run-on torque measurement using new nut.

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(d) If run-on torque is not acceptable after the third nut, contact Sikorsky Customer Service Engineer-
ing.

(7) Torque nuts to 100 inch-pounds.

(8) Service main gear box. (Refer to SERVICING, CHAPTER 12.)

(9) Run up helicopter and check for leaks.

(10) Install right main gear box fairing.

2. Inspection/Check Oil Filter Housing Mounting Studs.

A. Inspect Oil Filter Housing Mounting Studs (Figure 201).

(1) Using a magnifying glass (10X) and inspection mirror, visually inspect stud threads for signs of damage
such as galling and missing or flattened threads. None allowed. If damage is found, contact Sikorsky
Customer Service Engineering.

(2) Inspect studs for looseness. No side play allowed. If stud(s) are loose, contact Sikorsky field service
representative.

(3) Inspect studs for corrosion at housing base adjacent to studs. None allowed. If corrosion is found,
contact Sikorsky field service representative.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

D
FW A

FILTER
HOUSING
MOUNTING
STUDS

WASHER PACKING

NUT INLET
(TORQUE PLUG
100 IN. LBS)
RETAINING
RING
FILTER
HOUSING ELEMENT

ELEMENT
PACKING
(2 PLACES)
PACKING CB0111A
SA

Oil Filter - Removal/Installation

Figure 201

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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
OIL STRAINERS - DESCRIPTION AND OPERATION

1. Description and Operation.

Two oil strainers, one in each electric chip detector, are on the gear box. The strainers are cylinder-shaped and
made of No. 30. mesh, 0.015 brass wire. The strainers trap foreign material in the oil flowing through the chip
detectors and are easily removable by pushing and turning on a spring-loaded bayonet. For maintenance
practices on the strainers, refer to Gear Box Chip Detector/Overtemp Warning System, 66-64-00.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
SIGHT WINDOW- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

An oil level sight window is mounted on the aft right side of the main gear box below the oil filler. The lens
markings on the window reads 88MAINTAIN OIL LEVEL WITHIN BULL’S-EYE.’’ When the oil level is at the top of
the bull’s-eye, the gear box contains 3.040 gallons of oil. When the oil level drops to the bottom of the bull’s-eye,
the gear box contains about 2.500 gallons of oil and must be serviced.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

SIGHT WINDOW - MAINTENANCE PRACTICES

1. Removal/Installation Sight Window.

A. Remove Sight Window (Figure 201).

(1) Turn off all electrical power.

(2) Remove right main gear box fairing.

(3) Drain main gear box enough to bring oil level below sight window port. (Refer to SERVICING, CHAP-
TER 12.)

(4) Remove sight window.

B. Install Sight Window (Figure 201).

(1) Turn off all electrical power.

(2) If necessary, clean sight window using dry-cleaning solvent, Fed. Spec P-D-680, Type II, or equivalent.

(3) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing on sight window.

CAUTION: TO PREVENT DAMAGE TO THREADS IN GEAR BOX HOUSING, USE CARE NOT TO
CROSS THREADS WHEN INSTALLING SIGHT WINDOW.

(4) Install sight window in port on aft right side of gear box under oil filler. Torque sight window to 120-160
inch-pounds. Lockwire sight window to gearbox housing.

(5) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(6) Install right main gear box fairing.

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PACKING
A
SIGHT
D WINDOW
FW (TORQUE TO
120−160 IN. LBS)
CB0112A
SA

Sight Window - Removal/Installation

Figure 201

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 S-76B
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OIL FILLER- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

An oil filler is mounted on the aft right side of the main gear box above the oil level sight window. The filler
consists of a filler cap, a fitting with removable strainer, and a safety chain which connects the cap to the fitting
to prevent loss. To open, press the cap and turn counterclockwise. To close, press the cap and turn clockwise. An
oil filler funnel is secured to the gear box by the fitting and catches any overflow of oil and directs it downward.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL FILLER - MAINTENANCE PRACTICES

1. Removal/Installation Oil Filler.

A. Remove Oil Filler (Figure 201).

(1) Remove right main gear box fairing.

(2) Remove oil filler, using care not to damage chain connecting cap to fitting.

(3) Separate funnel from oil filler with strainer/fitting.

(4) Remove packing from fitting. If necessary, remove packing from cap.

B. Install Oil Filler (Figure 201).

(1) Insert oil filler with strainer/fitting through hole in funnel.

(2) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing on oil filler fitting.

(3) If necessary, apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00,
lightly to packing and install on cap.

CAUTION: TO PREVENT DAMAGE TO THREADS IN GEAR BOX HOUSING, USE CARE NOT TO
CROSS THREADS WHEN INSTALLING OIL FILLER.

(4) Install oil filler in oil filler port, using care not to damage chain connecting cap to fitting. Torque oil filler
to 130-180 inch-pounds and lockwire fitting to gear box.

(5) Install right main gear box fairing.

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 S-76B
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CAP

PACKING
FITTING (TORQUE
130−180 IN. LBS)

STRAINER

A SAFETY
CHAIN

FUNNEL
PACKING

FW
D

CB0113A
SA

Oil Filler - Removal/Installation

Figure 201

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
OIL COOLER- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

The main gear box oil cooler is installed between the two engine oil cooler/reservoirs above the plenum chamber.
Air is forced through the oil cooler by the oil cooler blower mounted on the aft side of the main gear box. Hot oil
is pumped from the gear box sump by oil pumps, through a filter to the oil cooler. If oil temperature is less than
68° to 74°C (155° to 165°F) or if differential pressure is greater than 40 psi, the oil is bypassed to the return line
by a thermostatically controlled bypass valve. Oil returning from the oil cooler or bypass is forced through the
lubrication jets of the main gear box.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL COOLER - MAINTENANCE PRACTICES

1. Servicing Oil Cooler.

A. Servicing.Filling of a new main gear box oil cooler is done by servicing the main gear box. Make certain
main gear box is full by checking sight window on right side. With qualified helicopter pilot at controls, start
engines and engage main rotor head per Flight Manual, SA 4047-76B-1. Allow enough time for main gear
box oil to reach a temperature above 71°C (160°F), and shut down helicopter. Service main gear box as
necessary. (Refer to SERVICING, CHAPTER 12.)

B. Draining.Draining of the main gear box oil cooler is done by removing the oil cooler from the oil cooler
ducting, tilting it in various directions, and then positioning it, after each tilting, so that residual oil will drain
through the inlet and outlet ports. This procedure should remove any oil trapped by the oil tube baffles within
the oil cooler.

2. Removal/Installation Oil Cooler.

A. Prepare for Removal.

(1) Special Tools and Equipment

(a) Caps and plugs (plug lines and ports)

B. Remove Oil Cooler (Figure 201).

(1) Open engine air inlet/bypass cowl and upper access panel.

(2) Disconnect oil in and oil out hoses from elbow and union on oil cooler. Drain oil into suitable container.
Install protective caps and plugs on hoses and oil cooler ports.

(3) Remove screws and retainer securing top of oil cooler.

CAUTION: WHEN REMOVING OIL COOLER FROM OIL COOLER DUCT, USE CARE NOT TO DAM-
AGE COOLER FINS.

(4) Tilt top of cooler aft and remove cooler from duct.

(5) If necessary, remove elbow, nut, and packing and union or reducer and packing from oil in and oil out
ports of oil cooler. Install protective plugs in ports.

C. Install Oil Cooler (Figure 201).

(1) If necessary, remove protective plug from oil cooler oil in port. Install elbow, nut, and packing in oil
cooler oil in port.

(2) If necessary, remove protective plug from oil cooler oil out port. On helicopters prior to 0449 not
modified by CSN 76-203, install union and packing in oil cooler oil out port.

NOTE: When a replacement main gear box is installed on helicopters prior to 0449, the lubrication
system should be modified by CSN 76-203 to remove union and packing from oil cooler oil
out port and install reducer and packing.

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(3) If necessary, remove protective plug from oil cooler oil out port. On helicopters prior to 0449 modified
by CSN 76-203 and helicopters 0449 and subsequent, install reducer and packing in oil cooler oil out
port.

CAUTION: WHEN INSTALLING OIL COOLER IN OIL COOLER DUCT, USE CARE NOT TO DAMAGE
COOLER FINS.

(4) Install oil cooler in duct by tilting bottom of cooler forward into position, then push top forward into
place in duct.

(5) Secure top of cooler with screws and retainer.

(6) Remove protective caps from hoses and connect hoses to elbow and union on oil cooler.

(7) Close and secure upper access panel and engine air inlet/bypass cowl.

(8) With qualified helicopter pilot at controls, start engines and engage main rotor head per S-76B Flight
Manual, SA 4047–76B-1. Allow enough time for main gear box oil to reach a temperature of above
71° C (160°F), and shut down engines.

(9) Open engine air inlet/bypass cowl and upper access panel. Visually inspect main gear box oil cooler,
cooler hoses, attachment fittings, and hose connections for leaks. No oil leaks are allowed.

(10) Close and secure upper access panel and engine air inlet/bypass cowl.

3. Cleaning Oil Cooler.

A. Clear Oil Cooler.

(1) Drain all residual oil from oil cooler.

(2) Steam-clean exterior surface.

CAUTION: USE ONLY THE CLEANING SOLVENT SPECIFIED. MANY SOLVENTS WHICH ARE SAT-
ISFACTORY FOR CLEANING COPPER PARTS ARE HIGHLY CORROSIVE TO ALUMINUM
AND WILL RESULT IN DESTRUCTION OF THE ALUMINUM CORE IF USED.

(3) Reverse flush oil cooler (outlet to inlet) for about 30 minutes using dry-cleaning solvent, Fed. Spec
P-D-680, Type II or equivalent at a pressure of 15 - 20 psi. Filter outgoing flushing fluid and check
trapped contamination. If there are any signs of metal particles, the cooler should be replaced.

(4) Clean and flush lubrication lines using dry-cleaning solvent, Fed. Spec P-D-680, Type II.

(5) Using compressed air, blow lines and fittings clear of foreign material.

4. Approved Repairs Oil Cooler.

A. Thermostat Replacement (Figure 201).

(1) Unscrew and remove thermostat from top of oil cooler.

(2) Remove packing from thermostat.

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(3) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and install on thermostat.

(4) Install thermostat finger tight in port on top of oil cooler until packing is seated. Torque thermostat to
375 inch-pounds and lockwire.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL COOLER

SCREW

PACKING

THERMOSTAT
(TORQUE TO
375 IN. LBS)
THERMOSTAT
(TORQUE TO
375 IN. LBS)

RETAINER

OIL
COOLER

UNION OR REDUCER,
PACKING (SEE NOTE)
D
FW
HOSE

NOTE
ELBOW,
NUT,
REFER TO MAINTENANCE PRACTICES PACKING
FOR EFFECTIVITY.
CB0591A
SA

Oil Cooler - Removal/Installation Oil Cooler - Removal/Installation

Figure 201 (Part 1 of 2) Figure 201 (Part 2)
66-11-06 66-11-06
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
OIL COOLER BLOWER- DESCRIPTION AND OPERATION

1. Description and Operation.

The No. 1 and No. 2 engine oil cooler blowers, mounted on the main gear box, also provide cooling air for the
main gear box oil cooler. For a complete description and maintenance practices of the oil cooler blowers, refer to
Oil Cooler Blower, 79-10-03.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
INTERMEDIATE GEAR BOX- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 401).

The intermediate gear box at the base of the vertical stabilizer transmits torque, changes the drive angle of the tail
drive shaft about 57°, and reduces the rpm from 3491 to 3370. The intermediate gear box weighs about 22.2
pounds when full of oil. Oil capacity is about 2.0 pounds or 0.260 gallon. The input and output housings have
direct drive bevel gears which change the angle of drive upward along the vertical stabilizer. The center housing
consists of an oil level sight window which reads MAINTAIN OIL LEVEL WITHIN BULL’S-EYE, on the right side, a
filler plug on the top right side, and a magnetic drain plug/chip detector/temperature sensor on the bottom. For
further information on the intermediate gear box chip detector, refer to Gear Box Chip Detector/Overtemp
System, 66-64-00. The intermediate gear box is splash-lubricated and air-cooled.

66-20-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

INTERMEDIATE GEAR BOX - SERVICING

1. Servicing.

Servicing the intermediate gear box consists of filling with lubricant. The gear box is filled with oil through the filler
cap on top right side of the center housing. Oil level is determined by MAINTAIN OIL LEVEL WITHIN BULL’S-EYE
marking on oil level sight window.

2. Draining Intermediate Gear Box.

A. Prepare for Draining.

(1) General. Draining is removal of lubricating oil from gear box, and should be done with gear box oil
warm, to aid oil flow.

(2) Special Tools and Equipment.

(a) Drain Attachment, H538A-3, Technical Development Corp.

(b) Container, Suitable

B. Drain Intermediate Gear Box.

(1) Remove chip detector and drain gear box into suitable container using drain attachment, H538A-3,
Technical Development Corp. (Refer to SERVICING, CHAPTER 12.)

(2) Inspect, clean, and install chip detector. Torque chip detector to 95 inch-pounds and lockwire chip
detector.

3. Flushing Intermediate Gear Box.

A. Prepare for Flushing.

(1) General. Gear boxes should be flushed when changing from any one of the approved oils to another,
when gear box is contaminated with metal chips, or when preservation for storage or shipment is
required.

B. Flush Intermediate Gear Box.

(1) Drain gear box.

(2) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(3) With qualified helicopter pilot at controls, start engines and engage main rotor head in accordance with
Flight Manual, SA 4047-76B-1. Run up gear box until main gear box oil temperature stabilizes in
normal operating range.

NOTE: If gear box has been removed from helicopter and cannot be run up, slosh warm oil in gear
box.

(4) Drain gear box.

(5) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

66-20-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

INTERMEDIATE GEAR BOX - REMOVAL/INSTALLATION

1. Removal/Installation Intermediate Gear Box.

A. Remove Intermediate Gear Box (Figure 401).

(1) Unscrew and remove tail rotor drive shaft aft cover and tail cone end fairing.

(2) Unscrew and remove tail rotor trailing edge fairing and disconnect control cables from tail gear box
quadrant. (Refer to Tail Rotor Control System, 67-20-00.)

(3) Remove pulley guard pins from pulley bracket and move cable clear of intermediate gear box.

(4) Unbolt and disconnect Section IV of tail rotor drive shaft at input side of intermediate gear box. (Refer
to Removal/Installation, 66-40-00.)

(5) Unbolt and disconnect Section V of tail rotor drive shaft at output side of intermediate gear box. (Refer
to Removal/Installation, 66-40-00.)

(6) Turn off all electrical power and disconnect electrical connector from chip detector on bottom of inter-
mediate gear box.

WARNING: TO PREVENT INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT, MAKE

SURE INTERMEDIATE GEAR BOX IS SUPPORTED USING THE AID OF AN ASSISTANT
OR A SUITABLE SUPPORT.

NOTE: Total weight of the Intermediate Gear Box is approximately 20 lbs.

(7) With an assistant or suitable support supporting the intermediate gear box assembly, remove washers
and nuts securing gear box to bulkhead and remove gear box.

B. Install Intermediate Gear Box (Figure 401).

(1) If new intermediate gear box is being installed, transfer pulley and bracket from removed gear box as
follows:

(a) Remove nuts and washers securing pulley bracket to intermediate gear box and remove bracket
with pulley attached. Remove serrated pads from gear box studs.

(b) Insulate bracket mounting area on new intermediate gear box with primer, MIL-PRF-23377.

(c) Install a serrated pad on each intermediate gear box stud. On helicopters with pulley bracket,
76209-04010-041, serrated pads are installed on the top two studs only. Position pulley bracket
with pulley attached on gear box studs and secure with washers and nuts. Torque nuts to 100
inch-pounds.

(2) Visually inspect mounting bolts and nuts for damage, wear, and corrosion. Replace if necessary.

(3) Test all used mounting nuts before installation. Install nut until two threads of stud are exposed beyond
nut. If breaking torque required to remove nut is 3.5 inch-pounds or more, nut is satisfactory for use.

(4) Insulate mounting area on bulkhead with primer, MIL-PRF-23377.

66-20-00
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 S-76B
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WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK INTERMEDIATE GEAR BOX ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING PARTS,

SAFETY INSTALLATION, AND INDICATED TORQUE ARE CRITICAL CHARACTERISTICS.
APPLY TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY
PARTS PROGRAM, CHAPTER 20.)

(5) Position gear box on bulkhead and secure with washers and nuts. Torque nuts to 100 inch-pounds.

(6) Apply fillet of sealing compound, AMS 3265, around adjoining areas of intermediate gear box and
bulkhead.

(7) When conditional maintenance checks indicate stabilized torque of intermediate gear box attachment
nuts, apply torque stripes. (Refer to Torque Striping Hardware, 20-04-00.)

(8) Connect electrical connector to chip detector and lockwire.

(9) Connect Section IV of tail rotor drive shaft to input side of intermediate gear box. (Refer to Removal/
Installation, 66-40-00.)

(10) Connect Section V of tail rotor drive shaft to output side of intermediate gear box. (Refer to Removal/
Installation, 66-40-00.)

(11) Check Section V tail drive shaft alignment. (Refer to Inspection/Check, paragraph 4.)

(12) Position tail rotor control cables on pulleys on aft side of intermediate gear box and install pulley guard
pins.

(13) Connect control cables to tail gear box quadrant. (Refer to Tail Rotor Control System, 67-20-00.)

(14) Adjust tail rotor cable tension. (Refer to Adjustment/Test, 67-20-00.)

(15) Service intermediate gear box. (Refer to SERVICING, CHAPTER 12.)

(16) Install and secure tail rotor drive shaft aft cover, tail cone end fairing, and tail rotor trailing edge
fairing.

(17) Do an operational check on new or overhauled gear boxes. (Refer to Adjustment/Test.)

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 S-76B
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C
CONTROL
CABLES
A

B
ELECTRICAL
INTERMEDIATE CONNECTOR
GEAR BOX

A PULLEY
GUARD PIN
SERRATED
ADJUSTMENT NUT, WASHER INTERMEDIATE
PLATE (TORQUE GEAR BOX
100 IN. LBS)
SERRATED
PAD

B
D

PULLEY
PULLEY
BRACKET PULLEY
GUARD PIN

INTERMEDIATE D
GEAR BOX

NUT, WASHER BULKHEAD

(TORQUE
100 IN. LBS)

CC3548
SA

Intermediate Gear Box - Removal/Installation

Figure 401
66-20-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
INTERMEDIATE GEAR BOX - ADJUSTMENT/TEST

1. General.

Intermediate gear boxes do not require a run-in test. However, when a new or overhauled intermediate gear box
is installed on a helicopter, an operational-check must be made before the helicopter is released for flight. (Refer
to Operational Check for New or Overhauled Intermediate Gear Boxes.)

2. Operational Check for New or Overhauled Intermediate Gear Boxes.

A. New, spare, or overhauled gear boxes require an operational check, in addition to pilot preflight check, to
make sure of proper installation and lubrication. With a qualified helicopter pilot at controls, do an opera-
tional check as follows:

WARNING: THIS CHECK IS MANDATORY AND MUST BE CONDUCTED FOR SAFETY OF FLIGHT.

(1) Operate helicopter on ground for 1/2 hour.

(2) Drain oil from intermediate gear box and strain through lint-free cloth.

(3) Remove and inspect chip detector for metal particles.

(4) Inspect gear box for external abnormalities.

(5) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(6) If conditions appear normal, release helicopter for flight.

66-20-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

INTERMEDIATE GEAR BOX - INSPECTION/CHECK

1. Allowable Oil Leakage.

A. General.Leakage of intermediate gear box caused by a damaged seal, gasket, packing, or shim is measured
at the oil level sight window on the right side of the gear box. Total leakage from all sources, during a period
of 10 flight hours, must not be over 1/2 the distance from the top to the bottom of the sight window
bull’s-eye.

2. Overspeed Inspection Requirements.

A. General.Main rotor head overspeed of over 366 rpm (121% triple tachometer indicator reading) requires a
serviceability check of intermediate gear box. Inspect intermediate gear box magnetic chip detector for metal
particles. (Refer to Inspection/Check, 66-10-00.)

3. Sudden Stoppage Inspection Requirements.

A. General.For a definition of sudden stoppage applicable to intermediate gear box, and for inspection require-
ments that must be followed after sudden stoppage, refer to Inspection/Check, 66-10-00.

4. Gear Box Serviceability Check.

(Refer to Inspection/Check, 66-10-00.)

5. Gear Box Corrosion Protection.

(For inspection procedures, refer to Gear Box Corrosion Protection, Inspection/Check, 66-10-00.)

A. General.Periodically apply corrosion-preventive compound, ACF-50 or equivalent, to bolted surfaces and

mounting surfaces of gear box.

(1) Every 12 months spray nut, cotter pin, and mating inside surfaces of input and output flanges with
corrosion preventative compound, ACF-50 (MIL-C-81309).

6. Intermediate Gear Box Corrosion Inspection.

A. Inspection Procedure.Do this inspection when required by the Scheduled Maintenance Checks, 5-20-00.
Inspect intermediate gear box assembly for corrosion as follows:

(1) Turn off all electrical and hydraulic power.

(2) The intermediate gear box center, input and output magnesium housing assemblies are to be evaluated
for corrosion evidence.

(a) Special attention is to be given to the condition of the sealant such as debonding and deterioration,
at all bolted connections, threaded bosses, lockwire attachment points, dissimilar metal interfaces,
and water entrapment areas.

(b) Remove deteriorated or disbonded sealant, as required, taking care not to damage parent mate-
rial.

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NOTE: Protective finishes and sealant are not to be removed unless deterioration is noted or
corrosion is evident in the area and removal is required to further evaluate or to institute
a repair procedure.

(c) Local blending to remove corrosion pits from magnesium housings shall be limited to 0.030 inch
maximum depth. If corrosion damage is beyond the 0.030 inch depth allowable notify Sikorsky
Commercial Support Services of this condition. Location and approximate depth of corrosion are to
be submitted. If acceptable, scrub residual pitting with chromic acid pickle solution as follows:

1 Prepare chromic acid pickle solution of 24 ounces of chromium-trioxide, Fed. Spec O-C-303
per gallon of water. Scrape corroded area with a plastic scraper and scrub vigorously with a
nylon brush saturated with solution. Scrub for 1 to 3 minutes, or until corrosion products have
been completely dissolved.

2 Etch reworked area to remove flowed metal using Acetic-Glycol etch. Penetrant inspect per
MIL-I-6866, Type I Method A or B.

(d) Before reapplication of sealing compound, MIL-S-8802, A-2, area, is to be cleaned with trichlo-
roethane solvent, Fed. Spec O-T-620.

(e) Blended areas are to be touched-up using (Dow 19) MIL-M-3171, Type VI, and two applications of
Amlguard, MIL-C-85054, applied waiting 1/2 hour between applications.

(3) All service related damage such as scratches, dents and fretting which have broken and/or removed
protective finish, must be repaired as follows:

(a) Remove grease and oil residue from corroded area by cleaning with dry-cleaning solvent, Fed.
Spec P-D-680, Type II. Dry thoroughly.

(b) If affected area has been painted, remove paint finish from surface using paint remover, MIL-R-
81294.

NOTE: Remove corrosion per step (c) or (d).

(c) Remove corrosion from magnesium surfaces using 320-400 grit aluminum oxide abrasive cloth,
Fed. Spec P-C-451, Scotch-Brite abrasive mat, MIL-S-9962, Class I, or abrasive non-woven nylon
wheel, MIL-W-81319.

(d) Prepare chromic acid pickle solution of 24 ounces of chromium-trioxide, Fed. Spec O-C-303 per
gallon of water. Scrape corroded area with a plastic scraper and scrub vigorously with a nylon
brush saturated with solution. Scrub for 1 to 3 minutes, or until corrosion products have been
completely dissolved.

(e) Remove small areas of mild corrosion with 320-400 grit aluminum oxide abrasive cloth, Fed. Spec
P-C-451, or Scotch-Brite abrasive mat, MIL-S-9962, Class 2, Type I.

(f) Remove heavy deposits of corrosion by using abrasive non-woven wheel. Use chromic acid pickle
solution for areas not accessible to mechanical removal.

(g) Feather undamaged paint around repair area using 320-400 grit aluminum abrasive cloth, Fed.
Spec P-C-451.

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(h) Rinse entire repair area with cold water. If chromic acid pickle solution was used, a slight golden
discoloration of the surface will be noted.

(i) Penetrant inspect per MIL-I-6866, Type I, Method A or B.

(j) Inspect surface for cleanliness and water-breakfree condition.

(k) Apply chemical conversion coating, MIL-M-3171 (Dow 19), with clean cheesecloth, Fed. Spec
CCC-C-440, to repair area. After 3 to 5 minutes flush with clean running water and allow to
air-dry. Do not wipe treated surface.

(l) Prime with epoxy polyamide primer, MIL-P-23377, Type I or II.

(m) Touch-up paint repaired surfaces by applying two coats of aliphatic polyurethane, MIL-C-83286.

(n) Air dry for 24 hours at room temperature or for two hours at 180 degrees F (82 degrees C).

(4) Evaluate the titanium input and output flanges for nicks, dents or scratches on all accessible surfaces,
paying particular attention to the outboard edges of the tri-lobes. Any damage identified is cause for
removal from helicopter for a more detailed inspection. Contact Sikorsky Commercial Support Services
for appropriate repair/scrap evaluation criteria.

(5) Corrective actions must be taken if oil leakage caused by damaged seal, gasket or packing is not within
specified leakage limits. (Refer to paragraph 1.)

(6) Using a small inspection mirror, inspect the external threaded portion of the input and output gears for
signs of corrosion pitting. The exposed portion of the associated internal bore of the gears should
likewise be inspected for corrosion pitting damage.

(7) Minor pitting, as indicated by local pin hole ferrous bleed thru stains, are acceptable without blend
removal operations.

(8) These minor pitting areas are to be locally cleaned with trichloroethane solvent, Fed. Spec O-T-620,
and water displacement corrosion preventive, ACF-50 spray, MIL-C-81309, or equivalent applied. Two
coats required, allowing 1/2 hour between applications.

(9) If major pitting is identified, gear box is to be removed for possible salvage procedures. Contact
Sikorsky Commercial Support Services for blend limits and protective finish application procedures.

(10) Upon successful completion/compliance of the above inspection, the helicopter logbook is to be anno-
tated.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
INTERMEDIATE GEAR BOX - CLEANING/PAINTING

1. Cleaning/Painting Intermediate Gear Box.

A. Clean Intermediate Gear Box.

CAUTION: TO PREVENT DAMAGE TO COMPONENTS, DO NOT ALLOW SOLVENT OR KEROSENE TO

SPLASH ON RUBBER COMPONENTS OR BEARINGS. COVER VENTED OIL FILLER, TO KEEP
SOLVENT OR KEROSENE OUT OF GEAR BOX.

(1) Wash external surfaces of intermediate gear box and associated components, using dry-cleaning sol-
vent, Fed. Spec P-D-680, Type II, or kerosene, Fed. Spec VV-K-211.

66-20-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

INTERMEDIATE GEAR BOX - APPROVED REPAIRS

1. Input Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Seal Installer, 76700-20117-101

(b) Torque Reactor, 76700-20103-041

(c) Wrench, 76700-20100-041 (used on 76351-09014-103 nut)

(d) Wrench, 76700-20100-042 (used on 76351-09014-106 nut)

(e) Sleeve Installer (included in sleeve replacement kit)

B. Replace Input Seal (Figure 801).

(1) Remove intermediate gear box from helicopter. (Refer to Removal/Installation.)

(2) Remove cotter pin securing nut to input gearshaft and remove nut using applicable wrench and torque
reactor, 76700-20103-041.

(3) Remove input flange from input gearshaft.

(4) Remove input seal using suitable puller.

(5) Replace sleeve. (Refer to Approved Repairs - Sleeve Replacement, 66-10-00.)

(6) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to new seal
and sleeve and coat OD with primer, MIL-PRF-23377.

(7) With primer wet, install input seal using seal installer, 76700-20117-101.

(8) Coat splines of flange with grease, MIL-L-81827, and install on input gearshaft.

(9) Install nut on input gearshaft using applicable wrench and torque reactor, 76700-20103-041. Torque
nut to 100 - 125 foot-pounds.

(10) Install new cotter pin to secure nut in position.

(11) Spray nut, cotter pin and mating inside surfaces of input flange with corrosion preventative compound,
ACF-50 (MIL-C-81309).

NOTE: Corrosion preventative compound, ACF-50 (MIL-C-81309) must be reapplied per step (11)
every 12 months.

(12) Install intermediate gear box on helicopter. (Refer to Removal/Installation.)

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D
FW

SEAL
A

GEAR
SHAFT
SLEEVE
A
B INPUT
FLANGE
INTERMEDIATE
NUT GEAR BOX
(TORQUE 100−125 FT. LBS)
COTTER
PIN

C B
SLEEVE
INPUT
FLANGE
0.190 TO
0.220 INCH

GEAR
SHAFT

COTTER
PIN
NUT

SLEEVE
SEAL

INPUT
FLANGE C

SLEEVE LOCATION

S76A_47425 (C27)
SA

Input Seal - Replacement

Figure 801
66-20-00
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 S-76B
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2. Output Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Seal Installer, 76700-20117-101

(b) Torque Reactor, 76700-20103-041

(c) Wrench, 76700-20100-041 (used on 76351-09014-103 nut)

(d) Wrench, 76700-20100-042 (used on 76351-09014-106 nut)

(e) Sleeve Installer (included in sleeve replacement kit)

B. Replace Output Seal (Figure 802).

(1) Remove intermediate gear box from helicopter. (Refer to Removal/Installation.)

(2) Remove cotter pin securing nut to output gearshaft and remove nut using applicable wrench and torque
reactor, 76700-20103-041.

(3) Remove output flange from output gearshaft.

(4) Remove output seal using suitable puller.

(5) Replace sleeve. (Refer to Approved Repairs - Sleeve Replacement, 66-10-00.)

(6) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to new seal
and sleeve and coat OD with primer, MIl-PRF-23377.

(7) With primer wet, install output seal using seal installer, 76700-20117-101.

(8) Coat splines of flange with grease, MIL-L-81827, and install on output gearshaft.

(9) Install nut on output gearshaft using applicable wrench and torque reactor, 76700-20103-041. Torque
nut to 100 - 125 foot-pounds.

(10) Install new cotter pin to secure nut in position.

(11) Apply fillet of sealing compound, AMS 3265 B-2, between edge of nut and bottom of output flange
cavity. Allow sealing compound to cure.

(12) Spray nut, cotter pin, and mating inside surfaces of output flange with corrosion preventive compound,
ACF-50 (MIL-C-81309).

NOTE: Corrosion preventative compound, ACF-50 (MIL-C-81309) must be reapplied per step (12)
every 12 months.

(13) Install intermediate gear box on helicopter. (Refer to Removal/Installation.)

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 S-76B
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NUT
(TORQUE
100−125 FT LBS)

OUTPUT
FLANGE
SEAL COTTER
PIN
GEAR
SHAFT

SLEEVE
INTERMEDIATE
GEAR BOX

A
D
FW

C B
COTTER
PIN

OUTPUT GEAR
SLEEVE LOCATION FLANGE SHAFT

SLEEVE
NUT

0.190 TO
0.220 INCH SEAL

SLEEVE

OUTPUT
FLANGE

S76A_47426 (C27)
SA

Output Seal - Replacement

Figure 802
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3. Oil Level Sight Window Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Drain Attachment, H538A-3, Technical Development Corp.

B. Replace Oil Level Sight Window (Figure 803).

(1) Unscrew and remove tail cone end fairing.

(2) Drain intermediate gear box enough to bring oil level below oil level sight window port using drain
attachment, H538A-3. (Refer to Servicing.)

(3) Remove oil level sight window.

(4) If necessary, clean oil level sight window using dry-cleaning solvent, Fed. Spec P-D-680, Type II, or
equivalent.

(5) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and install on oil level sight window.

CAUTION: TO PREVENT DAMAGE TO THREADS IN GEAR BOX HOUSING, USE CARE NOT TO
CROSS THREADS WHEN INSTALLING OIL LEVEL SIGHT WINDOW.

(6) Install oil level sight window in port on right side of intermediate gear box. Torque oil level sight window
to 137-151 inch-pounds and lockwire oil level sight window.

(7) Service intermediate gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(8) Install tail cone end fairing and secure with screws.

4. Oil Filler Replacement.

A. Replace Oil Filler (Figure 804).

(1) Unscrew and remove tail cone end fairing.

(2) Remove filler assembly, using care not to damage chain connecting cap to fitting.

(3) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and install on oil filler.

CAUTION: TO PREVENT DAMAGE TO THREADS IN GEAR BOX HOUSING, USE CARE NOT TO
CROSS THREADS WHEN INSTALLING OIL FILLER.

(4) Install oil filler in filler port on top right side of intermediate gear box. Torque oil filler to 90-100
inch-pounds and lockwire fitting to gear box.

(5) Install tail cone end fairing and secure with screws.

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 S-76B
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FW
D

INTERMEDIATE
GEAR BOX
A PACKING

OIL LEVEL SIGHT

WINDOW (TORQUE
137−151 IN. LBS)
CS0321
SA

Oil Level Sight Window - Replacement

Figure 803

66-20-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL FILLER (TORQUE

90−100 IN. LBS)

A PACKING

INTERMEDIATE
GEAR BOX

CC0909A
SA

Oil Filler - Replacement

Figure 804

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL GEAR BOX- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 401).

The tail gear box, mounted at the upper end of the vertical stabilizer, transmits torque and changes the angle of
drive from the intermediate gear box to the tail rotor. The tail gear box reduces rpm from 3370 to 1723, and
provides a housing for the tail rotor servo and pitch control mechanism for the tail rotor. The tail gear box weighs
about 49.6 pounds when full of oil. Oil capacity is about 1.8 pounds or 0.240 gallon. The output housing
contains an oil filler and an oil level sight window which reads MAINTAIN OIL LEVEL WITHIN BULL’S-EYE. The
input housing has a magnetic chip detector/drain plug/temperature sensor. For further information on the tail
gear box chip detector, refer to Gear Box Chip Detector/Overtemp System, 66-64-00. The tail gear box is
splash-lubricated and air-cooled.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TAIL GEAR BOX - SERVICING

1. Servicing.

Servicing the tail gear box consists of filling with lubricant. The gear box is filled with oil through the filler cap on
top of the output housing. Oil level is determined by MAINTAIN OIL LEVEL WITHIN BULL’S-EYE marking on oil
level sight window.

2. Draining Tail Gear Box.

A. Prepare for Draining.

(1) General. Draining is removal of lubricating oil from gear box, and should be done with gear box oil
warm, to aid oil flow.

(2) Special Tools and Equipment.

(a) Drain Attachment, H538A-3, Technical Development Corp.

(b) Container, Suitable

B. Drain Tail Gear Box.

(1) Remove chip detector and drain gear box into suitable container using drain attachment, H538A-3,
Technical Development Corp. (Refer to SERVICING, CHAPTER 12.)

(2) Inspect, clean, and install chip detector. Torque chip detector to 95 inch-pounds and lockwire chip
detector.

3. Flushing Tail Gear Box.

A. Prepare for Flushing.

(1) General. Gear boxes should be flushed when changing from any one of the approved oils to another,
when gear box is contaminated with metal chips, or when preservation for storage or shipment is
required.

B. Flush Tail Gear Box.

(1) Drain gear box.

(2) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(3) With qualified helicopter pilot at controls, start engines and engage main rotor head per Flight Manual,
SA 4047-76B-1. Run up gear box until main gear box oil temperature stabilizes in normal operating
range.

NOTE: If gear box has been removed from helicopter and cannot be run up, slosh warm oil in gear
box.

(4) Drain gear box.

(5) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

66-30-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL GEAR BOX - REMOVAL/INSTALLATION

1. Removal/Installation Tail Gear Box.

A. Prepare for Removal.

(1) Special Tools and Equipment.

(a) Caps and Plugs (for hydraulic ports, lines, and hoses).

(b) Drain Attachment, H538A-3, Technical Development Corp.

(c) Hoist, (capable of lifting 100 pounds).

(d) Lifting Eye, 76700-20124-101.

B. Remove Tail Gear Box (Figure 401).

(1) Unscrew and remove tail gear box fairing.

(2) Unbolt and disconnect Section V of tail rotor drive shaft from input of tail gear box. (Refer to Removal/
Installation, 66-40-00.)

(3) Remove tail rotor from tail gear box. (Refer to Removal/Installation, 65-21-00.)

(4) Turn off all electrical power and disconnect electrical connector from chip detector on bottom of gear
box.

(5) Drain tail gear box using drain attachment, H538A-3. (Refer to Servicing.)

(6) Remove bolt, washer, nut, and cotter pin and disconnect tail rotor servo pushrod from tail rotor servo
input lever.

(7) Remove bolt, washer, nut, and cotter pin and disconnect crank from bracket.

(8) Disconnect electrical connectors from both pressure switches on tail rotor servo actuator.

(9) Turn off all hydraulic power and disconnect pressure and return lines at first and second stage fittings on
tail rotor servo actuator. Cap lines and fittings on servo.

(10) Remove bolts, washers, and nuts securing bracket to tail rotor control assembly. Remove clip.

(11) Remove washers and nuts securing tail rotor servo actuator and bracket to tail gear box.

(12) Remove tail rotor servo actuator, bracket, and pitch change shaft from tail gear box as a unit.

(13) Remove bolt, washers, and nut and remove pitch change shaft from tail rotor servo actuator at link.

(14) Remove bracket from tail rotor servo actuator.

(15) Disconnect tail rotor control cables from quadrant on tail rotor control assembly. (Refer to Tail Rotor
Control System, 67-20-00.)

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 S-76B
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(16) Remove bolts, washers, and nuts securing clip to support and tail rotor control assembly.

(17) Remove bolts, washers, and nuts securing support to tail gear box output housing and tail rotor control
assembly. Remove shim.

(18) Remove washers and nuts and remove tail rotor control assembly from tail gear box.

(19) Attach lifting eye, 76700-20124-101, to tail gear box, and using suitable hoist, compensate for
weight of tail gear box so it does not fall when attaching bolts are removed.

(20) Remove forward and aft bolts, washers, barrel-nuts, and retainers securing tail gear box to vertical
stabilizer, and remove tail gear box from helicopter using suitable hoist.

C. Prepare for Installation.

(1) Special Tools and Equipment.

(a) Hoist (capable of lifting 100 pounds)

(b) Lifting Eye, 76700-20124-101

D. Install Tail Gear Box (Figure 401).

(1) Inspect pressure pads on tail gear box output flange and tail rotor outboard retaining plate for ply
separation, cracks, and minimum thickness. Replace any pad under minimum thickness at any location
or if ply separation or cracks are found.

Pressure Pad Minimum Thickness

76102-05004-109 0.128 inch
76102-05004-110 0.118 inch

CAUTION: TO PREVENT POSSIBLE FAILURE OF BARREL- NUT, ONLY RMLH2577 BARREL-NUTS, MANUFAC-
TURED BY ESNA OR SPS, SHALL BE USED. RMLH2577 BARREL-NUTS ARE IDENTIFIED WITH THE
LETTERS 9EN9 OR 9SPS9 STAMPED ON AN END. (ADDITIONAL MARKING MAY ALSO INCLUDE
LH2577.)

(1A) Visually inspect mounting bolts and barrel-nuts for damage, wear, and corrosion. Replace if neces-
sary.

(2) Test all used mounting bolts and barrel-nuts before installation. Using a vise to hold nut, install bolt until
two threads are exposed beyond nut. If breaking torque required to remove bolt is 9.5 inch-pounds or
more, bolt and nut are satisfactory for use.

(3) Coat mounting area of vertical stabilizer with primer, MIL-PRF-23377, and lift tail gear box into position
using lifting eye, 76700-20124-101, and suitable hoist.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL GEAR BOX MOUNTING BOLTS FOR SPECIFIED TORQUE.

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 S-76B
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WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING

PARTS, SAFETY INSTALLATION, AND INDICATED TORQUE ARE CRITICAL CHARAC-
TERISTICS. APPLY TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT
SAFETY PARTS PROGRAM, CHAPTER 20.)

(4) With primer wet, install forward bolts and washers, aft bolts, barrel-nuts, and retainers to secure tail
gear box to vertical stabilizer. Torque bolts to 405 inch-pounds.

(5) Only after the torque has stabilized per the 5-15 hour retorque requirement of the conditional mainte-
nance checks, 5-50-00, coat perimeter of forward boltheads and joining areas of tail gear box and
vertical stabilizer with sealing compound, AMS 3265, Class A. Fill top left barrel-nut cavity flush with
sealing compound, AMS 3265, to prevent water entrapment.

(5A) A temporary method of corrosion protection during the torque stabilization of the tail gear box
attachment bolts is permitted as follows:

(a) Temporary corosion protect by applying two coats of Fluid Film (non-aerosol spray) 8030-01-
381-6357 or MIL-C-85054, Type I. Reinspect every three days for presence of coating. Reapply
two coats at each torque stabilization check until torque has stabilized.

(b) After bolt torque has stabilized, remove Fluid Film or MIL-C-85054 using solvent, O-T-620,
Trichloroethane or equivalent, and do as outlined in step (5).

(6) When conditional maintenance checks indicate stabilized torque of tail gear box attachment bolts,
apply torque stripes. (Refer to Torque Striping Hardware, 20-04-00.)

NOTE: During tail gear box assembly, two additional washers are installed under nuts used for tail
rotor control assembly attachment. When installing tail rotor control assembly, omit two of the
three existing washers.

(7) Coat mounting surface for tail rotor control assembly with primer, MIL-PRF-23377, position tail rotor
control assembly on tail gear box, and secure with washers and nuts. Torque nuts to 100 inch-pounds.

(8) Position support on outboard end of tail gear box output housing and secure with bolts, washers, and
nuts. Torque nuts to 165 inch-pounds.

(9) Install shim and bolts, washers, and nuts securing support to tail rotor control assembly. Torque nuts to
100 inch-pounds.

(10) Position clip between support and tail rotor control assembly and secure with bolts, washers, and nuts.
Torque nuts to 100 inch-pounds.

(11) Coat packing lightly with same type lubricating oil, as used to service gear box per Servicing, 12-10-
00, and install in groove of tail rotor servo.

(12) Coat packing lightly with same type lubricating oil, as used to service gear box per Servicing, 12-10-
00, and install in groove of bracket.

(13) Install bracket on tail rotor servo actuator.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING

PARTS, SAFETY INSTALLATION, AND PROOF TORQUE OF SELF-RETAINING BOLT
ARE CRITICAL CHARACTERISTICS. APPLY TORQUE STRIPE. (REFER TO SELF-
RETAINING BOLT INSTALLATION/INSPECTION AND TORQUE STRIPING HARD-
WARE, FLIGHT SAFETY PARTS PROGRAM, CHAPTER 20.)

(14) Position link of pitch change shaft between clevis on tail rotor servo actuator and secure with bolt,
washers (as required), and nut. Torque nut to 60 - 100 inch-pounds and install cotter pin.

NOTE: When installing pitch change shaft, bracket, and tail rotor servo actuator in tail gear box,
make certain that centerline of flats on outboard end of pitch change shaft lines up with index
marks on edge of tail gear box output flange. There are four correct positions where align-
ment will occur (Detail C).

(15) Apply primer, MIL-PRF-23377, on servo mounting surface of tail gear box. Apply same type lubricat-
ing oil, as used to service gear box per Servicing, 12-10-00, to internal keyways of tail gear box
output shaft and to bearings and positioning keys of pitch change shaft, so that oil covers all contact
surfaces. Install pitch change shaft, bracket, and tail rotor servo actuator as a unit.

(16) Secure tail rotor servo actuator and bracket to tail gear box with washers and nuts. Torque nuts to 100
inch-pounds.

(17) Remove caps and plugs and connect first and second stage pressure and return lines to tail rotor servo
actuator.

(18) Line up holes in bracket with holes in tail rotor control assembly. Install clip at lower hole and secure
with bolts, washers, and nuts. Torque nuts to 100 inch-pounds.

(19) Position crank between fork of bracket and install bolt, washer, and nut. Torque nut to 60 - 100
inch-pounds and install cotter pin.

(20) Line up tail rotor servo pushrod and tail rotor servo input lever and install bolt, washer, and nut. Torque
nut to 30 - 50 inch-pounds and install cotter pin.

(21) Connect electrical connectors to both pressure switches on tail rotor servo actuator.

(22) Connect electrical connector to chip detector on bottom of tail gear box.

(23) Connect tail rotor control cables to quadrant on tail rotor control assembly. (Refer to Tail Rotor Control
System, 67-20-00.)

(24) Connect Section V of tail rotor drive shaft to input of tail gear box. (Refer to Removal/Installation,
66-40-00.)

(25) Check Section V tail drive shaft alignment. (Refer to Inspection/Check, paragraph 4.)

(26) Install tail rotor on tail gear box. (Refer to Removal/Installation, 65-21-00.)

(27) Service tail gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(28) Service and bleed first and second stage hydraulic systems. (Refer to Servicing, 29-00-00.)

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(29) Do a quick rigging check and flight check of the tail rotor controls. (Refer to Quick Rigging Check and
Flight Check of Control Rigging, 67-00-00.)

(30) Install tail gear box fairing and secure with screws.

(31) Do an operational check on new or overhauled gear boxes. (Refer to Adjustment/Test.)

(32) Check tail rotor balance. (Refer to Adjustment/Test, 65-21-00).

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

A
HYDRAULIC
LINES TAIL ROTOR
SERVO ACTUATOR BOLT, WASHER,
NUT, WASHER NUT, COTTER
FLATS (TORQUE 100 PIN (TORQUE
IN. LBS) 30-50 IN. LBS)

LOCATION " " INDEX BOLT, WASHERS,

A MARKS ON FLANGE NUT, COTTER PIN
C (TYPICAL FOUR (TORQUE 60-100
PLACES) IN. LBS)
INPUT
LEVER

BOLT, WASHER, NUT

COTTER PIN PACKING
(TORQUE 60-100 IN. LBS)
PITCH CHANGE OUTPUT
SHAFT FLANGE
BRACKET

PACKING
B PRESSURE
SWITCHES

PITCH CHANGE
FORWARD SHAFT ELECTRICAL
BOLT RETAINER CONNECTORS
(TORQUE
405 IN. LBS) BARREL-
NUT
WASHER BOLT, WASHER,
NUT (TORQUE
FW 100 IN. LBS)
BARREL-
D
NUT AFT BOLT
(TORQUE 405
IN. LBS)
RETAINER

TAIL GEAR BOX

C
NUT, WASHER,
(TORQUE 100
IN. LBS)

FW
D
B
BOLT, WASHER,
NUT (TORQUE TAIL ROTOR
100 IN. LBS) SERVO PUSHROD

SUPPORT CLIP

CRANK
TAIL ROTOR
BOLT, WASHER, BOLT, WASHER, CONTROL
NUT (TORQUE NUT (TORQUE ASSEMBLY
100 IN. LBS) SHIM
100 IN. LBS)
QUADRANT

BOLT, WASHER, NUT CLIP

(TORQUE 165 IN. LBS)
ELECTRICAL
CONNECTOR

CC0181B
Tail Gear Box - Removal/Installation Tail Gear Box - Removal/Installation SA

Figure 401 (Part 1 of 2) Figure 401 (Part 2)

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL GEAR BOX - ADJUSTMENT/TEST

1. General.

Tail gear boxes do not require a run-in test. However, when a new or overhauled tail gear box is installed on a
helicopter, an operational check must be done before the helicopter is released for flight. (Refer to Operational
Check for New or Overhauled Tail Gear Boxes.)

2. Operational Check for New or Overhauled Tail Gear Boxes.

A. New, spare, or overhauled tail gear boxes require an operational check, in addition to pilot preflight check,
to make sure of proper installation and lubrication. With a qualified helicopter pilot at controls, do an
operational check as follows:

WARNING: THIS CHECK IS MANDATORY AND MUST BE CONDUCTED FOR SAFETY OF FLIGHT.

(1) Operate helicopter on ground for 1/2 hour.

(2) Drain oil from tail gear box and strain through lint-free cloth.

(3) Remove and inspect magnetic chip detector for metal particles.

(4) Inspect gear box for external abnormalities.

(5) Service gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(6) If conditions appear normal, release helicopter for flight.

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MAINTENANCE MANUAL, SA 4047-76B-2

TAIL GEAR BOX - INSPECTION/CHECK

1. Allowable Oil Leakage.

A. General. Leakage of tail gear box caused by a damaged seal, gasket, packing, or shim is measured at the
oil level sight window on the forward side of the output housing. Total leakage from all sources, during a
period of 10 flight hours, must not be over 1/2 the distance from the top to the bottom of the sight window
bull’s-eye.

2. Overspeed Inspection Requirements.

A. General. Main rotor head overspeed of over 366 rpm (121% triple tachometer reading) requires a service-
ability check of tail gear box. Inspect tail gear box chip detector for metal particles. (Refer to Inspection/
Check, 66-10-00.)

3. Sudden Stoppage Inspection Requirements.

A. General. For a definition of sudden stoppage applicable to tail gear box and for inspection requirements that
must be done after sudden stoppage, refer to Inspection/Check, 66-10-00.

4. Gear Box Serviceability Check.

(Refer to Inspection/Check, 66-10-00.)

5. Pitch Change Shaft Assembly Rotational Play Inspection.

A. Inspection Procedure. Do this inspection when required by the Scheduled Maintenance Checks, 5-20-00.
Inspect pitch change shaft assembly as follows:

NOTE: Check oil level in tail gear box at each inspection interval. (Refer to SERVICING, CHAPTER 12.)

NOTE: To do this inspection without using external electrical and hydraulic power, disregard steps (1) and
(2). The NOTE following step (4) also applies.

(1) Connect source of external dc power and place EXT POWER switch, on master switch panel, ON.

(2) Connect source of external hydraulic power. Apply 3000 psi to either or both stages of hydraulic
system.

NOTE: Rotational play is caused by wear of tail gear box output shaft internal slots. The worn portion
of slots can be located by feel and sound as follows:

(3) Turn pitch beam by hand counterclockwise and hold with slight pressure while very slowly moving tail
rotor control pedals from left to right. Worn slots will be sensed by feel and clicking sound as positioning
keys of pitch change shaft ride in and out of worn portion of output shaft.

(4) Check rotational play of pitch change shaft through full range of travel. Do this by turning pitch beam
by hand, clockwise and counterclockwise, while very slowly moving tail rotor control pedals from left to
right and back again. Record total rotational motion at worn area per step (5).

NOTE: When doing check without external hydraulic power, about 80 pounds of force applied to
pedals and about 20 pounds of force applied to pitch beam is required to achieve adequate
pitch change shaft travel. This range should be greater than 1.30 inches.

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(5) Position a steel scale at centerline of bolt attaching pitch control rod to pitch beam to take linear
measurement along tangent to arc of rotation. Maximum rotational motion allowed is 0.35 inch. If
measurement is near maximum limit, verify measurement using a dial indicator. (Figure 601.)

(6) If gear box is over 0.35-inch limit replace pitch change shaft per following steps.

(7) Remove pitch change shaft/servo assembly. (Refer to Tail Gear Box, Removal/Installation.)

(8) Inspect positioning keys on pitch change shaft for wear. Measure width of top of each key and blend
smooth any worn areas, being careful not to remove too much material. Break sharp edges 0.010- to
0.020-inch chamfer or radius.

(9) If width of top of any key is worn below 0.200 inch, replace pitch change shaft.

(10) Inspect tail gear box output shaft internal slots for wear.

(a) Check number of slots that are worn. Gear boxes with maximum of four worn slots may be
continued in service. Break sharp edges, 0.015 - 0.030 inch.

(b) Remove gear boxes with more than four worn slots and send to Sikorsky Aircraft for output shaft
replacement.

(c) There must be at least four slots in output shaft that are not worn when mating with pitch change
shaft.

(11) If pitch change shaft and gear box are acceptable, reinstall pitch change shaft/servo assembly. (Refer
to Tail Gear Box, Removal/Installation.)

NOTE: Before installing pitch change shaft, apply same type lubricating oil, as used to service gear
box per Servicing 12-10-00, to internal slots of tail gear box output shaft and to bearings
and positioning keys of pitch change shaft, so that oil covers all contact surfaces.

(12) Recheck rotational motion per steps (1) through (6).

6. Pitch Change Shaft Assembly Axial Play Inspection.

A. Inspection Procedure. Do this inspection when required by the Scheduled Maintenance Checks, 5-20-00.
Inspect pitch change shaft assembly as follows:

(1) Turn off all electrical and hydraulic power.

(2) Rotate pitch beam by hand clockwise and counter-clockwise. With a small force, pitch beam should be
able to rotate back and forth a small amount with respect to blade retention plates. If pitch beam cannot
easily rotate, check clearance with 76101-05022 pilot bushing and replace if necessary. A binding
pilot bushing can prevent an accurate measurement of axial play.

(3) Remove tail gear box fairing.

(4) Mount dial test indicator on outboard retaining plate. Adjust to check for axial play on shaft centerline.

(5) Apply an axial force in and out on pitch beam sufficient to move pitch control shaft in both directions but
not enough to cause servo power piston motion and measure play.

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MEASURMENT TAKEN AT CENTERLINE

OF BOLT ATTACHING PITCH CONTROL
ROD TO PITCH BEAM.

S76C_67495 (C19)
SA

Pitch Change Shaft Rotational Play Inspection

Figure 601
(6) Record axial play. If movement is 0.010 inch or less, axial play is acceptable, do this:

(a) Check oil level in tail gear box. (Refer to Servicing, Chapter 12.)

(b) Install tail gear box fairing.

(7) If movement is greater than 0.010 inch, axial play is not acceptable, do this:

(a) Replace pitch control shaft assembly. (Refer to Tail Gear Box, Removal/Installation.)

(b) Connect external hydraulic power to first and second stage systems (Service and bleed hydraulic
systems). (Refer to Servicing, 29-00-00.)

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(c) Cycle controls and check for leaks, binds, and proper operation.

(d) Do a quick rigging check of tail rotor flight controls. (Refer to Quick Rigging Check, 67-00-00.)

(e) Disconnect external hydraulic power. Service hydraulic modules as required.

(f) Install tail gear box fairing.

(g) With pilot at controls, do a flight check of tail rotor controls per Flight Check Procedures Manual,
SA 4047-76B-6.)

7. Output Shaft At Flange Axial Play Inspection.

A. Inspection Procedure. Do this inspection when required by the Scheduled Maintenance Checks, 5-20-00.
Inspect output shaft at flange as follows:

(1) Turn off all electrical and hydraulic power.

(2) Disconnect tail rotor pitch control rods.

(3) Attach standard dial indicator to one of the tail gear box fairing attachment lugs on tail gear box output
housing.

(4) Take indicator reading off machined face on inboard face of output flange.

(5) Apply axial hand force to output flange and record dial indicator reading.

(a) Axial motion reading within range of 0.000 - 0.002 inch, no further action necessary. Repeat
inspection at next regular interval.

(b) Axial motion reading above 0.002 but not exceeding 0.004 inch, perform tail rotor balance check
per Adjustment/Test, 65-21-00. Conduct axial motion inspection every 100 flight hours.

NOTE: Annotate logbook/logcard to repeat this inspection every 100 flight hours.

(c) Axial motion reading above 0.004 but not exceeding 0.006 inch, perform tail rotor balance check
per Adjustment/Test, 65-21-00. Conduct axial motion inspection every 50 flight hours.

NOTE: Annotate logbook/logcard to repeat this inspection every 50 flight hours.

(d) Axial motion reading above 0.006 inch, replace tail gear box before next flight. (Refer to
Removal/Installation Tail Gear Box, 66-30-00.)

(6) Remove dial indicator.

(7) Connect tail rotor pitch control rods.

8. Output Flange Torque Check.

A. Torque Check. Do this check when required by the Conditional Maintenance Checks, 5-50-00.

(1) Remove lockwire from nine bolts.

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(2) Using dial type torque wrench, check bolts in a tightening direction for proper torque. Check all nine
bolts for a minimum of 75 inch-pounds. Record exact torque at which each bolt starts to turn, but do not
apply more than 100 inch-pounds torque. If torque reading is less than 75 inch-pounds on more than
two bolts, do step (4).

(3) If torque reading is at least 75 inch-pounds on seven of nine bolts, tighten one or two loose bolts to
90–100 inch-pounds and lockwire bolts. It is also permissible to optimize torque on all bolts that meet
the 75 inch-pound minimum:

NOTE: Optimizing torque is recommended and will not require any further torque checks since torque
was found stabilized at 75 inch-pounds on at least seven of nine bolts as noted in step (2).

(a) Torque one or two bolts that were below 75 inch-pounds to 90–100 inch-pounds.

(b) Apply torque of 90–100 inch-pounds to remaining bolts that met the 75 inch-pound minimum
using the sequence in step (4a).

(c) Lockwire bolts.

(4) If more than two bolts had less than 75 inch-pounds torque, loosen jamnuts and break torque on all
bolts, taking care not to disturb position of flange and nut. Tighten bolts as follows:

(a) Torque bolts to 30 inch-pounds in this sequence: 1, 5, 9, 2, 6, 10, 3, 7, 11, 4, 8, 12 according to

numbers on lockplate (Figure 802, Detail C, 66-30-00).

(b) Repeat torque to 60 inch-pounds in same sequence; then repeat again in same sequence to 90 -
100 inch-pounds.

(c) Torque jamnuts to 30 - 50 inch-pounds. Lockwire bolts.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC.

CAUTION: AT TIME INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS,

5-50-00, CHECK OUTPUT FLANGE RETENTION BOLTS FOR SPECIFIED TORQUE.
TORQUE MAY VARY TO AN ALLOWED MINIMUM OF 75 INCH-POUNDS.

(5) Recheck for loss of torque at specified interval until torque stabilizes. Lockwire jamnuts to adjacent bolts.
If torque has not stabilized by third torque check, cause of torque loss must be determined before further
flight. Torque readings should be permanently recorded in aircraft log.

9. Gear Box Corrosion Protection.

(For inspection procedures, refer to Gear Box Corrosion Protection, Inspection/Check, 66-10-00.)

A. General. Periodically apply corrosion-preventive compound, ACF-50, or equivalent, to bolted surfaces and
mounting surfaces of gear box.

(1) Every 12 months spray nut, cotter pin, and mating inside surface of input flange with corrosion preven-
tive compound, ACF-50 (MIL-C-81309).

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10. Tail Gear Box Corrosion Inspection.

A. Inspection Procedure. Do this inspection when required by the Scheduled Maintenance Checks, 5-20-00.
Inspect tail gear box assembly for corrosion as follows:

(1) Turn off all electrical and hydraulic power.

(2) Visually evaluate tail gear box for corrosion damage paying special attention to the magnesium
housings and the interface attachment joints.

(3) Sealant around the mounting feet, water entrapment areas, bolted connections, lockwire attachment
holes and housing ports are to be evaluated for deterioration and debonding.

(4) Deleted

(5) Remove sealant around mounting feet attachment joints, taking care not to damage the parent mate-
rial, for further corrosion evaluation as follows:

(a) Evaluate one tail gear box attachment point at a time. Remove sealant, degrease and clean using
trichloroethane solvent, Fed. Spec O-T-620.

(b) Remove attachment hardware and visually inspect the mounting foot area including barrel-nut
bore, as applicable, for presence of corrosion using a 10X power magnification glass. (Refer to
step (7) for repair.)

(c) Reinstall attachment hardware. (Refer to Removal/Installation, 66-30-00.)

(6) Repair local magnesium housing corrosion as follows:

(a) Remove grease and oil residue from corroded area by cleaning with dry-cleaning solvent, Fed.
Spec P-D-680, Type II. Dry thoroughly.

(b) If affected area has been painted, remove paint finish using paint remover, MIL-R-81294.

NOTE: Remove corrosion per step (c) or (d).

(c) Remove corrosion from magnesium surfaces using 320-400 grit aluminum oxide abrasive cloth,
Fed. Spec P-C-451, Scotch-Brite abrasive mat, MIL-S-9962, Class 2, Type I, abrasive non-woven
nylon wheel, MIL-W-81319. Maximum local blend limit is 0.030 inch. If corrosion is beyond
these limits, contact Sikorsky Commercial Support Services. Location and depth of corrosion is to
be provided to Sikorsky Commercial Support Services. As directed by Sikorsky Commercial Sup-
port Services proceed to next step.

(d) Prepare chromic acid pickle solution of 24 ounces of chromium-trioxide, Fed. Spec O-C-303 per
gallon of water. Scrape corroded area with a plastic scraper and scrub vigorously with a nylon
brush saturated with solution. Scrub for 1 to 3 minutes, or until corrosion products have been
completely dissolved.

(e) Remove small areas of mild corrosion with 320-400 grit aluminum oxide abrasive cloth, Fed.
Spec P-C-451, or Scotch-Brite abrasive mat, MIL-S-9962, Class 2, Type I.

(f) Remove heavy deposits of corrosion by using abrasive non-woven wheel. Use chromic acid pickle
solution for areas not accessible to mechanical removal.

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(g) Feather undamaged paint around repair area using 320-400 grit aluminum abrasive cloth, Fed.
Spec P-C-451.

(h) Rinse entire repair area with cold water. If chromic acid pickle solution was used, a slight golden
discoloration of the surface will be noted.

(i) Penetrant inspect per MIL-I-6866, Type I, Method A or B.

(j) Inspect surface for cleanliness and water-breakfree condition.

(k) Apply chemical conversion coating, MIL-M-3171 (Dow 19), with clean cheesecloth, Fed. Spec
CCC-C-440, to repair area. After 3 to 5 minutes flush with clean running water and allow to
air-dry. Do not wipe treated surface.

(l) Prime with epoxy polyamide primer, MIL-P-23377, Type I or II.

(m) Touch-up paint repaired surfaces by applying two coats of aliphatic polyurethane, MIL-C-83286.

(n) Air dry for 24 hours at room temperature or for two hours at 180 degrees F (82 degrees C).

(7) Repair barrel-nut bore as follows:

(a) Do step (6) above, as required, to degrease and remove corrosion from barrel-nut bore. Then do
as follows:

1 In area A, figure 602, (barrel-nut contact area) local blending is limited to not more than 5%
of area and not deeper than 0.030 inch.

2 In remaining bore area (barrel-nut non-contact area) blending is limited to not more than
20% of area and not deeper than 0.030 inch.

3 Reworked area shall have a 125 microinch surface finish.

(b) After blending area A, figure 602, residual pitting is allowed, providing it does not exceed an
additional 5% of area. Remove residual pitting by scrubbing with chromic-acid pickle solution as
described above in step (6) (d).

(c) Etch reworked area to remove flowed metal using Acetic-Glycol etch.

(d) Fluorescent penetrant inspect reworked area for cracks per MIL-I-6866, Type I, Method A or B.

(e) Touch-up reworked area per above step (6) (k).

(f) Impression stamp TS-76350-083-1, using machine control gang stamp, or individual stamps, on
reworked housing. Stamping shall not be more than 0.003 inch deep.

(8) If inspection identifies a condition beyond acceptable repair limits, remove and replace tail gear box
and contact Sikorsky Commercial Support Services.

(9) If tail gear box conforms to corrosion inspection, reinstall attachment hardware with applicable dis-
similar metal finish and torque per Tail Gear Box - Removal/Installation, 66-30-00.

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(10) Apply temporary corrosion protection during the torque stabilization. Apply specified sealing com-
pound after torque has stabilized. (Refer to Removal/Installation, 66-30-00.)

(11) Housings are to be inspected for service related damage such as scratches, dents and fretting which
have broken and/or removed the protective finish. These areas are to be evaluated for corrosion
damage and locally blended. (Refer to steps (6)(i) thru (6)(n)).

(12) The four outboard cowling/tail rotor control assembly support bracket attachment lugs of the tail
gear box output housing are to be inspected for integrity and/or corrosion damage as follows:

(a) Remove tail gear box cowlings and control assembly support brackets, as necessary, to gain
access to the inspection area.

(b) Inspect the four magnesium tail gear box output housing attachment lugs for fretting and cor-
rosion damage. Pay particular attention to the area immediately adjacent to the riveted nut-
plates and attachment hole.

(c) A cracked attachment lug, corrosion pitting exceeding 0.060 inch deep, or fretting damage
beyond 0.060 inch deep is cause for rejection and removal of the tail gear box from service.

(d) Notification of tail gear box removal is to be made to Sikorsky Commercial Support Services.

(e) Corrosion and/or fretting damage identified by this inspection, that is within the above depth
limits, may be locally blended and arrested.

(f) Apply MIL-M-3171, Type VI, (Dow 19) to all blended surfaces.

(g) At the faying surface apply non-curing sealant, mastinox 6856, during assembly, wipe all
squeeze out.

(h) Apply two applications of Amlguard per MIL-C-85054, to other blend areas, allowing 1/2 hour
between applications.

(13) Inspect pitch change shaft assembly rotational play. Refer to paragraph 5. Using existing
acceptance/rejection criteria in this section, evaluate the tail gear box. If inspection identifies that the
tail gear box requires replacement, notify Sikorsky Commercial Support Services.

(14) Inspect pitch change shaft assembly axial play. Refer to paragraph 6. Using existing acceptance/
rejection criteria in this section, evaluate the tail gear box. If inspection identifies that the tail gear box
requires replacement, notify Sikorsky Commercial Support Services.

(15) Upon successful completion/compliance of the above inspection, the helicopter logbook is to be
annotated.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

0.15 0.95
AREA A AREA A
B

1500

150

0.693
0.688

B SECTION B−B
VIEW A−A

NOTES

1. ALL DIMENSIONS ARE IN

INCHES UNLESS OTHERWISE
NOTED.
2. SYMBOL:
DIAMETER
CS0042
SA

Tail Gear Box Center Housing - Repair

Figure 602
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL GEAR BOX - CLEANING/PAINTING

1. Cleaning/Painting Tail Gear Box.

A. Clean Tail Gear Box.

CAUTION: TO PREVENT DAMAGE TO COMPONENTS, DO NOT ALLOW SOLVENT OR KEROSENE TO

SPLASH ON RUBBER COMPONENTS OR BEARINGS. COVER VENTED OIL FILLER, TO KEEP
SOLVENT OR KEROSENE OUT OF GEAR BOX.

(1) Wash external surfaces of tail gear box and associated components, using dry-cleaning solvent, Fed.
Spec P-D-680, Type II, or kerosene, Fed. Spec VV-K-211.

66-30-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TAIL GEAR BOX - APPROVED REPAIRS

1. Input Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Drain Attachment, H538A-3, Technical Development Corp.

(b) Seal Installer, 76700-20117-101

(c) Torque Reactor, 76700-20103-041

(d) Wrench, 76700-20100-041 (used on 76351-09014-103 nut)

(e) Wrench, 76700-20100-042 (used on 76351-09014-106 nut)

(f) Sleeve Installer (included in sleeve replacement kit)

B. Replace Input Seal (Figure 801).

(1) Remove screws and remove tail gear box fairing.

(2) Unbolt and remove Section V of tail rotor drive shaft. (Refer to Removal/Installation, 66-40-00.)

(3) Drain tail gear box using drain attachment, H538A-3. (Refer to Servicing.)

(4) Disconnect second stage hydraulic pressure tube at servo. Install red protective caps on tube and fitting.

(5) Remove cotter pin and nut from pinion shaft using applicable wrench and torque reactor, 76700-
20103-041.

(6) Remove input flange from pinion shaft.

(7) Remove seal from input housing using suitable puller.

(8) Replace sleeve. (Refer to Approved Repairs - Sleeve Replacement, 66-10-00.)

(9) Remove packing from pinion shaft.

(10) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and install on pinion shaft.

(11) Coat lip of new seal and sleeve lightly with same type lubricating oil, as used to service gear box per
Servicing, 12-10-00, and apply primer, MIL-PRF-23377, to OD.

(12) Install seal, with primer wet, in input housing using seal installer, 76700-20117-101.

(13) Coat splines of input flange lightly with grease, MIL-G-81827, and install on pinion shaft.

(14) Install nut on pinion shaft using applicable wrench and torque reactor, 76700-20103-041. Torque nut
to 1420 inch-pounds.

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 S-76B
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(15) Install cotter pin to secure nut.

(16) Spray nut, cotter pin, and mating inside surfaces of input flange with corrosion preventive compound,
ACF-50 (MIL-C-81309).

NOTE: Corrosion preventive compound, ACF-50 (MIL-C-81309) must be reapplied per step (16)
every 12 months.

(17) Remove protective caps and connect second stage hydraulic pressure tube at servo.

(18) Bleed second stage hydraulic system. (Refer to Servicing, 29-00-00.)

(19) Install Section V of tail rotor drive shaft. (Refer to Removal/Installation, 66-40-00.)

(20) Service tail gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(21) Install tail gear box fairing and secure with screws.

2. Output Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Seal Installer, 76700-20125-041

(b) Sleeve Installer (included in sleeve replacement kit)

B. Replace Output Seal (Figure 802).

(1) Remove screws and remove tail gear box fairing.

(2) Remove tail rotor from tail gear box. (Refer to Removal/Installation, 65-21-00.)

(3) Loosen jamnuts and remove bolts and jamnuts securing lockplate to nut.

(4) Remove lockplate, nut, plate, and outer cone from tail gear box output shaft.

(5) Remove output flange from tail gear box output shaft.

(6) Remove seal from tail gear box output housing using suitable puller, and remove packing from shaft.

(7) Replace sleeve. (Refer to Approved Repairs - Sleeve Replacement, 66-10-00.)

(8) Coat lip of new seal and sleeve lightly with same type lubricating oil, as used to service gear box per
Servicing, 12-10-00, and apply primer, MIL-PRF-23377, to OD.

(9) With primer wet, install new seal in tail gear box output housing using seal installer, 76700-20125-
041.

CAUTION: MAKE CERTAIN INNER CONE HAS BEEN INSTALLED IF IT HAS BEEN REMOVED TO
FACILITATE SEAL REPLACEMENT.

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 S-76B
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A D
FW

TAIL GEAR
PACKING BOX

SEAL

PINION
SHAFT

SLEEVE

INPUT
FLANGE
NUT
(TORQUE 1420
COTTER IN. LBS)
PIN

C B

0.190 TO
0.220 INCH

PACKING
SLEEVE

SEAL

SLEEVE INPUT
FLANGE

NUT
INPUT
FLANGE
COTTER PINION
PIN SHAFT
SLEEVE LOCATION
S76A_47441 (C27)
SA

Input Seal - Replacement

Figure 801
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(10) Install new packing, lightly coated with same type lubricating oil, as used to service gear box per
Servicing, 12-10-00, in groove of shaft assembly.

CAUTION: MAKE CERTAIN INDEX MARK ON FLANGE IS LINED UP WITH MISSING TOOTH ON
SHAFT.

(11) Coat splines of tail gear box output shaft with grease, MIL-G-81827, and install flange on shaft.

(12) Install outer cone, plate, and nut on shaft. Handtighten nut.

(13) Install lockplate on shaft and back off nut enough to line up nearest holes in lockplate with holes in nut.

(14) Install twelve bolts and three jamnuts (equally spaced) securing lockplate to nut.

(15) Torque bolts to 30 inch-pounds in this sequence: 1, 5, 9, 2, 6, 10, 3, 7, 11, 4, 8, 12 according to

numbers on lockplate (Figure 802, Detail C).

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC.

CAUTION: AT TIME INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-

00, CHECK OUTPUT FLANGE RETENTION BOLTS FOR SPECIFIED TORQUE. TORQUE
MAY VARY TO AN ALLOWED MINIMUM OF 75 INCH-POUNDS. (REFER TO
INSPECTION/CHECK.)

(16) Repeat torque to 60 inch-pounds in same sequence; then repeat again in same sequence to 90 - 100
inch-pounds.

(17) Torque jamnuts to 30 - 50 inch-pounds. Lockwire bolts and lockwire jamnuts to adjacent bolts.

(18) Install tail rotor on tail gear box. (Refer to Removal/Installation, 65-21-00.)

(19) Install tail gear box fairing and secure with screws.

3. Pitch Control Shaft Seal Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Seal Installer, 76700-20126-101

B. Replace Pitch Control Shaft Seal (Figure 803).

(1) Remove screws and remove tail gear box fairing.

(2) Remove tail rotor from tail gear box. (Refer to Removal/Installation, 65-21-00.)

(3) Remove retaining ring securing seal in tail gear box output shaft using suitable puller.

(4) Remove seal from tail gear box output shaft using suitable puller.

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 S-76B
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(5) Coat lip of new seal lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and apply primer, MIL-PRF-23377, to OD.

(6) With primer wet, install seal inside tail gear box output shaft using seal installer, 76700-20126-101.

(7) Install retaining ring to secure seal in position.

(8) Install tail rotor on tail gear box. (Refer to Removal/Installation, 65-21-00.)

(9) Install tail gear box fairing and secure with screws.

4. Oil Level Sight Window Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Drain Attachment, H538A-3, Technical Development Corp.

B. Replace Oil Level Sight Window (Figure 804).

(1) Remove screws and remove tail gear box fairing.

(2) Drain tail gear box enough to bring oil level below oil level sight window port using drain attachment,
H538A-3. (Refer to Servicing.)

(3) Remove sight window and packing.

(4) If necessary, clean oil level sight window using dry-cleaning solvent, Fed. Spec P-D-680, Type II, or
equivalent.

(5) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and install on oil level sight window.

CAUTION: TO PREVENT DAMAGE TO THREADS IN GEAR BOX HOUSING, USE CARE NOT TO
CROSS THREADS WHEN INSTALLING SIGHT WINDOW.

(6) Install oil level sight window in port on forward side of tail gear box. Torque oil level sight window to
137-151 inch-pounds and lockwire oil level sight window.

(7) Service tail gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(8) Install tail gear box fairing and secure with screws.

5. Oil Filler Replacement.

A. Replace Oil Filler (Figure 805).

(1) Remove screws and remove tail gear box fairing.

(2) Remove oil filler assembly and packing, using care not to damage chain connecting cap to fitting.

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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OUTPUT
FLANGE
TAIL GEAR
BOX

A
SEAL NUT

PACKING

JAMNUT

BOLT
A
PLATE
OUTER
CONE
LOCKPLATE
SLEEVE

OUTER
TAIL GEAR CONE PLATE
BOX
TAIL GEAR BOX
OUTPUT SHAFT
LOCKPLATE
PACKING
SEAL NUT
D
BOLT
JAMNUT
D C
OUTPUT
FLANGE FLUSH TO 0.010 INCH
B
C SLEEVE

SLEEVE

TAIL GEAR BOX

OUTPUT SHAFT
OUTPUT
FLANGE
MISSING "P" INDEX
TOOTH MARK HERE
SLEEVE LOCATION
S76A_47442 (C16)
SA

Output Seal - Replacement Output Seal - Replacement

Figure 802 (Part 1 of 2) Figure 802 (Part 2)
66-30-00 66-30-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

D
FW

A
B

RETAINING
A RING

TAIL
GEAR BOX
SEAL

TAIL GEAR BOX

OUTPUT SHAFT

RETAINING RING

SEAL

S76A_47443 (B)
SA

Pitch Control Shaft Seal - Replacement

Figure 803
66-30-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

D
FW

TAIL
PACKING GEAR
BOX
OIL LEVEL SIGHT
WINDOW (TORQUE
137−151 IN. LBS)
CS0322
SA

Oil Level Sight Window - Replacement

Figure 804
(3) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00 , and install on oil filler.

CAUTION: TO PREVENT DAMAGE TO THREADS IN GEAR BOX HOUSING, USE CARE NOT TO
CROSS THREADS WHEN INSTALLING OIL FILLER.

(4) Install oil filler in filler port on top of tail gear box output housing. Torque oil filler to 90-100 inch-
pounds and lockwire fitting to gear box.

(5) Install tail gear box fairing and secure with screws.

6. Pressure Pads Replacement.

A. Replace Pressure Pads (Figure 806).

CAUTION: THE TAIL GEAR BOX OUTPUT FLANGE IS A DYNAMICALLY BALANCED ASSEMBLY. IN
ORDER TO MAINTAIN TAIL ROTOR BALANCE, WHEN REPLACING PRESSURE PADS, MAKE
SURE ATTACHMENT SCREWS ARE REINSTALLED IN EXACTLY THE SAME POSITION ON
FLANGE.

(1) Unscrew and remove pressure pads from output flange.

CAUTION: TO INSURE PROPER TAIL ROTOR BLADE CLAMP-UP ON INSTALLATION, SCREWHEADS

MUST BE BELOW SURFACE OF PADS.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL FILLER (TORQUE

90−100 IN. LBS)
D
FW
PACKING

TAIL
GEAR
BOX
CS0403
SA

Oil Filler - Replacement

Figure 805
(2) Position new pressure pads on flange and install screws in correct position on flange. Torque screws to
20 inch-pounds.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TAIL GEAR BOX

PRESSURE PAD

SCREW
(TORQUE 20
IN. LBS)

OUTPUT
FLANGE

PRESSURE PAD
SCREW
(TORQUE 20
IN. LBS)

S76A_57337 (C27)
SA

Output Flange Pressure Pad - Replacement

Figure 806

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL DRIVE SHAFT- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 401).

The tail drive shaft transmits torque from the main gear box to the tail rotor. It consists of five sections and extends
from the tail takeoff flange of the main gear box to the input side of the intermediate gear box, and from the
output side of the intermediate gear box to the input of the tail gear box. Sections I and V consist of two flanges,
a shaft, and two flexible couplings each. Sections II, III, and IV each consist of two flanges, a shaft, a flexible
coupling, and a bearing support. Section I is reached by removing the aft engine cowl. Section II is enclosed in the
aft engine cowl and the forward tail rotor drive shaft fairing. Section III is under the forward tail rotor drive shaft
fairing. Section IV is enclosed in the forward tail rotor drive shaft fairing and the aft tail rotor drive shaft fairing.
Section V is reached by removing the intermediate gear box fairing and the tail gear box fairing. Sections II, III,
and IV are interchangeable with each other.

66-40-00
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Jan 15/92
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL DRIVE SHAFT - SERVICING

1. General.

Servicing the tail drive shaft consists of replenishing the bearing support housing fluid as required. All bearings
should be inspected and replaced as required per Inspection/Check and Scheduled Maintenance Checks, 5-20-
00. Bearings are prepacked with grease and are not relubricated.

2. Servicing Tail Drive Shaft Bearing Support.

A. Service Bearing Support.

(1) Hinge back aft engine cowl and remove tail drive shaft cover as required.

(2) Remove filler screws from bearing support housing.

(3) Fill housing with silicone fluid, DC-200 (100 centistokes). With support assembly in vertical position, air
bubble shall not be greater than 0.50 inch in length.

NOTE: If filler screws (NT352R0632VC-4N) are used in viscous damper tube, Permatex Aviation
Form-A-Gasket and the lockwiring requirement, of the screws, is not required. Filler screws
(NT352R0632VC-4N) have a gasket installed under each screw head and the screw heads
are not drilled.

(4) Coat threads of screws (MS35265-26) with Permatex Aviation Form-A-Gasket. Torque screws to 10-20
inch-pounds and lockwire.

NOTE: If fluid leakage occurs at filler screws after installation with Permatex, screws may be installed
using Permacel ribbon dope thread sealant, P412, in addition to application of Permatex.

(5) Install screws (NT352R0632VC-4N). Torque screws to 10-20 inch-pounds.

(6) Close and latch aft engine cowl and install tail drive shaft cover.

66-40-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL DRIVE SHAFT - REMOVAL/INSTALLATION

1. Removal Tail Drive Shaft.

CAUTION: TO PREVENT CONDITIONS LEADING TO FATIGUE FAILURE, TAKE CARE NOT TO DENT,
SCRATCH, OR IN ANY WAY DAMAGE ANY SECTION OF THE TAIL DRIVE SHAFT.

NOTE: If possible, maintain shim and hardware stack-ups at flexible couplings for reinstallation. This will save
installation time, particularly if same shafts are being reinstalled.

A. Prepare for Removal.

(1) Special Tools and Equipment.

(a) Modified 1/2-in. Box End Wrench, (Section IV).

B. Remove Section I Tail Drive Shaft (Figure 401).

(1) Open engine air inlet/bypass cowl.

(2) Hinge up and secure upper access panel.

(3) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section I to
flange on Section II of tail drive shaft (Figure 401, Detail B).

NOTE: Leave one bolt in place to hold shaft in position while disconnecting forward connection.

(4) Remove bolts, countersunk washers, shims, spherical washers, and nuts securing flexible coupling on
Section I of tail drive shaft to flange on main gear box (Figure 401, Detail A).

(5) Remove Section I of tail drive shaft.

C. Remove Section II Tail Drive Shaft (Figure 401).

(1) Open engine air inlet/bypass cowl.

(2) Hinge up and secure upper access panel.

(3) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section I to
flange on Section II of tail drive shaft (Figure 401, Detail B).

(4) Remove bolts, washers, and nuts securing Section II bearing support assembly to firewall (Figure 401,
Detail G).

(5) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section II to
flange on Section III of tail drive shaft (Figure 401, Detail B).

(6) Remove Section II of tail drive shaft.

D. Remove Section III Tail Drive Shaft (Figure 401).

(1) Remove forward tail drive shaft cover.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(2) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section II to
flange on Section III of tail drive shaft (Figure 401, Detail B).

(3) Remove bolts, washers, and nuts securing Section III bearing support assembly to support (Figure 401,
Detail F).

(4) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section III to
flange on Section IV of tail drive shaft (Figure 401, Detail B).

(5) Remove Section III of tail drive shaft.

E. Remove Section IV Tail Drive Shaft (Figure 401).

(1) Remove forward and aft tail drive shaft covers.

(2) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section III to
flange on Section IV of tail drive shaft (Figure 401, Detail B).

(3) Remove bolts, washers, shims (if installed), and nuts securing Section IV bearing support assembly to
support (Figure 401, Detail F).

(4) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section IV of
tail drive shaft to intermediate gear box input flange (Figure 401, Detail C).

NOTE: Grind a 1/2-in., 12-point, box-end wrench as necessary to get to and hold nuts on aft side of
intermediate gear box input flange (Figure 401, Detail H).

(5) Remove Section IV of tail drive shaft.

F. Remove Section V Tail Drive Shaft (Figure 401).

(1) Remove tail cone fairing and tail rotor gear box fairing.

(2) Disconnect tail rotor control cables at quadrant on tail rotor control assembly. (Refer to Tail Rotor Control
System, 67-20-00.)

(3) Remove bolts, spherical washers, shims, washers and nuts securing flexible coupling on Section V of tail
drive shaft to tail gear box input flange (Figure 401, Detail E).

(4) Remove bolts, spherical washers, shims, washers, and nuts securing flexible coupling on Section V of tail
drive shaft to output flange of intermediate gear box (Figure 401, Detail D).

(5) Remove Section V of tail drive shaft.

2. Installation Tail Drive Shaft (Figure 401).

NOTE: If only one section of tail drive shaft was removed, follow installation steps for that Section of shaft only.

66-40-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

SUPPORT
SECTION V
UNUSED SHIM
E (SECTION IV ONLY)
BOLT
SECTION I SECTION II SECTION III SECTION IV WASHER
BEARING SUPPORT
ASSEMBLY
A B B B C

SHIM NUT
(AS NECESSARY) (TORQUE
200 IN. LBS)
FLANGE
SPHERICAL F
WASHER
D BOLT

G F F WASHER
UNUSED SHIM (AS NECESSARY)
SHIM (SECTION IV ONLY)

FW WASHER
SHIM SHIM NUT D
(AS NECESSARY) (AS NECESSARY) (TORQUE NUT
200 IN. LBS) FLEXIBLE (TORQUE
SPHERICAL COUPLING 100 IN. LBS)
NUT WASHER SPHERICAL FLANGE
(TORQUE COUNTERSUNK WASHER
200 IN. LBS) WASHER
BOLT E

A B G H
WASHER
BOLT UNUSED
SHIM BOLT
UNUSED
SHIM WASHER SUPPORT
FITTING
FLANGE

FLEXIBLE FW
COUPLING FLEXIBLE D GRIND AS NECESSARY FOR
COUPLING BEARING BEST POSSIBLE FIT
SUPPORT
ASSEMBLY
C D
SHIM
(TOTALING 0.077 INCH THICK) WASHER
NUT UNUSED SHIM
SHIM (AS NECESSARY) BOLT
SPHERICAL FLANGE NUT
BOLT WASHER (TORQUE 1/2 IN., 12−POINT
(TORQUE 200 IN. LBS) FLANGE SPHERICAL BOX−END WRENCH
225 IN. LBS) WASHER WASHER
H
BOLT
WASHER
UNUSED
SHIM WASHER
NUT (TORQUE
SLEEVE
100 IN. LBS)
SHIM

WASHER
FLEXIBLE
COUPLING FLEXIBLE NUT (TORQUE CB4242
COUPLING 100 IN. LBS) SA

Tail Drive Shaft - Removal/Installation Tail Drive Shaft - Removal/Installation

Figure 401 (Part 1 of 2) Figure 401 (Part 2)
66-40-00 66-40-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
NOTE: If tail drive shaft misalignment is suspected or repairs to tail cone structure and/or drive shaft supports
was done, before installation of tail drive shaft, perform alignment check of drive shaft support(s) at
station(s) 412.38, 349.6, and 286.84.(Refer to Tail Rotor Drive Shaft Supports, 53-40-06.)

CAUTION: DO NOT REPLACE SHAFT SUPPORTSUNLESS SHAFT SUPPORTS ARE DAMAGED, OR OUT OF
ALIGNMENT. (REFER TO TAIL ROTOR DRIVE SHAFT SUPPORTS, 53-40-06).

CAUTION: TO PREVENT CONDITIONS LEADING TO FATIGUE FAILURE, TAKE CARE NOT TO DENT,
SCRATCH OR IN ANY WAY DAMAGE ANY SECTION OF THE TAIL DRIVE SHAFT.

A. Prepare for Installation.

(1) Special Tools and Equipment.

(a) Modified 1/2-in. Box-End Wrench (Section IV).

(b) Tail Drive Shaft Alignment Fixture, 76700-20025-041.

B. Install Section V Tail Drive Shaft (Figure 401).

(1) Position Section V of tail drive shaft between intermediate gear box output flange and tail gear box input
flange.

CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST

FLEXIBLE COUPLING.

(2) Support Section V to prevent damage to flexible coupling, and temporarily secure flexible coupling on
Section V to intermediate gear box output flange with bolts, spherical washers, and nuts. Do not install
shims now.

(3) Measure gap between lobes of tail gear box input flange and flexible coupling on Section V of tail drive
shaft. Divide this measurement by two to determine shim thickness necessary at upper and lower con-
nections of drive shaft.

(4) Unbolt and disconnect Section V of tail drive shaft from intermediate gear box output flange.

(5) Coat grip length of bolts and contact surfaces of washers and shims on both sides of intermediate gear
box output flange lobes with primer, MIL-PRF-23377. Do not prime threads of bolts.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL DRIVE SHAFT ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING PARTS,

SAFETY INSTALLATION, AND TORQUE ARE CRITICAL CHARACTERISTICS. APPLY
TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY PARTS
PROGRAM, CHAPTER 20.)

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 S-76B
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CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST
FLEXIBLE COUPLING.

CAUTION: TO PREVENT PRELOAD ON FLEXIBLE COUPLING, MAKE CERTAIN SHIMS ARE

INSTALLED SO THAT DISCS OF FLEXIBLE COUPLING ARE FLAT WITHIN 0.020 INCH
WHEN MEASURED AT ANY POINT AROUND OUTSIDE DIAMETER.

(6) With primer wet, secure flexible coupling on Section V of tail drive shaft to intermediate gear box output
flange with bolts, spherical washers, shims (number and thickness determined in step (3)) washers, and
nuts. Place unused shims under nuts. Torque nuts to 200 inch-pounds (Figure 401, Detail D).

NOTE: Install identical stackup of shims at each location between flexible coupling and flange.

(7) Coat grip length of bolts and contact surfaces of washers and shims on both sides of tail gear box input
flange lobes with primer, MIL-PRF-23377. Do not prime threads of bolts.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL DRIVE SHAFT ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING PARTS,

SAFETY INSTALLATION, AND TORQUE ARE CRITICAL CHARACTERISTICS. APPLY
TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY PARTS
PROGRAM, CHAPTER 20.)

CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST

FLEXIBLE COUPLING.

CAUTION: TO PREVENT PRELOAD ON FLEXIBLE COUPLING, MAKE CERTAIN SHIMS ARE

INSTALLED SO THAT DISCS OF FLEXIBLE COUPLING ARE FLAT WITHIN 0.020 INCH
WHEN MEASURED AT ANY POINT AROUND OUTSIDE DIAMETER.

NOTE: Install identical stackup of shims at each location between flexible coupling and lobes of flange.

(8) With primer wet, secure flexible coupling on Section V to tail gear box input flange with bolts, spherical
washers, shims (number and thickness determined in step (3)), washers, and nuts. Place unused shims
under nuts. Torque nuts to 200 inch-pounds (Figure 401, Detail E).

(9) Connect tail rotor control cables to quadrant on tail rotor control assembly. (Refer to Tail Rotor Control
System, 67-20-00.)

(10) Install and secure tail cone fairing and tail rotor gear box fairing.

(11) Check Section V tail drive shaft alignment. (Refer to Inspection/Check, paragraph 4.)

C. Install Section IV Tail Drive Shaft (Figure 401).

(1) Position Section IV of tail drive shaft between shaft support at station 412.38 and intermediate gear box
input flange.

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(2) To prevent damage to flexible coupling, temporarily secure bearing support assembly to shaft support
with bolts, washers, and nuts. Do not install shims or torque nuts at this time (Figure 401, Detail F).

(3) Coat grip length of bolts and contact surfaces of washers and shims on both sides of intermediate gear
box input flange lobes with primer, MIL-PRF-23377. Do not prime threads of bolts.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL DRIVE SHAFT ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING

PARTS, SAFETY INSTALLATION, AND TORQUE ARE CRITICAL CHARACTERISTICS.
APPLY TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY
PARTS PROGRAM, CHAPTER 20.)

CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST

FLEXIBLE COUPLING.

(4) With primer wet, secure flexible coupling on Section IV to intermediate gear box input flange with bolts,
spherical washers, shims totaling 0.077 inch thick, washers and nuts. Place unused shims under nuts.
Torque bolts to 225 inch-pounds, using extension as necessary on torque wrench (Figure 401, Detail C).

NOTE: Grind a 1/2-in., 12-point, box-end wrench as necessary to get to and hold nuts on aft side of
intermediate gear box input flange (Figure 401, Detail H).

NOTE: Install identical stackup of shims at each location between flexible coupling and lobes of
flange.

(5) Measure gaps between lobes of bearing support assembly flanges and support. Determine average of
four measurements and stack up shims as close as possible to average obtained.

CAUTION: TO PREVENT PRELOAD ON FLEXIBLE COUPLING, MAKE CERTAIN SHIMS ARE

INSTALLED SO THAT DISCS OF FLEXIBLE COUPLING ARE FLAT WITHIN 0.020 INCH
WHEN MEASURED AT ANY POINT AROUND OUTSIDE DIAMETER.

(6) Secure bearing support assembly to support with bolts, AN960KD416 washers, shims (number and
thickness determined in step (5)), AN960KD416 washers, and nuts. Apply thin coating of corrosion
inhibiting sealant, M6856KTUBE (Mastinox 6856K), or equivalent, to bolt shanks and washers installed
between support assembly housing and nuts. Place unused shims between washers at boltheads and
support. Torque nuts to 100 inch-pounds (Detail F).

NOTE: Install identical stackup of shims at each location between bearing support and support.

(7) Wipe excess sealant squeezeout and apply two coats of water-displacing corrosion preventive com-
pound (AMLGUARD), MIL-C-85054A(AS), Type I, or equivalent.

NOTE: Allow one hour drying time between coats.

(8) Install and secure forward and aft tail drive shaft covers.

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 S-76B
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D. Install Section III Tail Drive Shaft (Figure 401).

(1) Position bearing support assembly on forward end of Section III of tail drive shaft against aft side of
shaft support at STA 349.6 and secure with bolts, AN960KD416 washers, and nuts. Apply thin coating
of corrosion inhibiting sealant, M6856KTUBE (Mastinox 6856K), or equivalent, to bolt shanks and
washers installed between support assembly housing and nuts. Torque nuts to 100 inch-pounds (Figure
401, Detail F).

(1A) Wipe excess sealant squeezeout and apply two coats of water-displacing corrosion preventive com-
pound (AMLGUARD), MIL-C-85054A(AS), Type I, or equivalent.

NOTE: Allow one hour drying time between coats.

(2) Measure gaps between mounting lobes of flange on forward end of Section IV shaft and flexible
coupling on aft end of Section III of tail drive shaft. Determine average of three measurements and stack
up shims at each lobe as close as possible to average measurement obtained.

(3) Coat grip length of bolts and contact surfaces of washers and shims on both sides of flange lobes on
Section IV of tail drive shaft with primer, MIL-PRF-23377. Do not prime threads of bolts.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL DRIVE SHAFT ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING

PARTS, SAFETY INSTALLATION, AND TORQUE ARE CRITICAL CHARACTERISTICS.
APPLY TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY
PARTS PROGRAM, CHAPTER 20.)

CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST

FLEXIBLE COUPLING.

CAUTION: TO PREVENT PRELOAD ON FLEXIBLE COUPLING, MAKE CERTAIN SHIMS ARE

INSTALLED SO THAT DISCS OF FLEXIBLE COUPLING ARE FLAT WITHIN 0.020 INCH
WHEN MEASURED AT ANY POINT AROUND OUTSIDE DIAMETER.

(4) With primer wet, secure flange of Section IV to flexible coupling of Section III with bolts, spherical
washers, shims (number and thickness determined in step (2)), washers and nuts. Place unused shims
under nuts. Torque nuts to 200 inch-pounds (Figure 401, Detail B).

NOTE: Install identical stackup of shims at each location between flexible coupling and lobes of
flange.

(5) Install and secure forward tail drive shaft cover.

E. Install Section II Tail Drive Shaft (Figure 401).

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(1) Position bearing support assembly on Section II of tail drive shaft against aft side of support fitting. Install
bolts, AN960KD416 washers, and nuts at top attachment holes. Install bolts, AN960KD416 washers,
spacers, shims, and nuts at bottom attachment holes. Apply thin coating of corrosion inhibiting sealant,
M6856KTUBE (Mastinox 6856K), or equivalent, to bolt shanks and washers installed between support
assembly housing and nuts. Torque nuts to 100 inch-pounds (Figure 401, Detail G).

(1A) Wipe excess sealant squeezeout and apply two coats of water-displacing corrosion preventive com-
pound (AMLGUARD), MIL-C-85054A(AS), Type I, or equivalent.

NOTE: Allow one hour drying time between coats.

(2) Measure gaps between mounting lobes of flange on forward end of Section III shaft and flexible cou-
pling on aft end of Section II of tail drive shaft. Determine average of three measurements and stack up
shims at each lobe as close as possible to average measurement obtained.

(3) Coat grip length of bolts and contact surfaces of washers and shims on both sides of flange lobes on
Section III of tail drive shaft with primer, MIL-PRF-23377. Do not prime threads of bolts.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL DRIVE SHAFT ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING PARTS,

SAFETY INSTALLATION, AND TORQUE ARE CRITICAL CHARACTERISTICS. APPLY
TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY PARTS
PROGRAM, CHAPTER 20.)

CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST

FLEXIBLE COUPLING.

CAUTION: TO PREVENT PRELOAD ON FLEXIBLE COUPLING, MAKE CERTAIN SHIMS ARE

INSTALLED SO THAT DISCS OF FLEXIBLE COUPLING ARE FLAT WITHIN 0.020 INCH
WHEN MEASURED AT ANY POINT AROUND OUTSIDE DIAMETER.

(4) With primer wet, secure flange of Section III to flexible coupling of Section II with bolts, spherical
washers, shims (number and thickness determined in step (2)), washers and nuts. Place unused shims
under nuts. Torque nuts to 200 inch-pounds (Figure 401, Detail B).

NOTE: Install identical stackup of shims at each location between flexible coupling and lobes of flange.

(5) Hinge down and secure upper access panel.

(6) Close and secure engine air inlet/bypass cowl.

F. Install Section I Tail Drive Shaft (Figure 401).

(1) Position Section I of tail drive shaft between main gear box tail takeoff flange and flange on Section II of
drive shaft at forward face of station 286.84 support fitting.

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CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST
FLEXIBLE COUPLING.

(2) Support Section I to prevent damage to flexible coupling and temporarily secure flexible coupling on
Section I to main gear box tail takeoff flange with bolts, spherical washers, washers, and nuts. Do not
install shims now.

(3) Insert bolts and measure gaps between mounting lobes of flange on forward end of Section II shaft, and
flexible coupling on aft end of Section I of tail drive shaft. Divide this measurement by two to determine
shim thickness necessary at forward and aft connections to center Section I between flanges.

(4) Remove bolts from flanges on Section I to Section II drive shafts.

(5) Unbolt and disconnect Section I of tail drive shaft from main gear box takeoff flange.

(6) Coat grip length of bolts and contact surfaces of washers and shims on both sides of lobes of main gear
box tail takeoff flange with primer, MIL-PRF-23377. Do not prime threads of bolts.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL DRIVE SHAFT ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING PARTS,

SAFETY INSTALLATION, AND TORQUE ARE CRITICAL CHARACTERISTICS. APPLY
TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY PARTS
PROGRAM, CHAPTER 20.)

CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST

FLEXIBLE COUPLING.

CAUTION: TO PREVENT PRELOAD ON FLEXIBLE COUPLING, MAKE CERTAIN SHIMS ARE

INSTALLED SO THAT DISCS OF FLEXIBLE COUPLING ARE FLAT WITHIN 0.020 INCH
WHEN MEASURED AT ANY POINT AROUND OUTSIDE DIAMETER.

(7) With primer wet, secure Section I flexible coupling to main gear box tail takeoff flange with bolts,
countersunk washers, shims (number and thickness determined in step (3)), spherical washers, and nuts.
Place unused shims under nuts. Torque nuts to 200 inch-pounds (Figure 401, Detail A).

NOTE: Make certain countersunk side of MS20002C5 washer is installed against bolthead (Figure
401, Detail A).

NOTE: Install identical stackup of shims at each location between flexible coupling and lobes of flange.

(8) Coat grip length of bolts and contact surfaces of washers and shims on both sides of flange lobes on
Section II of tail drive shaft with primer, MIL-PRF-23377. Do not prime threads of bolts.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF TORQUE STABILIZATION IS A CRITICAL CHARACTERISTIC. AT TIME

INTERVAL SPECIFIED UNDER CONDITIONAL MAINTENANCE CHECKS, 5-50-00,
CHECK TAIL DRIVE SHAFT ATTACHMENT NUTS FOR SPECIFIED TORQUE.

WARNING: FLIGHT SAFETY PARTS

VERIFICATION OF PROPER HARDWARE INSTALLATION, JOINING OF MATING PARTS,

SAFETY INSTALLATION, AND TORQUE ARE CRITICAL CHARACTERISTICS. APPLY
TORQUE STRIPE. (REFER TO TORQUE STRIPING HARDWARE, FLIGHT SAFETY PARTS
PROGRAM, CHAPTER 20.)

CAUTION: SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS BE INSTALLED AGAINST

FLEXIBLE COUPLING.

CAUTION: TO PREVENT PRELOAD ON FLEXIBLE COUPLING, MAKE CERTAIN SHIMS ARE

INSTALLED SO THAT DISCS OF FLEXIBLE COUPLING ARE FLAT WITHIN 0.020 INCH
WHEN MEASURED AT ANY POINT AROUND OUTSIDE DIAMETER.

(9) With primer wet, secure Section I flexible coupling to flange of Section II with bolts, spherical washers,
shims (number and thickness determined in step (3)), washers, and nuts. Place unused shims under nuts.
Torque nuts to 200 inch-pounds (Figure 401, Detail B).

NOTE: Install identical stackup of shims at each location between flexible coupling and lobes of flange.

CAUTION: TO PREVENT DAMAGE TO TAIL DRIVE SHAFT, MAKE SURE PROPER CLEARANCE IS
MAINTAINED BETWEEN TAIL DRIVE SHAFT AND CENTER FIREWALL. (REFER TO CHAP-
TER 66, CONDITIONAL MAINTENANCE CHECKS, 5-50-00.)

(10) Hinge down and secure upper access panel.

(11) Close and secure engine air inlet/bypass cowl.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TAIL DRIVE SHAFT - INSPECTION/CHECK

1. Overspeed Inspection Requirements.

A. General.Main rotor head overspeed of over 366 rpm (121% Nr) requires inspection of tail drive shaft.
Inspect tail drive shaft as follows:

(1) Inspect tail drive shaft for damage or distortion.

(2) Inspect tail drive shaft supports for cracks originating from attachment holes.

(3) Inspect flexible coupling discs and flanges for yielding, distortion, or cracks.

NOTE: If main rotor head overspeed is over 380 rpm (130% Nr), additional inspection is required as
follows:

(4) Remove all sections of tail drive shaft and disassemble as necessary. (Refer to Removal/Installation.)

(5) Inspect tail drive shaft bearing supports for cracks originating from attachment holes.

(6) Inspect flexible coupling flanges and discs for cracks and distortion; check all bolt holes for elongation.
Maximum permissible elongation of 0.3140- to 0.3145-inch bolt holes is 0.0005 inch. Maximum
permissible diameter is 0.315 inch.

(7) Inspect ends of tail drive shaft sections for signs of yielding, indicated by loose lockbolts, elongated
lockbolt holes, and paint flaking near lockbolts.

(8) Inspect bearing housings for bond separations. Inspect bearing housings for tears in rubber and leak-
age.

(9) Visually inspect tail drive shaft sections for cracks and distortion.

(10) If there is no distortion or cracks, install tail drive shaft. If there is distortion or cracks, replace tail drive
shaft.

(11) Inspect drive shafts for loss of balance weights; if weights are lost, replace shaft.

2. Sudden Stoppage Inspection Requirements.

A. General.For a definition of sudden stoppage applicable to tail drive shaft, and for inspection requirements
that must be complied with after sudden stoppage, refer to Inspection/Check, 66-10-00.

3. Tail Drive Shaft, Bearing and Bearing Support Inspection.

A. Tail Drive Shaft Flange-To-Shaft Attachment Torque Check.

NOTE: There are four fasteners at three TDS locations.

(1) Inspect tail drive shaft flange-to-shaft attachment nuts and bolts for evidence of looseness or movement
as follows (Refer to Figure 601):

(a) Visually inspect hardware for evidence of torque stripe movement. (Refer to Figure 602).

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(b) Attempt to rotate nut by applying torque with fingers.

(2) If there is any evidence of movement, torque stripe is misaligned, or hardware can be rotated by hand,
remove tail drive shaft assembly and replace with serviceable unit. (Refer to Tail Drive Shaft - Removal/
Installation, 66-40-00).

B. Inspect Bearings and Bearing Supports.

(1) Remove tail drive shaft covers.

(2) Inspect at all three bearings for discrepancies, as follows:

NOTE: During this inspection, also inspect bearing support attachment brackets for security and
cracks.

(a) Overheating, as shown by discoloration of bearing inner/outer race, liner of the viscous damper
and burnt grease odor.

(b) Loss of grease, as shown by quantity of grease deposited under, or on, bearing support.

NOTE: Purged grease can sling out onto seals, adjacent components, cowling or anywhere
within 360 degree plane of bearing rotation. Puddling of grease beneath new viscous
damper bearing should not occur after 10 flight hours. Majority of grease purging should
abate within 100 flight hours. A thin film of grease uniformly around full 360 degrees of
the bearing seal is acceptable.

(c) Presence of bearing seals and seal retaining rings.

NOTE: Bearing seal is to be continuous with no tears.

(d) Obvious visual corrosion pitting on the bearing inner/outer race end face is cause for removal.

(e) Evidence of bearing inner race turning on bonded liner to produce obvious wear.

NOTE: Creeping between bearing inner race and liner and between bearing outer race and
housing liner is not detrimental, as long as there is no obvious wear. This creeping
includes both rotational and axial movement of bearing races. Bearing installation does
not permanently lock these races into position.

NOTE: The bearing installation is 0.0002 to 0.0018 inch loose fit. This allows the bearing to float
axially and locate its normal operating position. The axial floating reduces the possibility
of axial preloading the bearing.

(f) Any rubber area that is cracked or separated from the viscous damper housing.

CAUTION: TO PREVENT DAMAGE TO RUBBER BLADDER USE CARE WHEN INSERTING FEELER
GAGE.

(g) Using feeler gage, 0.005/0.010 inch, carefully insert between bladder and liner. Measure depth
and extent of separation on both sides of viscous bearing support assembly.

NOTE: Disbonding of rubber bladder from liner up to maximum allowed is not cause for viscous
damper replacement unless damper fluid leakage occurs.

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(h) Maximum allowable disbond on viscous damper shall be no greater than 0.200 inch in depth for
40% of circumference on one or both sides.

(3) Except as noted, where discrepancies are found, replace that section of tail drive shaft, bearing support,
or bearing. (Refer to Removal/Installation and Approved Repairs.)

CAUTION: TO AVOID MARRING OR DAMAGING SURFACE FINISH OF LINER OR SHAFT WHEN

APPLYING LOCATION MARKS, DO NOT USE SCRIBE, AWL, OR OTHER SHARP INSTRU-
MENT.

(4) To assist with future inspections, apply location marks, with yellow or white paint or with tape, across
each bonded liner and onto shaft. Marking of bearing races or outer housings is not necessary.

4. Section V Tail Drive Shaft Alignment Check.

A. Prepare for Alignment Check.

(1) Special Tools and Equipment.

(a) Alignment Bar, 76700-20120-042

(b) Dial Indicator, 7739, Brown and Sharpe Co. or equivalent

B. Alignment Check (Figure 603). When intermediate gear box, tail gear box, Section V tail drive shaft/flexible
coupling, or stabilizer support fitting is removed and installed/replaced for scheduled inspection/
maintenance, do this:

NOTE: Tail drive shaft TIR readings are measured with proper tail rotor cable tension applied.

(1) Unscrew and remove tail cone fairing.

(2) Remove one bolt and nut from intermediate gear box output flange and flexible coupling and install
alignment bar, 76700-20120-042, leaving all washers and shims installed.

(3) Attach dial indicator, 7739, to alignment bar and adjust indicator to rest against pylon (Section V) drive
shaft at distance D (about 7 to 8 inches) from centerline of flexible coupling.

(4) Determine D dimension. (D dimension is distance between centerline of flexible coupling and centerline
of dial indicator.)

(5) Turn pylon drive shaft 360° and record total indicator reading (TIR) and rotational position at which
maximum and minimum TIR readings occur.

NOTE: If unable to obtain TIR readings within specified limits, check horizontal stabilizer support fitting
installation for proper shimming. (Refer to Maintenance Practices, 55-10-00.)

NOTE: These TIR readings are equivalent to 0.27° lateral.

(6) If TIR maximum and minimum readings occur within 6 30° of fore-and-aft, the maximum permissible TIR
misalignment is calculated as follows:

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TIR(max) = 0.0125 x D

(7) If TIR maximum and minimum readings occur at greater than 6 30° of fore-and-aft (within 6 60° of left
and right), the maximum permissible TIR misalignment is calculated as follows:

TIR (max) = 0.0094 x D

(8) If TIR is more than 0.0125 x D or 0.0094, as applicable, before further flight, contact Commercial
Customer Service for additional instructions.

(9) Remove dial indicator and alignment bar from output flange and coupling.

(10) Install bolt through coupling and flange making sure washer and shim stackup is not disturbed and
install nut. Torque nut to 200 inch-pounds.

(11) Install tail cone fairing.

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SECTION I

SECTION V

SECTION II, III, IV

NUT

THIN AND
THICK WASHER

SPHERICAL
WASHER

BOLT

CB0288
SA

Tail Drive Shaft Flange-to-Shaft Hardware Inspection

Figure 601
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 S-76B
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TORQUE
STRIPE

FWD

CB0289
SA

Tail Drive Shaft Flange-to-Shaft Hardware Torque Stripe Inspection

Figure 602

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 S-76B
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STA
0

30O 30O 30O 30O

TIR MAX = TIR MAX = TIR MAX = TIR MAX = TIR MAX =
0.0125 x D 0.0094 x D 0.0125 x D 0.0094 x D 0.0125 x D

VIEW A

TIR MAX =
0.0125 x D

30O 30O
SECTION V
STA TAIL DRIVE SHAFT
0

60O FWD 60O

TIR MAX = TIR MAX = DIAL

LEFT RIGHT INDICATOR
0.0094 x D 0.0094 x D

60O 60O
AFT

D
30O 30O

TIR MAX =
0.0125 x D ALIGNMENT
BAR

VIEW A
JAMNUT

JAMNUT FLEXIBLE
COUPLING

SHIMS

INTERMEDIATE
GEAR BOX
D = DISTANCE BETWEEN CENTERLINE OF FLEXIBLE OUTPUT FLANGE
COUPLING AND DIAL INDICATOR PLUNGER, SEVEN
TO EIGHT INCHES.

FORMULA:
TIR MUST EQUAL NO MORE THAN 0.0125 x D WHEN
READINGS OCCUR WITHIN 30O OF FORE−AND−AFT.
TIR MUST EQUAL NO MORE THAN 0.0094 x D WHEN
READINGS OCCUR AT GREATER THAN 30O OF FORE−
AND−AFT (WITHIN 60O OF LEFT AND RIGHT).

CB0651
SA

Section V Tail Drive Shaft - Alignment Check

Figure 603
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TAIL DRIVE SHAFT - CLEANING/PAINTING

1. Cleaning/Painting Tail Drive Shaft.

A. Clean Tail Drive Shaft.

CAUTION: TO PREVENT WATER AND/OR DEGREASING SOLVENTS FROM ENTERING GREASE

PACKED AREA OF BEARINGS, DO NOT USE SOLVENTS, CLEANING AGENTS, OR DETER-
GENTS ON TAIL DRIVE SHAFT VISCOUS DAMPER ASSEMBLIES.

CAUTION: DO NOT DIRECT HIGH PRESSURE WATER FLOW AT TAIL DRIVE SHAFT VISCOUS DAMPER
ASSEMBLIES OR SUPPORTS.

NOTE: Do not use brushes, spray or aerosol applicators, or compressed air.

(1) Clean surfaces of tail drive shaft using clean rags moistened sparingly with kerosene, Fed. Spec VV-K-
211 or dry-cleaning solvent, Fed. Spec P-D-680, Type II. Thoroughly wipe dry of cleaning agents, all
cleaned surfaces.

(2) Clean tail drive shaft viscous damper assemblies using clean rags or towels.

66-40-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TAIL DRIVE SHAFT - APPROVED REPAIRS

1. Scratches.

A. General.Repair of tail drive shaft is limited to polishing out scratches on the tubular shaft. Polishing must not
be done on flanges or stub shafts. Tubular shaft may be polished to a depth of not over 0.010 inch. Total
repaired surface of any one shaft not to go beyond 5 square inches.

2. Repair Bearing Support Assembly.

A. Prepare for Repair.

(1) Special Tools and Equipment.

(a) Torque Wrench, 50 - 150 inch-pounds.

(b) Locally Fabricated 12 point socket.

B. Replace Bearing Support and Bearing (Figure 801).

(1) Remove applicable tail drive shaft section. (Refer to Removal/Installation.)

(2) Temporarily match mark flange and tail drive shaft to make sure flange is reinstalled in same position to
maintain shaft balance.

NOTE: All shaft to flange attaching hardware is one time use. After removal discard bolts, radius
washers, washers, and nuts.

(3) Use locally fabricated 12 point socket to access nuts securing flange to tail drive shaft. If locally fabri-
cated 12 point socket is unavailable, remove snapring closest to flange and slide bearing support
assembly away from flange to access nuts with common tools.

(4) Remove bolts, radius washers, washers and nuts securing flange to tail drive shaft. Remove flange from
tail drive shaft.

(5) Remove bearing support assembly from tail drive shaft.

(6) If snapring was removed in step (3) and bearing will not be replaced, reinstall snapring. Make sure
snapring is seated and locked in groove.

(7) If replacing bearing, do as follows:

(a) Remove snaprings and press out bearing from support.

(b) Coat OD of new bearing and ID of bearing liner with corrosion preventive compound, MIL-PRF-
81309, Type II or III, and press bearing into support. Remove excess squeeze out. Install snaprings.

(8) Install bearing support assembly on tail drive shaft so that bearing inner race is over liner on shaft.

(9) Line up match marks and install flange on tail drive shaft.

NOTE: Do not prime threads of bolts.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

NOTE: All shaft to flange hardware is one time use. When installing flange on tail drive shaft for shaft
assemblies 76361-04004 or 76361-04604, use new bolts, radius washers, washers, and
nuts.

(10) Coat grip length of new bolts, and contact surfaces of new radius washers and washers with Epoxy
Polyamide Primer, MIL-PRF-23377.

NOTE: Make sure that radius washer is properly seated against the inside diameter of the tail drive
shaft.

(11) With primer wet, secure flange to tail drive shaft with new bolts, radius washers, washers, and nuts as
follows:

(a) Hand tighten attaching hardware in all locations.

(b) Use locally fabricated 12 point socket to access nuts securing flange to tail drive shaft. If locally
fabricated 12 point socket is unavailable, remove snapring closest to flange and slide bearing
support assembly away from flange to access nuts with common tools.

CAUTION: THE NUT, SS5086-04, IS TO BE TO BE TORQUED WHILE THE BOLT IS HELD

STATIONARY.

(c) Measure prevailing torque of nuts at every location and record value. Prevailing torque values
should be between 3.5 - 30 inch-pounds. If prevailing torque value on any nut is below 3.5
inch-pounds, replace nut. If prevailing torque value on any nut is above 30 inch-pounds, replace
nut and bolt.

(d) Torque nuts to 50 inch-pounds in the sequence shown in Figure 803.

(e) Repeat torque sequence on nuts at 75 inch-pounds.

(f) Repeat torque sequence on nuts at 105 - 115 inch-pounds plus measured prevailing torque for
each location until torque has stabilized for each location.

(g) If snapring was removed in step (b), reinstall snapring. Make sure snapring is seated and locked
in groove

(12) Apply torque stripe, to nuts, washers, and bolt ends. (Refer to Torque Striping Hardware, 20-04-00.)

(13) Install tail drive shaft section. (Refer to Removal/Installation.)

3. Viscous Damper Tube Replacement.

A. Replace Viscous Damper Tube (Figure 801).

(1) Remove bearing support assembly from tail drive shaft and press out bearing from support. (Refer to
paragraph 2.)

(2) Remove snapring and inner housing from outer housing.

(3) Remove viscous damper tube from outer housing. Remove filler screws from tube.

(4) Install new viscous damper tube in outer housing. Make sure tube is properly seated. Install filler screws.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

NUT
(TORQUE LINER
105−115 IN. LBS)
A
TAIL DRIVE
WASHER SHAFT

FLANGE

RADIUS WASHER
BOLT

BEARING SUPPORT
ASSEMBLY

A B
FILLER SCREW
(TORQUE
B 10−20 IN. LBS)

INNER
HOUSING

SNAPRING
SNAPRING SNAPRING

BEARING
OUTER
HOUSING
VISCOUS
DAMPER
SUPPORT
TUBE

CB0136B
SA

Bearing Support Assembly - Approved Repairs

Figure 801
66-40-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

0.435
1/4 INCH DRIVE x 7/16 INCHES 0.425
12 POINT SOCKET (MCMASTER
P / N 5543A35 OR EQUIVALENT)
0.300 MIN
A

0.600 (REF)

0.130 O
A 0.120 X 45

SECTION A−A

CS0402
SA

Locally Fabricated 12 Point Socket

Figure 802
(5) Install inner housing and secure with snapring.

(6) Seal joint between tube filler neck and support with sealing compound, AMS-3265, Class B.

(7) Install bearing in support assembly. (Refer to paragraph 2.)

CAUTION: THE INTERNAL CAVITY OF THE VISCOUS DAMPER BLADDER ASSEMBLIES MAY CON-
TAIN A WHITE POWDER (SODIUM CYANIDE, HAZARDOUS SUBSTANCE). USE EYE
AND RESPIRATORY PROTECTION AND RUBBER GLOVES DURING FLUSHING AND
SERVICING PROCEDURES.

(8) Remove filler screws and fill viscous damper tube, before sealing, to capacity with silicone fluid, DC-200
(100 centistokes). With support assembly in vertical position, air bubble shall not be greater than 0.50
inch in length.

NOTE: If filler screws (NT352R0632VC-4N) are used in viscous damper tube, Permatex Aviation
Form-A-Gasket and the lockwiring requirement, of the screws, is not required. Filler screws
(NT352R0632VC-4N) have a gasket installed under each screw head and the screw heads
are not drilled.

(9) Coat threads of screws (MS35265-26) with Permatex Aviation Form-A-Gasket. Torque screws to 10-20
inch-pounds and lockwire.

NOTE: If fluid leakage occurs at filler screws after installation with Permatex, screws may be installed
using Permacel ribbon dope thread sealant, P412, in addition to application of Permatex.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

1
BOLT
NUT

THIN WASHER
THICK WASHER

RADIUS WASHER

4 3

2 CS0323
SA

Flange Torque Sequence

Figure 803
(10) Install bearing support assembly onto tail drive shaft. (Refer to paragraph 2.)

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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
FLEXIBLE COUPLINGS- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 1).

Flexible couplings are between adjoining flanges of the tail drive shaft sections and gear boxes and serve to
compensate for minor misalignments. Each flexible coupling is 0.173 to 0.185 inch thick and consists of a stackup
of 15 6 1 stainless steel discs. The discs are marked A and B. Each is indexed by flats to make sure they line up
when stacked. In A discs, the grain direction is perpendicular to the indexing flats, and in B discs the grain
direction is parallel to the indexing flats. When the discs are stacked to make a coupling, the grain direction of the
A discs is laid 90° opposite that of the B discs. This is assured by alternating the A and B discs and making certain
the indexing flats are in line.

CAUTION: IF ANY ONE OF THE FLEXIBLE STEEL DISCS IS DAMAGED, REPLACE ENTIRE STACK UP. DO NOT
SEPARATE DISCS DURING HANDLING, AS INCORRECT REASSEMBLY MAY OCCUR. INFORMA-
TION IS PROVIDED FOR BETTER UNDERSTANDING OF OPERATION ONLY.

66-40-01
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
SPHERICAL COUNTERSUNK
WASHER WASHER SPHERICAL
WASHER
WASHER

NUT NUT
BOLT (TORQUE (TORQUE
200 IN. LBS) 200 IN. LBS)
BOLT

FLEXIBLE FLANGE FLANGE

COUPLING FLEXIBLE
COUPLING

DETAIL A DETAIL B

INDEXING
FLAT

NOTES

1. FLEXIBLE COUPLING ATTACHMENT TO

A B A B
FORWARD END OF SECTION I AND AFT
END OF SECTION V OF TAIL DRIVE
SHAFT. (DETAIL A)
2. FLEXIBLE COUPLING ATTACHMENT TO
FORWARD END OF SECTION V AND AFT
END OF SECTION I, II, III AND IV OF TAIL
DRIVE SHAFT. (DETAIL B)
3. GRAIN DIRECTION OF DISC A DETAIL C
PERPENDICULAR TO INDEXING FLATS.
GRAIN DIRECTION OF DISC B
PARALLEL TO INDEXING FLATS.
(DETAIL C)
S76A_47498 (C27)
SA

Flexible Couplings
Figure 1

66-40-01
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

FLEXIBLE COUPLINGS - MAINTENANCE PRACTICES

1. Removal/Installation Flexible Couplings.

A. Remove Flexible Couplings (Figure 1).

(1) Remove applicable tail drive shaft section. (Refer to Removal/Installation, 66-40-00.)

(2) Unbolt and remove flexible couplings from tail drive shaft.

B. Install Flexible Couplings (Figure 1).

(1) Apply a coat of primer, MIL-PRF-23377, to bolt grip length and to washers that contact flange.

(2) Attach flexible coupling to applicable tail drive shaft flange as follows:

CAUTION: IN THE FOLLOWING STEPS, SPHERICAL SIDE OF SPHERICAL WASHERS MUST ALWAYS
BE INSTALLED AGAINST FLEXIBLE COUPLINGS.

(a) For forward end of Section I and aft end of Section V, install bolts, spherical washers, washers, and
nuts. Torque nuts to 200 inch-pounds (Detail A).

(b) For forward end of Section V and aft end of Sections I, II, III, and IV, install bolts, countersunk
washers (with countersunk side facing bolthead), spherical washers, and nuts. Torque nuts to 200
inch-pounds (Detail B).

(3) Install applicable tail drive shaft section. (Refer to Removal/Installation, 66-40-00.)

(4) If Section V tail drive shaft/flexible coupling maintenance was performed, check Section V tail drive
shaft alignment. (Refer to Inspection/Check, paragraph 4.)

2. Inspection/Check Flexible Couplings.

A. Inspect Flexible Couplings. Do this procedure when required by the Scheduled Maintenance Checks, 5-20-
00.

(1) Clean OD of flexible coupling by wiping with clean cloth.

(2) Visually inspect OD of coupling discs for evidence of cracks, paying particular attention to area around
attachment boltholes.

CAUTION: IF ANY ONE FLEXIBLE STEEL DISC IS CRACKED, REPLACE ENTIRE COUPLING.

(3) Replace any flexible coupling with cracks.

(4) Inspect flexible coupling for gaps between discs. No more than 0.030-inch spread between discs is
permitted. Loosen all bolts and retorque if gap of 0.030 inch between discs is found.

(5) Apply clear corrosion-preventive compound, MIL-DTL-85054, or equivalent, to couplings.

NOTE: Flexible couplings examined and found discolored or seeming to be rusted are not corroded.
This condition is caused by fretting, which is not cause for rejection and replacement of
coupling, unless beyond limitations. Couplings with this condition can be cleaned and in most

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

cases reused. If any other discrepancies are found or for additional limitations and approved
repairs, refer to Inspect Removed Couplings and Approved Repairs.

B. Inspect Removed Couplings. When flexible couplings are removed for any special inspections, inspect cou-
plings as follows:

(1) Disassemble flexible coupling and visually inspect each coupling disc for distortion, twisting, and/or
bending. Bending of individual discs not more than 1/64 inch is acceptable. Replace entire coupling if
disc is found bent more than 1/64 inch.

NOTE: Discs may not lie flat after use. This, in itself, is not cause for rejection.

NOTE: Individual disc can be replaced if damage was caused only by mishandling.

(2) Inspect each disc for cracks, especially at edge of each bolthole.

CAUTION: IF ANY ONE FLEXIBLE STEEL DISC IS CRACKED, REPLACE ENTIRE COUPLING.

(3) Inspect edges of each disc for nicks and dents. Nicks and dents on edges of individual discs not more
than 0.020 inch deep are acceptable if they are blended out. (Refer to Approved Repairs.)

(4) Inspect for fretting of discs, paying particular attention to area where washers touched. Fretting is
acceptable provided it is not more than 0.0005 inch deep and the fretting is blended out. (Refer to
Approved Repairs.)

(5) Replace entire coupling if fretting is over 0.0005 inch deep.

(6) Check boltholes for elongation. Replace entire coupling if holes are elongated.

(7) Make certain flexible couplings are properly assembled before installing them. (Refer to Description and
Operation.)

3. Approved Repairs Flexible Coupling.

A. Fretting.

(1) Fretting of a disc that results in loss of thickness of up to 0.0005 inch is considered acceptable. Any
fretting above this limit is considered unacceptable. Fretting within acceptable limits should be removed.
Use a 400-grit wet or dry paper, such as abrasive paper, Fed. Spec P-P-101, followed by crocus cloth,
Fed. Spec P-C-458, to blend it out.

NOTE: If fretting is found in area of etched part numbers, determine whether disc is A or B type before
repair. Tag or mark disc with felt-tip pen. A and B identifications are required for proper
stackup of flexible coupling.

(2) After fretting has been removed, measure thickness of disc in repaired areas. If more than 0.0005 inch
has been lost from original thickness, replace entire coupling.

(3) If fretting clean-up results in loss of identification of disc type (A or B), reidentify disc as recorded in
NOTE after step (1) , using electroetch method.

NOTE: If disc type cannot be determined, replace disc.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

B. Nicks and Dents.

(1) Blend out any nick or dent that is not more than 0.020 inch deep. Disc is then acceptable.

NOTE: Individual disc can be replaced if nick or dent is more than 1/64 inch deep and damage was
caused only by mishandling.

NOTE: No more than half the total number of discs in coupling assembly may be blended out.

66-40-01
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
ROTOR BRAKE SYSTEM- DESCRIPTION AND OPERATION

1. General.

A rotor brake system is available to keep the rotors from turning when the helicopter is parked, while starting the
engines, and to assist in stopping the rotors after engine shutdown. A manually-operated hydraulic brake is
installed.

2. Description (Figure 1).

The system consists of a master cylinder and system pressure gage in the cockpit overhead above the pilot, an
accumulator/reservoir installed on the upper main gear box housing, a brake and disc assembly bolted to the tail
rotor drive shaft takeoff flange at the main gear box, a ROTOR BRAKE caution light on the caution/advisory
panel, and a circuit breaker marked RTR BRK WARN on the lower circuit breaker panel. The accumulator/
reservoir also contains a pressure relief valve, bleed valve, and pressure switch.

3. Operation (Figure 2).

The manual rotor brake system is controlled by the master cylinder handle. By stroking rotor brake handle twice,
at least 200 psi hydraulic pressure is produced, as indicated on the cockpit pressure gage, which actuates
opposing lined pistons in both brake assemblies. This produces a clamping action on a rotating disc bolted to the
tail rotor drive shaft takeoff flange on the main gear box. After the rotor head is stopped, the rotor brake handle
can be stroked to obtain a maximum of 300 6 30 psi which is the opening pressure for the system relief valve.
The accumulator will maintain a system pressure of about 255 psi (closing pressure of system relief valve) to
prevent rotation of the rotors when the helicopter is parked. An overcenter linkage in the master cylinder will hold
the brake handle in the park position. When pressure in the system is greater than 10 psi, the contacts of the
pressure switch installed in the accumulator/reservoir close, supplying power to turn on the ROTOR BRAKE
caution light. Power for the caution light circuit is supplied by the RTR BRK WARN circuit breaker on the lower
circuit breaker panel. To release the rotor brake, the master cylinder handle is placed in off detent. This action
releases system pressure. When system pressure goes below 7 psi, the ROTOR BRAKE caution light goes off.

Rotor brake system limitations and operating precautions:

A. Rotor brake application with rotor turning is limited to one or two engines operating at idle or both engines
shut down.

B. Normal Nr for rotor brake application with one or both engines at idle or with both engines shut down is 40%
to 60% Nr.

C. Maximum rotor speed for normal rotor brake application is 65% Nr.

D. Maximum rotor speed for emergency rotor brake application with both engines shut down is 107% Nr.

E. Engine operation with rotor stopped (rotor brake applied) is limited to one or both engines at idle.

F. A rotor stop using the rotor brake shall not be performed more than once in any 10-minute period.

G. With one or both engines operating and rotor stopped, the main rotor blades must be positioned at approxi-
mately 45° to the longitudinal axis of the helicopter.

66-50-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

P912 / J912

P900 / J900

P118 / J118

C
D
FW

ROTOR BRAKE
LOWER CIRCUIT
BREAKER PANEL B

C
D

P1 A

P212 / J212
D

MASTER
CYLINDER

ROTOR
BRAKE

PRESSURE
GAGE

P920

D
CAUTION ADVISORY PANEL FW

MASTER CYLINDER ACCUMULATOR/RESERVOIR CB0114

SA

Rotor Brake System - Location Diagram Rotor Brake System - Location Diagram
Figure 1 (Part 1 of 2) Figure 1 (Part 2)
66-50-00 66-50-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

SIGHT GAGE FILLER

ACCUMULATOR / RESERVOIR

PRESSURE RELIEF VALVE

OPEN 300 30 PSI
CLOSED 255 PSI

ROTOR BRAKE
CAUTION
LIGHT

CAUTION LIGHT
PRESSURE SWITCH
(NOTES 1 AND 2) B

A C

MASTER CYLINDER

HANDLE GAGE

RTR BRK WARN

DC
ESNTL 2
AMP

ROTOR BRAKE
NOTES
LEGEND
1. PINS B AND C OPEN, AND PINS B AND
A CLOSE WHEN PRESSURE PRESSURE
INCREASES TO 10 PSI.
2. PINS B AND A OPEN, AND PINS B AND C RETURN
CLOSE WHEN PRESSURE DECREASES
TO 6 3 PSI. WIRING
CC1990
SA

Rotor Brake System - Simplified Schematic Diagram

Figure 2
H. Maximum manual rotor brake application is not recommended when commenced below 30% Nr. Brake
applications begun at less than 30% Nr should be light enough to produce a smooth, gentle stop. Sudden
stoppage of helicopter rotor blades exposes components to abnormal forces that may cause damage. Fol-
lowing sudden stoppage it is necessary to inspect or replace and overhaul or scrap these components,
depending on the degree of sudden stoppage experienced. For coverage of sudden stoppage inspection and
disposition of components, refer to Inspection/Check, 65-11-00, 65-12-00, and 66-10-00.

I. If rotor should begin to turn during engine start with rotor brake on, shut down the engine(s) or release the
rotor brake. Refer to Flight Manual for emergency procedures.

J. If ROTOR BRAKE caution capsule goes on with rotor brake handle in off detent and with rotor turning with
helicopter on the ground, shut down engines and troubleshoot rotor brake system.

66-50-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
K. If ROTOR BRAKE caution capsule goes on during flight, make sure rotor brake handle is in off detent. If
ROTOR BRAKE caution capsule remains on, check for rotor brake fire (smoke, unusual noises or vibrations,
etc.). If rotor brake fire is suspected, land immediately.

L. Although the rotor brake is capable of holding the rotor with both engines at ground idle, persons must be
alert to the possibility or a rotor strike since brake slippage or release will allow the rotor to turn. Treat the
rotors as if they are turning whenever an engine is running.

66-50-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
ROTOR BRAKE SYSTEM - TESTING AND TROUBLESHOOTING

1. Testing and Troubleshooting.

A. Operational Test (Figures 101 and 102).

(1) On lower circuit breaker panel, make certain RTR BRK WARN circuit breaker is pushed in.

(2) Place BATT switch, on master switch panel, ON.

(3) Place rotor brake handle in off detent.

RESULT:

- ROTOR BRAKE caution capsule should go off within 3 seconds.

- Rotor brake pressure gage should indicate 0 psig.

CORRECTIVE ACTION:

- If ROTOR BRAKE caution capsule is on but no pressure is indicated on rotor brake pressure gage, go
to Trouble No. 1.

- If ROTOR BRAKE caution capsule is on and pressure is indicated on rotor brake pressure gage,
replace master cylinder.

(4) Move rotor brake handle slightly out of off detent.

RESULT:

- ROTOR BRAKE caution capsule should go on.

- There should be no pressure indicated on rotor brake pressure gage.

CORRECTIVE ACTION:

- If ROTOR BRAKE caution capsule does not go on, go to Trouble No. 2.

- If pressure is indicated on rotor brake pressure gage, go to Trouble No. 3.

(5) Stroke rotor brake master cylinder handle twice.

RESULT:

- Rotor brake pressure gage should indicate at least 200 psi.

CORRECTIVE ACTION:

- If rotor brake pressure gage does not indicate at least 200 psi, go to Trouble No. 4.

(6) Slowly stroke rotor brake master cylinder until the accumulator relief valve opens. Indicated pressure on
the rotor brake pressure gage will begin to decrease when this occurs.

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 S-76B
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RESULT:

- Rotor brake pressure gage should indicate from 270 to 330 psi when relief valve opens.

- Accumulator relief valve should close at 255 psi or greater as indicated by no further pressure drop
on rotor brake pressure gage.

CORRECTIVE ACTION:

- If rotor brake pressure gage indicates less than 270 psi or more than 330 psi when valve opens, or
less than 255 psi when valve closes, replace accumulator/reservoir.

(7) Place rotor brake handle in off detent.

RESULT:

- ROTOR BRAKE caution capsule should go off within 3 seconds.

- Rotor brake pressure gage should indicate 0 psig.

CORRECTIVE ACTION:

- If ROTOR BRAKE caution capsule is on and pressure is indicated on rotor brake pressure gage,
replace master cylinder.

(8) Place BATT switch, on master switch panel, OFF.

(9) Stroke rotor brake master cylinder until a minimum of 255 psi is indicated on rotor brake pressure
gage.

(10) Wipe off any residual hydraulic fluid from rotor brake components.

(11) Maintain rotor brake handle in LOCKED position for minimum of 8 hours.

RESULT:

- Rotor brake pressure should not decrease more than 10 psi.

- There should be no evidence of external leakage at any rotor brake component.

CORRECTIVE ACTION:

- If pressure decreases more than 10 psi and there is no evidence of external leakage, replace
accumulator/reservoir.

- If evidence of external leakage is observed: repair leak, bleed system, and repeat check.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TROUBLE NO. 1 TROUBLE NO. 2

WITH BATT SWITCH ON AND ROTOR ROTOR BRAKE CAUTION CAPSULE
BRAKE HANDLE IN OFF DETENT, DOES NOT GO ON WITH BATT SWITCH
ROTOR BRAKE CAUTION CAPSULE IS ON AND ROTOR BRAKE HANDLE
ON BUT NO PRESSURE IS INDICATED SLIGHTLY OUT OF OFF DETENT.
ON GAGE.

DISCONNECT CONNECTOR P920 CHECK THAT RTR BRK WARN

FROM PRESSURE SWITCH ON CIRCUIT BREAKER IS IN.
ROTOR BRAKE ACCUMULATOR /
RESERVOIR. DOES ROTOR YES NO
BRAKE CAUTION CAPSULE GO
OFF?

YES NO

REMOVE PRESSURE SWITCH CHECK FOR SHORTS BETWEEN PUSH TEST BUTTON ON CAU− PUSH IN CIRCUIT BREAKER. IF
FROM ACCUMULATOR / RESER− PINS A AND B OF CONNECTOR TION / ADVISORY PANEL. DOES CIRCUIT BREAKER POPS, CHECK IS ANY PRESSURE INDICATED ON
VOIR AND RECONNECT CON− P920. CAPSULE GO ON? SYSTEM FOR SHORT CIRCUIT. ROTOR BRAKE PRESSURE GAGE?
NECTOR P920 TO SWITCH. DOES REPAIR / REPLACE COMPONENTS
ROTOR BRAKE CAUTION CAP− YES NO OR WIRING AS REQUIRED.
YES NO
SULE GO ON?

YES NO
DISCONNECT CONNECTOR P920 CHECK SYSTEM FOR PROPER
FROM PRESSURE SWITCH ON SERVICING.
CONTINUE TO SLOWLY MOVE REPLACE BULB. ROTOR BRAKE ACCUMULATOR /
REPLACE PRESSURE SWITCH. REPLACE MASTER CYLINDER. ROTOR BRAKE HANDLE OUT OF RESERVOIR. INSTALL JUMPER YES NO
OFF DETENT. DOES CAPSULE GO WIRE BETWEEN PINS A AND B OF
ON? CONNECTOR P920. DOES LIGHT
GO ON?
YES NO
YES NO

IS ANY PRESSURE INDICATED ON

ROTOR BRAKE PRESSURE GAGE? REPLACE PRESSURE SWITCH. CHECK FOR 28 VDC AT PIN A OF REPLACE MASTER CYLINDER. SERVICE SYSTEM AND REPEAT
CONNECTOR P920. OPERATIONAL TEST.
YES NO
YES NO

REPLACE PRESSURE SWITCH ON STROKE ROTOR BRAKE MASTER

ROTOR BRAKE ACCUMULATOR / CYLINDER HANDLE TWICE AND DISCONNECT CONNECTOR P1 WITH POWER OFF, CHECK RTR
RESERVOIR. CHECK FOR A MINIMUM OF 200 FROM CAUTION / ADVISORY BRK WARN CIRCUIT BREAKER
PSI ON GAGE. PANEL. WITH JUMPER INSTALLED FOR CONTINUITY.
BETWEEN PINS A AND B OF CON−
YES NO NECTOR P920, CHECK FOR 28 YES NO
VDC AT PIN L OF CONNECTOR P1.

YES NO

SYSTEM IS OK. BLEED SYSTEM AND REPEAT

CHECK. IF ROTOR BRAKE MAS−
TER CYLINDER STILL CAN NOT
PRODUCE 200 PSI IN TWO REPAIR / REPLACE CAUTION / REPAIR / REPLACE WIRING BE− REPAIR / REPLACE WIRING BE− REPLACE CIRCUIT BREAKER.
STROKES, REPLACE MASTER ADVISORY PANEL. TWEEN PIN L OF CONNECTOR P1 TWEEN RTR BRK WARN CIRCUIT
CYLINDER. AND PIN B OF CONNECTOR BREAKER AND PIN A OF CONNEC−
P920. TOR P920.

S76A_67536_1 (C27)
SA

Rotor Brake System - Troubleshooting Chart Rotor Brake System - Troubleshooting Chart
Figure 101 (Part 1 of 3) Figure 101 (Part 2)
66-50-00 66-50-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TROUBLE NO. 3 TROUBLE NO. 4

ROTOR BRAKE CAUTION CAPSULE ROTOR BRAKE PRESSURE GAGE DOES
GOES ON WHEN ROTOR BRAKE NOT INDICATE A MINIMUM OF 200 PSI
HANDLE IS SLIGHTLY OUT OF OFF WHEN ROTOR BRAKE MASTER CYLIN−
DETENT BUT PRESSURE IS INDICATED DER HANDLE IS STROKED TWICE.
ON ROTOR BRAKE PRESSURE GAGE.

CHECK ROTOR BRAKE ACCUMU−

PLACE ROTOR BRAKE HANDLE IN LATOR / RESERVOIR FOR PROP−
OFF DETENT. ER SERVICING.

YES NO

REMOVE RIGHT MAIN GEAR BOX BLEED SYSTEM AND REPEAT SERVICE AND BLEED SYSTEM.
FAIRING. DISCONNECT ROTOR OPERATIONAL TEST. DOES REPEAT OPERATIONAL TEST.
BRAKE PRESSURE HOSE AND ROTOR BRAKE PRESSURE GAGE CHECK FOR LEAKS.
TEE IN A 0−50 PSI PRESSURE INDICATE 200 PSI WHEN ROTOR
GAGE IN PRESSURE LINE. BRAKE MASTER CYLINDER
HANDLE IS STROKED TWICE?

YES NO

WITH AN ASSISTANT OBSERVING SYSTEM OK. PLACE ROTOR BRAKE HANDLE IN

0−50 PSI GAGE, SLOWLY MOVE OFF DETENT.
ROTOR BRAKE HANDLE OUT OF
OFF DETENT UNTIL ROTOR
BRAKE CAUTION CAPSULE GOES
REMOVE RIGHT MAIN GEAR BOX
ON. DOES 0−50 PSI GAGE READ
FAIRING. DISCONNECT ROTOR
GREATER THAN 10 PSI?
BRAKE PRESSURE HOSE AND
YES NO TEE IN A 0−400 PSI PRESSURE
GAGE IN PRESSURE LINE.

REPLACE ROTOR BRAKE PRES− REPLACE ROTOR BRAKE PRES− WITH AN ASSISTANT OBSERVING
SURE SWITCH. SURE GAGE. 0−400 PSI GAGE, STROKE MASTER
CYLINDER HANDLE TWICE. DOES
0−400 PSI GAGE READ A MINIMUM
OF 200 PSI?

YES NO

REPLACE ROTOR BRAKE PRES− PLACE ROTOR BRAKE HANDLE IN

SURE GAGE. OFF DETENT.

USING A SUITABLE DRIP PAN,

DISCONNECT PRESSURE TUBE
FROM MASTER CYLINDER AND
INSTALL 0−400 PSI PRESSURE
GAGE IN PRESSURE PORT ON
MASTER CYLINDER. STROKE
MASTER CYLINDER HANDLE
TWICE. DOES 0−400 PSI GAGE
READ A MINIMUM OF 200 PSI?

YES NO

REPLACE ROTOR BRAKE AC− REPLACE ROTOR BRAKE MASTER

CUMULATOR RESERVOIR. CYLINDER.

CA0706_2
SA

Rotor Brake System - Troubleshooting Chart

Figure 101 (Part 3)
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 S-76B
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RTR BRK FILLER AND

WARN SCREEN
P118 J118
DC
ESS 2 G
BUS AMP SIGHT
GAGE

SPRING
LOWER CIRCUIT BREAKER PANEL

PISTON
ACCUMULATOR / RESERVOIR

PRESSURE RELIEF VALVE

OPEN > 300 +
_ 30 PSI
CLOSED < 255 PSI

P920
P1 J212 P212 P900 J900 J912 P912 C
ROTOR L M B
G M
BRAKE
L L A

CAUTION / (SEE DETAIL B) CAUTION LIGHT

(SEE DETAIL A)
ADVISORY PANEL PRESSURE SWITCH
(SEE NOTES 2 AND 3)

INSTRUMENT PANEL

SPRING PISTON SPRING

STOP SHUTOFF
RELIEF
VALVE

GAGE

HANDLE REPLENISHMENT PISTON MASTER

LEGEND VALVE CYCLINDER

J900 P900
PRESSURE
M
RETURN
L
WIRING

EFFECTIVITY: HELICOPTERS
PRIOR TO 0419.

NOTES DETAIL A

1. FOR WIRE NUMBERS REFER TO WIRING P212 J212

MANUAL SA4047−76B−3. ROTOR BRAKE
G
2. P920 PINS B AND C OPEN, AND PINS B
AND A CLOSE WHEN PRESSURE
INCREASES TO 10 PSI.
3. P920 PINS B AND A OPEN, AND PINS B EFFECTIVITY: HELICOPTERS
AND C CLOSE WHEN PRESSURE PRIOR TO 0432.
DECREASES TO 6 +_ 3 PSI.
DETAIL B CB0135A
SA

Rotor Brake System - Schematic Diagram

Figure 102
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ROTOR BRAKE SYSTEM - MAINTENANCE PRACTICES

1. Servicing Rotor Brake System.

A. Prepare for Servicing.

(1) Special Tools and Equipment.

(a) Hydraulic Handpump, 1102SP, or equivalent.

B. Servicing.

(1) Release rotor brake pressure by moving handle on master cylinder to off position.

(2) Turn off all electrical power to rotor brake system.

(3) Hinge open left engine air inlet/bypasscowl.

(4) Remove cap on top of accumulator/reservoir.

(5) Using hydraulic handpump, 1102SP, or equivalent, add hydraulic fluid, MIL-H-5606 or MIL-H-83282,
to reservoir until fluid reaches FULL mark on sight gage.

(6) Remove handpump hose and install cap on reservoir.

2. Bleeding Rotor Brake System.

A. Prepare for Bleeding.

(1) Special Tools and Equipment.

(a) Hydraulic Handpump, 1102SP, or equivalent.

B. Bleeding Rotor Brake System (Figure 201, 66-50-05). For proper operation of the manual-hydraulic rotor
brake, with a minimum of master cylinder strokes, the brake system must be fully bled.

NOTE: The master cylinder and brake calipers must be filled with hydraulic fluid and bled before installa-
tion in the helicopter.

(1) Remove protective caps from master cylinder supply and pressure ports. Install return tube on master
cylinder supply port.

(2) With handle in detent position and master cylinder in horizontal position, fill master cylinder through
return tube with hydraulic fluid, MIL-H-5606 or MIL-H-83282, until fluid flows from pressure port.

(3) Cap pressure port, continue filling return tube until overflow point is reached, then install protective plug,
MS21913-6, in end of return tube.

(4) Turn master cylinder to upright position with pressure port at top. Remove protective cap and fill through
pressure port until overflow is reached.

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 S-76B
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(5) Install pressure tube on master cylinder pressure port. Turn master cylinder to horizontal position (handle
side down) and fill pressure tube to overflow.

(6) Remove protective plug from return tube. Both tubes should be at full level at this time. If not, fill to
overflow.

(7) Install master cylinder in helicopter and connect pressure and return tubes to upper deck bulkhead
elbows. (Refer to Removal/Installation, 66-50-02.)

NOTE: In following bleeding steps, do not move master cylinder handle until final system purge (step
18). Master cylinder will remain totally filled if handle is not moved.

(8) Fill brake calipers:

(a) Before installation, fully retract caliper pistons and place suitable shim (approximately 1/2 inch
thick) between brake linings.

(b) Connect hydraulic handpump, 1102SP, or equivalent, to brake caliper inlet port (bottom port on
left and right caliper). While applying pressure with handpump, rotate caliper to six positions, top
up, bottom up, left side up, right side up, front up, and back up and bleed in each position.

(c) Remove handpump and install protective plug on inlet port. Remove shim from between brake
linings.

(d) Install brake calipers on main gear box. (Refer to Removal/Installation, 66-50-01.)

(9) With pressure gage and pressure tube installed in cockpit, connect pressure tube to upper deck bulk-
head elbow and rotate tube to vertical position. Fill gage and pressure tubes with hydraulic fluid. After
filling, rotate tube back to horizontal position and connect to tee in pressure manifold.

(10) On right side of main gear box, remove cap from bleed valve and connect handpump to valve.

(11) Loosen fittings on pressure tubes, 76651-01005-049 and -050, at forward bulkhead elbows and
pump until air free fluid flows from fittings. Tighten fittings at forward bulkhead elbows.

(12) Loosen fitting at caliper end of one brake caliper pressure tube. Pump until air-free fluid flows from
fitting. Tighten fitting. Repeat this procedure for other brake caliper pressure tube.

(13) Open accumulator/reservoir bleed valve by turning clockwise and pump until all entrapped air flows
from bleed valve. Close valve. Remove handpump from bleed valve and install cap on valve.

(14) On right side of main gear box, disconnect aft end of return hose from return tube. Install protective
cap on end of return tube and connect handpump to return hose.

(15) Loosen fitting on return tube, 76651-01005-043, at forward bulkhead elbow and pump until air free
fluid flows from fitting. Tighten fitting; remove handpump, and fill return hose to overflow. Install
protective plug in hose.

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(16) With protective cap on end of return tube and other end connected to accumulator/reservoir, fill
reservoir through filler port to a level above the highest point in return tube. Bleed return tube by
loosening protective cap. Remove protective cap and plug and connect return hose to return tube.

(17) Remove protective cap and plug and connect pressure hose to pressure tube.

(18) Master cylinder in cockpit can now be used for further bleeding of system. Loosen upper deck pressure
line fittings while maintaining pressure until air free fluid flows. Do not retract handle with fittings loose.
Tighten fittings. Bleed at accumulator/reservoir bleed valve and at brake calipers bleed screws.

(19) Pump system to relief valve pressure (valve opens at 300 6 30 psi). Continue to pump (partial retrac-
tion strokes) to further relieve system of air.

(20) With master cylinder handle in off position, service accumulator/reservoir through fill port to replace
any hydraulic fluid lost in bleeding or drain reservoir of excess fluid to FULL level on sight gage using
accumulator/reservoir bleed valve.

3. Flushing Rotor Brake System.

NOTE: Flushing of rotor brake system is recommended every 12 months to remove possibly contaminated
hydraulic fluid.

A. Prepare for Flushing.

(1) Special Tools and Equipment.

(a) Container, suitable

(b) Hydraulic Handpump, 1102SP, McDermott Associates, Inc., or equivalent.

B. Flushing.

(1) Hinge open left engine air inlet/bypass cowl.

(2) Release rotor brake pressure by moving handle on master cylinder to off position.

(3) Turn off all electrical power to rotor brake system.

(4) Remove cap and connect hydraulic handpump, 1102SP, or equivalent, filled with hydraulic fluid, MIL-
H-5606 or MIL-H-83282, through at least one 10-micron filter to fill port on top of accumulator/
reservoir.

(5) Disconnect hydraulic line between accumulator/reservoir and tee below brake assembly at tee, and
position suitable container under line.

(6) Maintain fluid level in hydraulic power unit or accumulator/reservoir at FULL, using handpump.

(7) Pump handle on master cylinder until clean hydraulic fluid flows from hydraulic line into container; then
place handle to off position.

(8) Connect hydraulic line to tee below brake assembly.

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 S-76B
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(9) Make certain sight gage on accumulator/reservoir shows FULL and disconnect handpump.

(10) Install cap on top of accumulator/reservoir.

(11) Bleed rotor brake system. (Refer to paragraph 2.)

4. Deactivate/Reactivate Rotor Brake System.

A. Deactivate rotor brake system.Deactivate rotor brake system when system is known to be malfunctioning or
inoperative and corrective maintenance cannot be accomplished before the next flight.

(1) Make sure master cylinder handle is in the full retracted or detent position, where pin on handle is in full
contact with pin of housing.

(2) Hinge open left engine air inlet/bypasscowl and gain access to rotor brake.

(3) Position suitable container under brake calipers. Remove hydraulic pressure supply line from each
caliper. Have assistant pump master cylinder handle in cockpit until fluid no longer comes out of
pressure line.

(4) Check pressure gage in cockpit. There should be no pressure indicated.

(5) Remove bleed screw from each caliper to make sure calipers are fully drained.

(6) Check clearance between rotating disc and each brake lining pad. There should be 0.050 inch mini-
mum clearance.

(7) Reinstall bleed screws in calipers and lockwire.

(8) Remove pressure line between accumulator tee fitting and calipers.

CAUTION: ROTOR BRAKE CAN INADVERTENTLY BE APPLIED BY THERMAL EXPANSION OF AIR/

FLUID WHEN MAIN GEAR BOX HEATS UP UNLESS VENT HOLE IS IN CAP.

(9) Prior to installing caps (MS21914-4) on elbows installed in each caliper, drill 1/16 (0.062) inch vent
hole in end of cap. Install caps.

(10) In cockpit, pull RTR BRK WARN circuit breaker on lower circuit breaker panel.

(11) Place BATT switch, located on master switch panel, to ON. ROTOR BRAKE caution light should be off.

(12) Move master cylinder handle to out-of-detent position. ROTOR BRAKE caution light should be off, and
no pressure should be indicated on pressure gage.

(13) Secure circuit breaker in pulled position by installing tiedown strap (MS3367-1-9) around stem.

(14) Close and secure left engine air inlet/bypass cowl.

(15) Place placard in cockpit to inform all concerned that rotor brake system has been deactivated.

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 S-76B
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B. Reactivate rotor brake system.Reactivate rotor brake system after corrective maintenance action has been
accomplished.

(1) Hinge openleft engine inlet/bypasscowl and gain access to rotor brake.

(2) Position suitable container under brake calipers and remove caps from caliper inlet elbows.

(3) Remove cap from tee fitting on accumulator and install pressure line between accumulator and brake
calipers.

(4) Fill accumulator/reservoir through fill port to full level on sight gage with hydraulic fluid, MIL-H-5606 or
MIL-H-83282.

(5) Position suitable container under master cylinder in cockpit.

(6) Disconnect pressure line to master cylinder, and connect hydraulic handpump, 1102SP or equivalent, to
line. Install cap (MS21914-4) on pressure port.

NOTE: Ensure master cylinder handle is in the full retracted or detent position.

(7) Pump fluid into system until the pressure gage reads 200 to 250 psi.

(8) Loosen bleed screw on either brake caliper to allow air/fluid to seep out around screw until the pressure
gage reads 880’’ psi. Tighten bleed screw.

(9) Repeat steps (7) and (8) on opposite caliper.

(10) Repeat steps (7) through (9) until air free fluid flows out of bleed port.

(11) Disconnect hydraulic handpump from pressure line in cockpit, remove cap, and connect pressure line
to master cylinder.

(12) Check and reservice accumulator/reservoir if required.

(13) Utilizing master cylinder handle, pump up the system to achieve 300 6 30 psi on the pressure gage.

(14) Slowly loosen bleed screw on either brake caliper to allow air/fluid to seep out. Tighten screw prior to
obtaining 880’’ pressure on the pressure gage in cockpit.

(15) Complete steps (12) through (14) on opposite caliper.

(16) Check system fluid, and repressurize system as outlined in steps (11) and (12).

(17) Tighten bleed screws and lockwire.

(18) Remove tiedown strap installed around the RTR BRK WARN circuit breaker, and reset.

(19) Close and secure left engine air inlet/bypass cowl.

(20) Do an operational test of rotor brake system. (Refer to Testing and Troubleshooting.)

(21) Remove deactivation placard in cockpit.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
ROTOR BRAKE- DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

The hydraulic, disc-type rotor brake is mounted on the rear cover of the main gear box. Two brake assemblies are
mounted 180° apart, with the brake disc rotating through them. The two brake assemblies contain replaceable
brake linings (pucks) which, when actuated hydraulically, produce a clamping action on the rotating disc. The
brake disc is bolted to the main gear box tail takeoff flange. On some helicopters a hinged cover may be installed
to allow access to the rotor brake for doing disc-to-puck clearance checks. On CAA registered helicopters a rotor
brake shield is installed that has a hinged door to allow access for the clearance checks. The rotor brake receives
hydraulic power from the master cylinder mounted overhead in the cockpit and the accumulator/reservoir
mounted on the main gear box upper housing.

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MAINTENANCE MANUAL, SA 4047-76B-2

ROTOR BRAKE - MAINTENANCE PRACTICES

1. Removal/Installation Rotor Brake.

A. Remove Rotor Brake (Figure 201 or 202).

(1) Hinge open left engine air inlet/bypass cowl.

(2) Remove access panels and ducting as necessary to get to rotor brake mounted on main gear box rear
cover. (Refer to Oil Cooler Ducts, 79-10-04.)

(3) Turn off all electrical power and disconnect electrical connector from rotor brake accumulator/reservoir
on main gear box upper housing.

(4) Disconnect hydraulic tube from tee between left and right brakes, and drain system into suitable con-
tainer. Remove hydraulic tubes and tee from left and right brakes.

(5) If necessary, unclamp and remove hydraulic tube from accumulator/reservoir.

NOTE: Bolts attaching the shield assemblies and brake to the main gear box have a one time use.

(6) Remove bolts, washers, and shields, and remove left and right brake from main gear box rear cover.

(7) On CAA registered helicopters with rotor brake shield, 76076-35001, remove bolts and washers and
bolts, washers and nuts securing cover to plate. Release hinged door fastener and remove covers from
plate. Remove bolts and washers securing left and right brakes to main gear box cover.

(8) Remove union, nut, retainer, and packing from bottom of each brake.

(9) Unbolt and remove Section I of tail rotor drive shaft. (Refer to Removal/Installation, 66-40-00.)

(10) Remove bolts, washers, and nuts, and remove brake disc and shim from tail takeoff flange.

NOTE: Shim is an assembly consisting of six pairs of shim halves. One or more unused pairs may be
installed against forward face of takeoff flange.

(11) On CAA registered helicopters with rotor brake shield, 76076-35001, remove plate from tail takeoff
flange.

B. Install Rotor Brake (Figure 201 or 202).

(1) On CAA registered helicopters with rotor brake shield, 76076-35001, position plate over tail takeoff
flange.

(2) Position brake disc on tail takeoff flange, and secure with bolts, washers, and nuts. Torque nuts to 100
inch-pounds. Do not install shim now.

(3) Dip packings in hydraulic fluid, MIL-H-5606, and install union, nut, retainer, and packing in bottom of
each brake.

NOTE: Brake calipers must be completely filled and bled before installation. (Refer to Bleeding Rotor
Brake System, 66-50-00.)

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(4) Temporarily install left and right brakes against gear box rear cover and secure with bolts and washers.
Do not install shields at this time.

(5) Measure gap between brake disc and brake housings on both sides of disc. Subtract smaller gap from
larger gap and divide result by two. Prepare shim to match this dimension.

(a) From six pairs of shim halves select one or more pairs whose total thickness is closest to required
dimension.

NOTE: Complete shim assembly is made up of three pairs of shim halves 0.015 inch thick, two
pairs 0.025 inch thick, and one pair 0.045 inch thick.

(6) Unbolt and remove left and right brakes from rear cover and brake disc from tail takeoff flange.

(7) Position selected thickness of shim and brake disc on tail takeoff flange and secure with bolts, washers,
and nuts. Torque nuts to 100 inch-pounds.

(a) Place only selected pair or pairs of shim halves between takeoff flange and brake disc, install bolt
and washer in each hole, and install remaining pairs of shim halves on bolts against forward face
to flange.

(8) Insulate mating surfaces of left and right brake and main gear box rear cover with primer, MIL-PRF-
23377.

NOTE: Bolts attaching shield assembly and brake to the main gear box are self-locking and have a
one time use. A minimum prevailing torque of 9.0 inch-pounds is required. Use new bolts for
installation.

(9) Apply several drops of Threadlocker, Loctite 271 to portion of threads of the bolts attaching shield
assemblies to the main gear box.

(10) Position left and right brakes over disc and against gear box rear cover. Locate two lower mounting
holes and install shields over disc using new bolts and washers. Install three washers between shields
and rotor brake at each mounting location. Torque bolts to 325 inch-pounds.

(11) On CAA registered helicopters with rotor brake shield, 76076-35001, position left and right brakes
over disc and against plate at main gear box cover. Locate brake mounting holes in plate and secure
brakes to main gear box cover with bolts and washers. Torque bolts to 325 inch-pounds.

(12) Install covers to plate with bolts and washers, and bolts, washers, and nuts. Torque bolts or nuts to
95-105 inch-pounds. Close and secure hinged door on cover.

(13) Apply sealing compound, AMS 3265, Class A, to joining areas of brakes and gear box rear cover.

(14) Install hydraulic tubes and tee between union on left brake and right brake.

(15) Connect hydraulic tube to tee between left and right brakes. If tube was completely removed, connect
upper end to elbow on accumulator/reservoir.

(16) If necessary, clamp hydraulic tube to bracket at top of main gear box using clamp, screw, washers,
and nut. Clamp hydraulic tube to bracket at bottom of main gear box using clamp, bolt, washer, and
nut.

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(17) Install Section I of tail rotor drive shaft. (Refer to Removal/Installation, 66-40-00.)

(18) Connect electrical connector to accumulator/reservoir on main gear box upper housing.

(19) Service rotor brake system. (Refer to Servicing, 66-50-00.)

(20) Bleed rotor brake system. (Refer to Servicing, 66-50-00.)

(21) Check clearance between brake disc and each lining (puck). (Refer to Inspection/Check, paragraph
C.)

(22) Install ducting and access panels which were removed to get to rotor brake. (Refer to Oil Cooler Ducts,
79-10-04.)

(23) Close and secure left engine air inlet/bypass cowl.

(24) Do an operational test of rotor brake system. (Refer to Testing and Troubleshooting, 66-50-00.)

2. Inspection/Check Rotor Brake.

CAUTION: THE INDIVIDUAL COMPONENTS THAT MAKE UP THE ROTOR BRAKE SYSTEM (DISC, LININGS/
PUCKS, AND CALIPERS) MUST BE FROM THE SAME MANUFACTURER. NO INTERMIXING IS
PERMITTED.

A. Rotor Brake Linings Wear Inspection.

(1) Hinge open engine air inlet/bypass cowls.

(2) Apply rotor brake by moving master cylinder handle forward (two strokes required).

(3) Clean top portion of brake linings and exposed piston housings using cotton swab and dry-cleaning
solvent, MIL-PRF-680, Type II or equivalent.

(4) Inspect brake lining wear. Measure thickness of all four linings. Replace all four linings if any lining
thickness is less than 0.100 inch. (Refer to Approved Repairs.)

(5) Close and secure engine air inlet/bypass cowls.

B. Rotor Brake Disc Inspection. Refer to Goodrich Component Maintenance Manual, 2-1489 or Parker Hannifin
Component Maintenance Manual, PH030-21300MM Revision C or later revision, as applicable.

(1) At each 600-hour inspection interval for rotor brake lining wear, conduct a dimensional thickness
inspection of the rotor brake disc, 76363-09103-102/-105, in the area of lining contact per steps (a)
through (f) below.

(a) Using Disc Brake - Ball Joint Caliper, 9950500 (Chicago Brand) or equivalent, measure the thick-
ness of the disc in the lining contact area at three locations approximately 120° apart.

(b) Average the three readings to obtain disc thickness.

(c) Replace brake disc, 76363-09103-102/-105, if disc thickness is 0.495 inch or less. (Refer to
Removal/Installation.)

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 S-76B
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SHIELD

BOLT,
WASHERS,
(TORQUE 325
IN. LBS)

TAIL TAKEOFF
FLANGE

BLEED
SCREW

SHIM BLEED
LEFT BRAKE
SCREW

MAIN GEAR BOX

REAR COVER
BOLT,
WASHERS,
NUT
(TORQUE BRAKE SCREW,
100 IN. LBS) DISC WASHERS,
NUT

HYDRAULIC
RIGHT TUBE
BRAKE

SHIELD UNION, NUT, CLAMP

UNION, NUT, RETAINER,
RETAINER, PACKING
PACKING

BOLT, WASHERS
(TORQUE 325 BOLT,
IN. LBS) WASHER,
NUT
HYDRAULIC
TUBE
CLAMP

TEE
D
FW
HYDRAULIC
TUBE S76B_151322 (C6)
SA

Rotor Brake - Removal/Installation

Figure 201
66-50-01
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

HINGED
BOLT, DOOR
WASHER
(TORQUE
TAIL TAKEOFF
95−105
FLANGE
IN. LBS)

COVER

BOLT,
WASHER
(TORQUE
BLEED 95−105
SCREW IN. LBS)
COVER
LEFT
BOLT, BRAKE
WASHERS,
(TORQUE 325
IN. LBS)

SHIM

BOLT,
WASHER,
NUT
(TORQUE
95−105
BOLT, IN. LBS)
WASHERS, PLATE
NUT MAIN GEAR BOX
(TORQUE BLEED REAR COVER
100 IN. LBS) SCREW

BRAKE SCREW,
DISC WASHERS,
BOLT,WASHERS NUT
(TORQUE 325
IN. LBS)
HYDRAULIC
UNION,NUT, RIGHT TUBE
RETAINER, BRAKE
PACKING COVER
CLAMP

COVER

UNION,NUT,
RETAINER, BOLT,
HYDRAULIC PACKING
TUBE WASHER,
NUT
CLAMP

FWD
TEE

HYDRAULIC
EFFECTIVITY TUBE

ON CAA REGISTERED HELICOPTERS

WITH ROTOR BRAKE SHIELD,
76076−35001. CB4122
SA

Rotor Brake (CAA Configuration) - Removal/Installation

Figure 202
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(d) For brake disc, 76363-09103-102/-105, if disc thickness is above 0.495 inch, conduct a wear
rate calculation per the following formula:

Wear Rate = 0.523 Inch - Current Disc Thickness

*Current A/C Flight Hours - A/C Flight Hours when New Disc installed

*If operational disc flight hours can not be established, an estimate is to be used.

(e) For brake disc, 76363-09103-105, if disc thickness is below 0.500 inch but above 0.495 inch,
conduct periodic magnetic particle inspection per Parker Hannifin Component Maintenance
Manual.

(f) To calculate disc replacement interval to make sure disc thickness does not go below the minimum
limit of 0.495 inch before next 300-hour inspection interval use the following formula:

Projected Disc Replacement Interval

= Current Disc Thickness - 0.495 Inch

Wear Rate

(g) If projected disc replacement interval is less than 300 flight hours, the disc is to be replaced or the
rotor brake system deactivated per paragraph 4.A. Deactivate/Reactivate Rotor Brake System,
66-50-00, until a replacement disc can be obtained.

(2) After an emergency application of the rotor brake (above 65% Nr), remove rotor brake disc and do the
following:

(a) For brake disc, 76363-09103-102/-105, conduct disc inspection including magnetic particle
inspection per Parker Hannifin Component Maintenance Manual or Goodrich Component Main-
tenance Manual, as applicable.

(b) Inspect brake disc, 76363-09103-102/-105, for minimum thickness and conduct wear rate cal-
culation per step (1) above.

C. Rotor Brake Clearance Check.

(1) Cycle rotor brake three times by moving master cylinder handle forward (two strokes required) and
back to detent three times.

(2) With master cylinder handle in detent (off), measure gap between brake disc and each lining (puck) on
both sides of disc using gauge, 76070-30015-108 or equivalent. Brake clearance should not be less
than 0.050 inch.

NOTE: On CAA registered helicopters with rotor brake shield 76076-35001 installed, open hinged
door to check rotor brake clearance.

3. Approved Repairs Rotor Brake.

A. Replacement Rotor Brake Linings. Refer to Goodrich Component Maintenance Manual, 2-1489 or Parker
Hannifin Component Maintenance Manual, PH030-21300MM Revision C or later revision, as applicable.

NOTE: There are four linings on each brake assembly, two on the left brake and two on the right brake.
Replacement procedures for all linings are the same.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(1) Remove rotor brake from main gear box rear cover. (Refer to Removal/Installation.)

(2) Inspect brake disc for minimum thickness per applicable component maintenance manual.

(3) Replace brake linings per applicable component maintenance manual.

(4) Install rotor brake on main gear box rear cover. (Refer to Removal/Installation.)

NOTE: Do not install ducting, access panels, or close engine air inlet/bypass cowls at this time.

(5) Service rotor brake system. (Refer to Servicing, 65-50-00.)

(6) Bleed rotor brake system. (Refer to Servicing, 65-50-00.)

(7) Check clearance between brake disc and each lining. (Refer to Inspection/Check, paragraph C.)

(8) Install ducting and access panels which were removed to get to rotor brake. (Refer to Oil Cooler Ducts,
79-10-04.)

(9) Close and secure engine air inlet/bypass cowls.

(10) Do an operational test of rotor brake system. (Refer to Testing and Troubleshooting, 66-50-00.)

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MASTER CYLINDER (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

The master cylinder is mounted overhead in the cockpit above the pilot. A handle on the master cylinder allows the
pilot to manually actuate the rotor brake. Hydraulic fluid is supplied to the master cylinder from the accumulator/
reservoir through a tube assembly. Pushing the handle down and forward provides hydraulic pressure to actuate
the rotor brake. Two strokes are required to develop the pressure necessary for stopping the rotor effectively. The
time required to stop the rotor system can be controlled by varying the rate at which the master cylinder handle
is applied during the second stroke. Normal rotor brake application is at 65% Nr or less with both engines shut
off, or one engine at idle.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MASTER CYLINDER (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES

1. Removal/Installation Master Cylinder.

A. Remove Master Cylinder (Figure 201).

(1) Turn off all electrical power.

(2) Release rotor brake pressure by moving rotor brake handle on master cylinder off.

(3) Position a container under master cylinder hydraulic tube connections to catch hydraulic fluid, and
disconnect pressure and return tubes. Install protective caps and plugs on tubes and fittings.

(4) Remove bolts and washers securing master cylinder to airframe and remove master cylinder.

B. Install Master Cylinder (Figure 201).

(1) Turn off all electrical power.

(2) Fill master cylinder with hydraulic fluid before installation. (Refer to Bleeding Rotor Brake System,
66–50–00.)

(3) Install master cylinder on airframe and secure with bolts and washers. Torque bolts to 110 inch-pounds.

(4) Remove protective caps and plugs and connect pressure and return tubes to master cylinder.

(5) Service and bleed rotor brake system. (Refer to Servicing and Bleeding Rotor Brake System, 66-50-00.)

(6) Do an operational test of rotor brake system. (Refer to Testing and Troubleshooting, 66-50-00.)

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

FORMER
PRESSURE
TUBE

RETURN
TUBE

BOLT, WASHER
(TORQUE 110 IN. LBS)
MASTER
CYLINDER

S76A_67562 (C21)
SA

Master Cylinder - Removal/Installation

Figure 201

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
PRESSURE GAGE (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

The pressure gage is mounted next to the master cylinder overhead in the cockpit. The gage visually indicates
hydraulic pressure in the system. It has a scale range of 0 - 800 psi. Normal system operating pressure is about
200 - 250 psi.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
PRESSURE GAGE (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES

1. Removal/Installation Pressure Gage.

A. Remove Pressure Gage (Figure 201).

(1) Turn off all electrical power.

(2) Release rotor brake pressure by moving rotor brake handle on master cylinder off.

(3) Position a container under pressure gage to catch hydraulic fluid.

(4) Disconnect pressure tube from gage. Remove nut and remove gage from bracket. Install protective plug
on pressure tube.

(5) Remove bolts and washers and remove bracket from cockpit overhead.

B. Install Pressure Gage (Figure 201).

(1) Turn off all electrical power.

(2) Install bracket on cockpit overhead and secure with bolts and washers. Torque bolts to 50 inch-pounds.

(3) Install pressure gage on bracket and secure with nut.

(4) Remove protective plug from pressure tube and connect pressure tube to gage.

(5) Service and bleed rotor brake system. (Refer to Servicing and Bleeding, 66-50-00.)

(6) Do an operational test of rotor brake system. (Refer to Testing and Troubleshooting, 66-50-00.)

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
PRESSURE
TUBE

BOLT, WASHER
(TORQUE NUT
50 IN. LBS)

BRACKET

PRESSURE
GAGE

MASTER
CYLINDER

CC0915
SA

Pressure Gage - Removal/Installation

Figure 201

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
ACCUMULATOR/RESERVOIR (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

The accumulator/reservoir is mounted on top of the main gear box between the engine oil cooler blowers.
Itconsists of an accumulator, reservoir, relief valve, bleed valve, and pressure switch. A sight gage on the side of
the reservoir provides a visual indication of fluid level. The reservoir supplies the rotor brake master cylinder with
hydraulic fluid through a connecting tube assembly. The accumulator and relief valve maintains constant maxi-
mum hydraulic pressure to the rotor brake system. Hydraulic fluid passed by the accumulator relief valve is
returned to the reservoir. The relief valve actuates at 300 psi 6 30 psi. A fill port with a screen and protective cap
is provided at the top of the accumulator/reservoir for servicing the reservoir. The bleed valve can be used to
purge air from the system. When system pressure is 10 psi or more the pressure switch actuates completing an
electrical circuit to light the ROTOR BRAKE caution light on the caution/advisory panel.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
ACCUMULATOR/RESERVOIR (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES

1. Removal/Installation Accumulator/Reservoir.

A. Remove Accumulator/Reservoir (Figure 201).

(1) Turn off all electrical power.

(2) Release rotor brake pressure by moving rotor brake handle off.

(3) Open engine air inlet/bypass cowl, upper access panel, and oil cooler blower access panel.

(4) Disconnect electrical connector from pressure switch on side of accumulator/reservoir.

(5) Position suitable container under accumulator/reservoir, disconnect return tube from fitting and drain
reservoir. Install protective plug on return line.

(6) Position container under accumulator/reservoir, disconnect pressure tubes from tee, and drain any
remaining fluid. Install protective plugs on pressure tubes.

(7) Support accumulator/reservoir and remove bolts, washers, nuts, and spacers securing clamps to bracket
and clip. Remove clamps and accumulator/reservoir. If necessary, remove clip, screw, washer, and nut
from clip.

(8) Remove bolts and washers and remove bracket, standoffs, and washers from main gear box.

(9) On helicopters 0387 and subsequent and helicopters prior to 0387 with main gear box, 76351-
09600-044, do this:

(a) Remove bolts and remove bracket from main gear box drive pad.

(b) If necessary, remove remaining bolt and washer from cover plate and remove cover plate.

(c) If necessary, remove standoffs from drive pad.

(d) If necessary, remove cover from drive pad studs.

(10) Remove pressure switch and packing from accumulator/reservoir.

(11) Remove bleed valve, nut, retainer, and packing from accumulator/reservoir.

(12) Remove tee, nut, retainer, and packing from accumulator/reservoir.

(13) Install protective caps/plugs on accumulator/reservoir ports, electrical connector, and pressure switch.

B. Install Accumulator/Reservoir (Figure 201).

NOTE: Coat all fitting threads and new packings with hydraulic fluid, MIL-H-5606, before installation.

(1) Turn off all electrical power.

(2) Remove protective caps/plugs from accumulator/reservoir ports, electrical connector, and pressure
switch.

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(3) Install tee, nut, retainer, and packing on accumulator/reservoir.

(4) Install bleed valve, nut, retainer, and packing on accumulator/reservoir.

(5) Install pressure switch and packing on accumulator/reservoir.

(6) Install standoffs and washers on main gear box. Torque standoffs to 100 inch-pounds. Lockwire stand-
offs. Install bracket on standoffs and secure with bolts and washers. Torque standoffs to 110 inch-
pounds. Lockwire bolts.

(7) On helicopters 0387 and subsequent and helicopters prior to 0387 with main gear box, 76351-09600-
044, do this:

(a) If removed, install cover on main gear box drive pad studs.

(b) Install standoffs on drive pad studs and torque standoffs to 100 inch-pounds.

(c) Install cover plate on cover. Install forward bolt and washer. Position bracket on cover plate and
install bolts. Torque all bolts to 110 inch-pounds. Lockwire bolts.

(d) Using sealing compound, MIL-S-8802, Class B2, seal around perimeters of cover-to-drive pad,
cover-to-cover plate, and around all bolts including lockwire.

(8) Position accumulator/reservoir in bracket. Clamp accumulator/reservoir to bracket with clamps, spac-
ers, bolts, washers, and nuts. Torque nuts to 100 inch-pounds. If removed, install clip on bracket with
screw, washer, and nut. Clamp pressure tube to clip using screw, washer, and nut.

(9) Remove protective plugs from pressure tubes and return tube. Connect pressure tubes to tee and connect
return tube to fitting on side of accumulator/reservoir.

(10) Connect electrical connector to pressure switch.

(11) Service and bleed rotor brake system. (Refer to Servicing and Bleeding, 66-50-00.)

(12) Close and secure oil cooler blower access door, upper access panel, and engine air inlet/bypass cowl.

(13) Do an operational test of rotor brake system. (Refer to Testing and Troubleshooting, 66-50-00.)

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

SPACER
BOLT,
CLAMP WASHER
(TORQUE
110 IN. LBS) A

RETURN BRACKET
ACCUMULATOR / TUBE BOLT
RESERVOIR (TORQUE
110 IN. LBS)

BRACKET
BOLT, WASHERS,
NUT (TORQUE
100 IN. LBS)
A

BLEED VALVE,
NUT, RETAINER,
PACKING

SCREW, BOLT, WASHER

WASHER, (TORQUE 110
NUT IN. LBS)

COVER
PLATE
STANDOFF
(TORQUE CLIP
100 IN. LBS) PRESSURE
TUBE
CLAMP

STANDOFF
CLAMP (TORQUE
100 IN. LBS)
PRESSURE
SWITCH,
PACKING COVER

PRESSURE ELECTRICAL
TUBE CONNECTOR

TEE, NUT,
RETAINER,
PACKING

EFFECTIVITY
D
FW HELICOPTERS 0387 AND SUBSEQUENT
AND HELICOPTERS PRIOR TO 0387 WITH
MAIN GEAR BOX, 76351−09600−044. CB0379A
SA

Accumulator/Reservoir - Removal/Installation Accumulator/Reservoir - Removal/Installation

Figure 201 (Part 1 of 2) Figure 201 (Part 2)
66-50-04 66-50-04
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
HYDRAULIC LINES (ROTOR BRAKE SYSTEM) - DESCRIPTION AND OPERATION

1. Description and Operation (Figure 201).

The manual rotor brake system hydraulic lines consist of high-pressure tubes and hoses which direct hydraulic
fluid to and from the accumulator/reservoir, master cylinder, and rotor brake assemblies. Hydraulic fluid is
supplied from the reservoir to the master cylinder. Pumping the master cylinder, by means of the master cylinder
handle, provides hydraulic pressure to the brake assemblies. The brake assemblies produce braking action when
the lined opposing pistons are actuated hydraulically.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
HYDRAULIC LINES (ROTOR BRAKE SYSTEM) - MAINTENANCE PRACTICES

1. Removal/Installation Hydraulic Lines.

A. Remove Hydraulic Lines (Figure 201).

NOTE: As hydraulic lines are disconnected, drain fluid into suitable containers and cap or plug all ports,
lines, and fittings, to prevent contamination. If necessary, tag lines for ease of installation.

NOTE: Unclamp lines as required. For ease of installation, note position of clamping on removal.

(1) Turn off all electrical power.

(2) Open left engine air inlet/bypass cowl. Remove right main gear box fairing and forward fairing.

(3) Disconnect and remove pressure tube from between tee at accumulator/reservoir and tee below rotor
brake.

(4) Disconnect and remove pressure tubes from unions at bottom of each brake. Remove pressure tubes
from tee. Remove unions, nuts, retainers, and packings from brakes.

(5) Disconnect and remove pressure tube and return tube from between accumulator/reservoir and hoses
on right side of main gear box.

(6) Remove bleed valve and cap from pressure hose.

(7) Remove tee, nut, retainer, and packing from accumulator/reservoir.

(8) Disconnect and remove pressure hose and return hose from pressure manifold and return tube.

(9) At forward end of pressure manifold, disconnect pressure tube from manifold tee. Disconnect and
remove pressure manifold from elbow at station 116 on upper deck.

(10) Disconnect and remove return tube from elbow at station 117 on upper deck.

(11) Disconnect and remove pressure tube from other elbow at station 117.

(12) From inside cockpit, disconnect and remove pressure tube and return tube from between master
cylinder and elbows.

(13) Disconnect and remove pressure tube from between pressure gage and elbow.

(14) Remove elbows, nuts, and washers from upper deck.

B. Install Hydraulic Lines (Figure 201).

CAUTION: BEFORE INSTALLATION, MAKE SURE ALL CAPS AND PLUGS ARE REMOVED FROM HYDRAU-
LIC PORTS AND LINES, AND CHECK AND MAKE SURE THAT LINES ARE CLEAR OF FOREIGN
MATTER.

NOTE: Coat all fitting threads and new packings with hydraulic fluid, MIL-H-5606, before installation.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(1) Install elbows through upper deck and secure with washers and nuts.

(2) Connect pressure tube between pressure gage and elbow.

(3) Connect pressure tube and return tube between master cylinder and elbows.

(4) On upper deck, connect pressure tube to elbow at station 117.

(5) Connect return tube to other elbow at station 117.

(6) Connect pressure manifold to elbow at station 116. Connect pressure tube to manifold tee.

(7) Connect pressure hose and return hose to pressure manifold and return tube.

(8) Clamp pressure manifold and return tube together and secure to upper deck as follows:

(a) If necessary, install each bracket on upper deck and secure with bolt, washer, and nut; or bolt and
washers; as applicable. Torque bolts to 50 inch-pounds.

NOTE: Brackets at stations 192, 201, and on main gear box are bonded in place.

(b) Install clamping blocks and retainers on tubes and secure to brackets with bolts, washers, and
spacers. Torque bolts to 50 inch-pounds.

(c) Install clamps on tubes at station 180 and secure to frame with spacers, screws, washers, and nuts.

(9) Install tee, nut, retainer, and packing on accumulator/reservoir.

(10) Install bleed valve and cap on pressure hose on right side of main gear box.

(11) Connect pressure tube and return tube between accumulator/reservoir and hoses on right side of main
gear box.

(12) Install clamping blocks and retainers on tubes and secure to each bracket on main gear box with bolt,
washer, and spacer or bolt, washers, spacer, and nut. Torque bolt to 50 inch-pounds or torque nut to
45 inch-pounds.

(13) Install bracket on main gear box and secure with screw and washer. Clamp tubes together and to
bracket and secure with screw, washer, and nut.

(14) Install unions, nuts, retainers, and packings on bottom of brakes.

(15) Connect pressure tubes to tee and to unions on brakes.

(16) Connect pressure tube between tee at accumulator/reservoir and tee below rotor brake.

(17) Clamp pressure tube to brackets on main gear box with clamps, bolts, washers, and nuts.

(18) Service and bleed rotor brake system. (Refer to Servicing and Bleeding, 66-50-00.)

(19) Install right main gear box fairing and forward fairing. Close and secure left engine air inlet/bypass
cowl.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
BOLT, WASHER,
BRACKET
NUT (TORQUE D
50 IN. LBS)

BLOCK

RETAINER

BOLT, WASHER
(TORQUE 50
IN. LBS)

SPACER

STA
F 192

STA
B 171

STA
B 153

STA
B 143
C

STA
A 127

PRESSURE
MANIFOLD B C
RETURN
TUBE BOLT, WASHER BRACKET SPACER
(TORQUE 50
IN. LBS)
ELBOW, NUT, CLAMP
WASHER BLOCK
ELBOW, NUT,
WASHER SCREW,
WASHERS,
NUT

PRESSURE
TUBE BOLT, WASHER
MASTER (TORQUE 50
CYLINDER IN. LBS)

RETURN
TUBE SPACER

SPACER

RETAINER
CLAMP
PRESSURE
GAGE CB0115_1
SA

Hydraulic Lines - Removal/Installation Hydraulic Lines - Removal/Installation

Figure 201 (Part 1 of 4) Figure 201 (Part 2)
66-50-05 66-50-05
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
BRACKET
D SCREW, (BONDED)
WASHERS,
NUT

SPACER

CLAMP

BOLT, WASHER
(TORQUE 50
TEE, NUT, IN. LBS)
PRESSURE RETAINER, ACCUMULATOR /
TUBE PACKING RESERVOIR G BLOCK

CLAMP,
SCREW, RETAINER
RETURN WASHER,
HOSE NUT
F

BOLT,
E WASHER
(TORQUE
50 IN. LBS)

RETAINER

SPACER

J H
BLOCK
BOLT,
WASHER,
F NUT BRACKET
(TORQUE
STA
201 45 IN. LBS) CLAMP

J RETURN PRESSURE
TUBE HOSE

BLEED VALVE, BRACKET BRACKET

CAP (BONDED)
PRESSURE
TUBE
H

PRESSURE
TEE TUBE

UNION, D
NUT, FW SCREW,
PRESSURE WASHER,
TUBE RETAINER,
PACKING NUT
(2 PLACES) CLAMP CB0115_2
SA

Hydraulic Lines - Removal/Installation Hydraulic Lines - Removal/Installation

Figure 201 (Part 3) Figure 201 (Part 4)
66-50-05 66-50-05
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(20) Do an operational test of rotor brake system. (Refer to Testing and Troubleshooting, 66-50-00.)

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
GEAR BOX INDICATING SYSTEM- DESCRIPTION AND OPERATION

1. Description and Operation.

The gear box indicating system consists of two indicating systems and three warning systems. The indicating
systems are main gear box oil pressure and main gear box oil temperature, which are combined on one indicator
located on the instrument panel. The warning systems are main gear box low oil pressure, main gear box oil hot,
and gear box chip detector. The warning lights for the warning systems are on the caution/advisory panel on the
instrument panel.

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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL TEMPERATURE/PRESSURE INDICATING SYSTEM-DESCRIPTION AND OPERATION

1. Description and Operation (Figures 1 and 2).

A combined main gear box oil temperature and pressure indicator marked XMSN OIL X10 indicates oil pressure
at the main gear box oil inlet port pressure transmitter and oil temperature in the main gear box sump at the
temperature sensor. The left scale on the indicator is marked T (temperature) and the right scale is marked P
(pressure). The temperature indicator is connected to the dc essential bus by a circuit breaker marked OIL XMSN
TEMP and shows oil temperature in degrees celsius. The pressure indicator is connected to the dc essential bus by
a circuit breaker marked OIL XMSN PRESS and shows oil pressure in pounds per square inch.

66-61-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

B
P912 / J912

P900 / J900

P118 / J118

P208 / J208
P913 / J913

P901 / J901

15 15
XMSN 10
10 OIL
5 T P 5
P109 x10
P213 / J213
A 0 0
P207 / J207 −5

C MAIN GEAR BOX OIL

TEMPERATURE/PRESSURE
OIL INDICATOR P11
PRESSURE
TRANSMITTER
P909 B

OIL
TEMPERATURE
SENSOR
P908

OIL PRESSURE TRANSMITTER OIL TEMPERATURE SENSOR CB0116A

SA

Main Gear Box Oil Temperature/Pressure Indicating System - Location Diagram

Figure 1
66-61-00
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Jul 31/96
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
OIL XMSN
TEMP P11
NO. 2
DC PRI 2 A
BUS AMP

B
OIL XMSN
PRESS
NO. 1
DC PRI 2 L
BUS AMP

P
P908
A G

B F
OIL TEMPERATURE
BULB

P909
A R
D H
C J
B M

OIL PRESSURE
TRANSMITTER TRANSMISSION OIL
TEMPERATURE/PRESSURE INDICATOR
CB0117
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Simplified Schematic Diagram
Figure 2

66-61-00
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Jan 31/98
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL TEMPERATURE/PRESSURE INDICATING SYSTEM - TESTING AND TROUBLESHOOTING

1. Testing and Troubleshooting.

A. Operational Test (Figure 101 - All Helicopters, Figure 102 - Helicopters Prior to 0419, Figure 103 - Heli-
copters 0419 - 0431, and Figure 104 - Helicopters 0432 - 9999).

(1) On upper circuit breaker panel, make certain OIL XMSN PRESS and OIL XMSN TEMP circuit breakers
are pushed in.

(2) On lower circuit breaker panel, make certain XMSN OIL WARN PRESS and XMSN OIL WARN TEMP
circuit breakers are pushed in.

(3) Connect source of external dc power.

RESULT:

- MAIN XMSN OIL PRESS capsule on caution/advisory panel should go on.

CORRECTIVE ACTION:

- IF MAIN XMSN OIL PRESS caution capsule does not go on, go to Trouble No. 1.

(4) With qualified pilot at controls, start No. 1 engine, engage rotor head, and operate at 107% Nr. (Refer
to S-76B Flight Manual.)

RESULT:

- MAIN XMSN OIL PRESS caution capsule should go off.

- Main gear box oil pressure indicator should read in green range (50 - 90 psi).

- MAIN XMSN OIL HOT caution capsule should go off.

- Main gear box oil temperature indicator should stabilize in green range (15° to 120°C).

CORRECTIVE ACTION:

- If MAIN XMSN OIL PRESS caution capsule does not go off and main gear box oil pressure indicator
reads in green range (50 - 90 psi), shut down engine and replace main gear box oil pressure switch.

- If MAIN XMSN OIL PRESS caution capsule does not go off and main gear box oil pressure indicator
pointer does not move, shut down engine and go to Trouble No. 2.

- If MAIN XMSN OIL PRESS caution capsule does not go off and main gear box oil pressure indicator
shows low pressure, not in green range (50 - 90 psi), shut down engine and go to Trouble No. 3.

- If MAIN XMSN OIL PRESS caution capsule goes off and main gear box oil pressure indicator pointer
does not move, go to Trouble No. 4.

- If main gear box oil pressure indicator pointer is not steady, go to Trouble No. 5.

- If main gear box oil pressure indicator shows too high a pressure reading, replace indicator with one

66-61-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
known to be serviceable. If indicator still reads high, replace pressure transmitter.

- If main gear box oil pressure indicator reads low pressure (20 - 50 psi), go to Trouble No. 6.

- If MAIN XMSN OIL HOT caution capsule goes on and main gear box oil temperature indicator reads
in green range (15° to 120°C), remove main gear box oil temperature switch and install a switch
known to be serviceable. Repeat ground run. If capsule goes on, go to Trouble No. 11.

- If MAIN XMSN OIL HOT caution capsule goes on and main gear box oil temperature indicator reads
in yellow range (120° to 135°C), shut down engine and go to Trouble No. 7.

- If main gear box oil temperature indicator reads in yellow range (120° to 135°C), but MAIN XMSN
OIL HOT caution capsule does not go on, shut down engine and go to Trouble No. 8.

- If main gear box oil temperature indicator pointer does not move, go to Trouble No. 9.

- If main gear box oil temperature indicator pointer is not steady, go to Trouble No. 10.

- If main gear box oil temperature indicator is believed to have wrong reading, go to Trouble No. 11.

- If operating in a cold environment and main gear box will not warm up to green range (15° to
120°C), replace oil cooler thermostatic bypass valve.

(5) Shut down engine. (Refer to S-76B Flight Manual.)

(6) Disconnect external dc power.

66-61-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TROUBLE NO. 1 TROUBLE NO. 2

MAIN XMSN OIL PRESS CAUTION CAP− MAIN XMSN OIL PRESS CAUTION CAP−
SULE DOES NOT GO ON (MAIN ROTOR SULE DOES NOT GO OFF AND MAIN
NOT TURNING). GEAR BOX OIL PRESSURE INDICATOR
POINTER DOES NOT MOVE (MAIN
ROTOR TURNING).

CHECK THAT XMSN OIL WARN

PRESS CIRCUIT BREAKER IS IN.

YES NO CHECK THAT MAIN GEAR BOX OIL

LEVEL IS OK.

YES NO
PUSH TEST BUTTON ON CAU− PUSH IN CIRCUIT BREAKER, IF
TION / ADVISORY PANEL. DOES CIRCUIT BREAKER POPS, CHECK
CAPSULE GO ON? SYSTEM FOR SHORT CIRCUIT.
REPAIR / REPLACE COMPONENTS CHECK OIL LINES AND OIL COOL− SERVICE MAIN GEAR BOX.
YES NO OR WIRING AS REQUIRED. ER FOR LEAKS.

YES NO

CHECK FOR CONTINUITY BE− REPLACE BULB. REPAIR / REPLACE / TIGHTEN ON LEFT LUBRICATION PUMP,
TWEEN PINS 2 AND 3 OF MAIN HOSES AND FITTINGS AND / OR REMOVE PLUG OPPOSITE PRES−
GEAR BOX OIL PRESSURE REPLACE OIL COOLER. SURE REGULATOR. CONNECT
SWITCH. A 0−100 PSI PRESSURE GAGE TO
PUMP WITH A HOSE LONG
YES NO ENOUGH THAT GAGE MAY BE
READ SAFELY DURING A GROUND
RUN WITH FAIRINGS CLOSED.

CHECK FOR 28 VDC AT PIN 2 OF REPLACE MAIN GEAR BOX OIL

CONNECTOR P918. PRESSURE SWITCH.
START NO. 1 ENGINE, ENGAGE
YES NO ROTOR HEAD, AND OPERATE AT
107% Nr. DOES PRESSURE GAGE
READ ABOVE 50 PSI?

YES NO
WITH POWER OFF, CHECK FOR WITH POWER OFF, CHECK FOR
CONTINUITY BETWEEN PIN 3 OF CONTINUITY BETWEEN PIN 2 OF
CONNECTOR P918 AND PIN R OF CONNECTOR P918 AND XMSN OIL
CONNECTOR P1. WARN PRESS CIRCUIT BREAKER.
REPLACE MAIN GEAR BOX. SHUT DOWN ENGINE. CONNECT
YES NO YES NO PRESSURE GAGE TO RIGHT LU−
BRICATION PUMP AND REPEAT
GROUND RUN. DOES PRESSURE
GAGE READ ABOVE 50 PSI?

REPAIR / REPLACE CAUTION / REPAIR / REPLACE WIRING. REPLACE XMSN OIL WARN REPAIR / REPLACE WIRING. YES NO
ADVISORY PANEL. PRESS CIRCUIT BREAKER.

REPLACE MAIN GEAR BOX. REPLACE LEFT AND RIGHT LU−

BRICATION PUMP.

CB0118_1
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart
Figure 101 (Part 1 of 9) Figure 101 (Part 2)
66-61-00 66-61-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TROUBLE NO. 3 TROUBLE NO. 4

MAIN XMSN OIL PRESS CAUTION CAP− MAIN XMSN OIL PRESS CAUTION CAP−
SULE DOES NOT GO OFF AND MAIN SULE GOES OFF AND MAIN GEAR BOX
GEAR BOX OIL PRESSURE INDICATOR OIL PRESSURE INDICATOR POINTER
SHOWS LOW PRESSURE, NOT IN DOES NOT MOVE (MAIN ROTOR TURN−
GREEN RANGE (50 TO 90 PSI), (MAIN ING).
ROTOR TURNING).

CHECK THAT PRESS XMSN

CHECK THAT MAIN GEAR BOX OIL (MARKED OIL XMSN PRESS ON
LEVEL IS OK. HELICOPTERS PRIOR TO 0419)
CIRCUIT BREAKER IS IN.
YES NO
YES NO

CHECK OIL LINES AND OIL COOL− SERVICE MAIN GEAR BOX.
ER FOR LEAKS. CHECK FOR 28 VDC AT PIN L OF PUSH IN CIRCUIT BREAKER. IF
CONNECTOR P11. CIRCUIT BREAKER POPS, CHECK
YES NO SYSTEM FOR SHORT CIRCUIT.
YES NO REPAIR / REPLACE COMPONENTS
OR WIRING AS REQUIRED.

REPAIR / REPLACE / TIGHTEN CHECK OIL FILTER FOR POPPED

HOSES AND FITTINGS AND / OR INDICATOR BUTTON.
REPLACE OIL COOLER. CHECK FOR GROUND AT PINS B, WITH POWER OFF, CHECK PRESS
YES NO C, AND P OF CONNECTOR P11. XMSN (MARKED OIL XMSN PRESS
ON HELICOPTERS PRIOR TO 0419)
YES NO CIRCUIT BREAKER FOR CONTIN−
UITY.

YES NO
REPLACE FILTER ELEMENT AND DISCONNECT LUBRICATION SHUT DOWN ENGINE. ON LEFT
MAKE CERTAIN FILTER BYPASS HOSES FROM MAIN GEAR BOX LUBRICATION PUMP, REMOVE
VALVE IS NOT CLOGGED OR OB− OIL COOLER LINE FITTINGS ON PLUG OPPOSITE PRESSURE
STRUCTED. DO A SERVICEABIL− FORWARD TRANSVERSE WALL. REGULATOR. CONNECT A 0−100
ITY CHECK ON MAIN GEAR BOX. CONNECT LINES TOGETHER PSI PRESSURE GAGE TO PUMP REPAIR / REPLACE WIRING BE−
REPLACE INDICATOR WITH ONE REPAIR / REPLACE GROUND. REPLACE CIRCUIT BREAKER.
USING AN AN919−20 REDUCER. WITH A HOSE LONG ENOUGH TWEEN PRESS XMSN (MARKED
KNOWN TO BE SERVICEABLE.
THAT GAGE MAY BE READ SAFE− OIL XMSN PRESS ON HELICOP−
DOES INDICATOR WORK?
LY DURING A GROUND RUN WITH TERS PRIOR TO 0419) CIRCUIT
FAIRINGS CLOSED. YES NO BREAKER AND PIN L OF CON−
NECTOR P11.

PREPARE HELICOPTER FOR START NO. 1 ENGINE, ENGAGE SYSTEM OK. REPLACE OIL PRESSURE TRANS−
GROUND RUN. WITH QUALIFIED ROTOR HEAD, AND OPERATE AT MITTER WITH ONE KNOWN TO BE
PILOT AT CONTROLS, START NO. 107% Nr. DOES PRESSURE GAGE SERVICEABLE. DOES INDICATOR
1 ENGINE, ENGAGE ROTOR HEAD, READ ABOVE 50 PSI? WORK?
AND OPERATE AT 107% Nr, RE−
FER TO FLIGHT MANUAL. YES NO YES NO

DOES MAIN GEAR BOX OIL PRES− DO A SERVICEABILITY CHECK OF SHUT DOWN ENGINE. CONNECT SYSTEM OK. REPAIR / REPLACE WIRING BE−
SURE INDICATOR READ IN GREEN MAIN GEAR BOX. PRESSURE GAGE TO RIGHT LU− TWEEN PINS A, B, C, AND D OF
RANGE (50 T0 90 PSI)? BRICATION PUMP AND REPEAT CONNECTOR P909 AND PINS M, H,
GROUND RUN. DOES PRESSURE J, AND R OF CONNECTOR P11.
YES NO GAGE READ ABOVE 50 PSI?

YES NO

REPLACE MAIN GEAR BOX OIL

COOLER AND CONNECT LUBRI−
CATION HOSES TO OIL COOLER
LINE FITTINGS ON FORWARD REPLACE MAIN GEAR BOX. REPLACE LEFT AND RIGHT LUBRI−
TRANSVERSE WALL. CATION PUMP.

CB0118_2A
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart
Figure 101 (Part 3) Figure 101 (Part 4)
66-61-00 66-61-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TROUBLE NO. 5 TROUBLE NO. 6 TROUBLE NO. 7

MAIN GEAR BOX OIL PRESSURE INDI− MAIN GEAR BOX OIL PRESSURE INDI− MAIN XMSN OIL HOT CAUTION CAP−
CATOR POINTER IS NOT STEADY CATOR READS LOW PRESSURE (20 TO SULE GOES ON AND MAIN GEAR BOX
(MAIN ROTOR TURNING). 50 PSI) (MAIN ROTOR TURNING). OIL TEMPERATURE INDICATOR READS
IN YELLOW RANGE (120OC TO 135OC)
(MAIN ROTOR TURNING).

SOME MOVEMENT IS OK DUE TO ON LEFT LUBRICATION PUMP,

NORMAL VIBRATION. REMOVE PLUG OPPOSITE PRES−
SURE REGULATOR. CONNECT CHECK THAT MAIN GEAR BOX OIL
A 0−100 PSI PRESSURE GAGE TO LEVEL IS OK.
PUMP WITH A HOSE LONG
ENOUGH THAT GAGE MAY BE YES NO
CHECK FOR LOOSE ELECTRICAL READ SAFELY DURING A GROUND
CONNECTIONS OR WIRING. RUN WITH FAIRINGS CLOSED.
YES NO
CHECK OIL COOLER RADIATOR SERVICE MAIN GEAR BOX.
FOR CLOGGING EXTERNALLY.

YES NO
TIGHTEN LOOSE CONNECTIONS. REPLACE INDICATOR WITH ONE START NO. 1 ENGINE, ENGAGE
KNOWN TO BE SERVICEABLE. IS ROTOR HEAD, AND OPERATE AT
POINTER STEADY? 107% Nr. DOES PRESSURE GAGE
READ ABOVE 50 PSI?
YES NO CLEAN RADIATOR. CHECK OIL COOLER DUCTS FOR
YES NO CRACKS OR DAMAGE.

YES NO

SYSTEM OK. REPLACE OIL PRESSURE TRANS− SHUT DOWN ENGINE AND DIS− REPLACE LEFT LUBRICATION
MITTER. CONNECT PRESSURE GAGE PUMP.
FROM LEFT PUMP AND REIN− REPAIR / REPLACE DUCTS. REMOVE OIL COOLER BLOWER
STALL PLUG. REMOVE PLUG ON COVER AND CHECK IMPELLER
RIGHT PUMP AND CONNECT FOR BROKEN VANES.
PRESSURE GAGE TO PUMP.
YES NO

REPEAT GROUND RUN. DOES

PRESSURE GAGE READ ABOVE 50
PSI? REPLACE IMPELLER. TURN MAIN ROTOR THROUGH BY
HAND AND CHECK THAT IMPEL−
YES NO LER TURNS.

YES NO

SHUT DOWN ENGINE AND DIS− REPLACE RIGHT LUBRICA−

CONNECT PRESSURE GAGE TION PUMP.
FROM RIGHT PUMP AND REIN− REPLACE THERMOSTATIC BY− REMOVE OIL COOLER BLOWER
STALL PLUG. PASS VALVE. REPEAT GROUND DRIVE AND CHECK FOR DAMAGE.
RUN. IF MAIN GEAR BOX STILL
OVERHEATS, REPLACE GEAR YES NO
BOX.
REPLACE OIL PRESSURE INDI−
CATOR WITH ONE KNOWN TO BE
SERVICEABLE. REPEAT GROUND
RUN. DOES INDICATOR READ OK?
REPLACE OIL COOLER BLOWER REPLACE MAIN GEAR BOX.
YES NO DRIVE AND DO A SERVICEABILITY
CHECK OF MAIN GEAR BOX.

SYSTEM OK. REPLACE OIL PRESSURE TRANS−

MITTER.

CB0118_3
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart
Figure 101 (Part 5) Figure 101 (Part 6)
66-61-00 66-61-00
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Jan 15/92
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TROUBLE NO. 8 TROUBLE NO. 9

MAIN GEAR BOX OIL TEMPERATURE MAIN GEAR BOX OIL TEMPERATURE
INDICATOR READS IN YELLOW RANGE INDICATOR POINTER DOES NOT MOVE
( 120O C TO 135O C ), BUT MAIN XMSN (MAIN ROTOR TURNING).
OIL HOT CAUTION CAPSULE DOES NOT
GO ON (MAIN ROTOR TURNING).

CHECK THAT XMSN OIL TEMP

(MARKED OIL XMSN TEMP ON
CHECK THAT XMSN OIL WARN HELICOPTERS PRIOR TO 0419)
TEMP CIRCUIT BREAKER IS IN. CIRCUIT BREAKER IS IN.

YES NO YES NO

PUSH TEST BUTTON ON CAU− PUSH IN CIRCUIT BREAKER. IF CHECK FOR 28 VDC AT PIN A OF PUSH IN CIRCUIT BREAKER. IF
TION / ADVISORY PANEL. DOES CIRCUIT BREAKER POPS, CHECK CONNECTOR P11. CIRCUIT BREAKER POPS, CHECK
CAPSULE GO ON? SYSTEM FOR SHORT CIRCUIT. SYSTEM FOR SHORT CIRCUIT.
REPAIR / REPLACE COMPONENTS YES NO REPAIR / REPLACE COMPONENTS
YES NO OR WIRING AS REQUIRED. OR WIRING AS REQUIRED.

IF AVAILABLE, REPLACE MAIN REPLACE BULB. CHECK FOR GROUND AT PINS B, WITH POWER OFF, CHECK XMSN
GEAR BOX OIL TEMPERATURE C, AND P OF CONNECTOR P11. OIL TEMP (MARKED OIL XMSN
SWITCH WITH ONE KNOWN TO BE TEMP ON HELICOPTERS PRIOR
SERVICEABLE AND RECHECK YES NO TO 0419) CIRCUIT BREAKER FOR
SYSTEM. IF NOT AVAILABLE, RE− CONTINUITY.
MOVE MAIN GEAR BOX OIL TEM−
PERATURE SWITCH AND PLACE YES NO
IT IN A HOT OIL BATH OF GEAR
BOX OIL. HEAT OIL TO 113O TO
121O C ( 235O TO 250O F ). CHECK
FOR CONTINUITY BETWEEN PINS REPLACE INDICATOR WITH ONE REPAIR / REPLACE GROUND. REPAIR / REPLACE WIRING BE− REPLACE CIRCUIT BREAKER.
A AND B OF SWITCH AT THIS KNOWN TO BE SERVICEABLE. TWEEN XMSN OIL TEMP (MARKED
TEMPERATURE. DOES INDICATOR WORK? OIL XMSN TEMP ON HELICOPTERS
YES NO PRIOR TO 0419) CIRCUIT BREAKER
YES NO AND PIN A OF CONNECTOR P11.

CHECK FOR 28 VDC AT PIN A OF REPLACE MAIN GEAR BOX OIL

CONNECTOR P916. TEMPERATURE SWITCH. SYSTEM OK. WITH TEMPERATURE BULB AT 20O
TO 30O C ( 68O TO 86O F ), CHECK
YES NO FOR A RESISTANCE OF 96.5 TO
101.5 OHMS BETWEEN PINS A
AND B OF TEMPERATURE SEN−
SOR.
WITH POWER OFF, CHECK FOR WITH POWER OFF, CHECK FOR
CONTINUITY BETWEEN PIN B OF CONTINUITY BETWEEN PIN A OF YES NO
CONNECTOR P916 AND PIN S OF CONNECTOR P916 AND XMSN OIL
CONNECTOR P1. WARN TEMP CIRCUIT BREAKER.

YES NO YES NO
REPAIR / REPLACE WIRING BE− REPLACE TEMPERATURE SEN−
TWEEN PINS A AND B OF CON− SOR.
NECTOR P908 AND PINS G AND F
OF CONNECTOR P11.
REPAIR / REPLACE CAUTION / REPAIR / REPLACE WIRING. REPLACE CIRCUIT BREAKER. REPAIR / REPLACE WIRING.
ADVISORY PANEL.

CB0118_4A
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart
Figure 101 (Part 7) Figure 101 (Part 8)
66-61-00 66-61-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TROUBLE NO. 10 TROUBLE NO. 11

MAIN GEAR BOX OIL TEMPERATURE MAIN GEAR BOX OIL TEMPERATURE
INDICATOR POINTER IS NOT STEADY INDICATOR IS BELIEVED TO HAVE
(MAIN ROTOR TURNING). WRONG READING (MAIN ROTOR
TURNING).

SOME MOVEMENT IS OK DUE TO

NORMAL VIBRATION. REPLACE INDICATOR WITH ONE
KNOWN TO BE SERVICEABLE.
TEMPERATURE READING OK?

CHECK FOR LOOSE ELECTRICAL YES NO

CONNECTIONS OR WIRING.

YES NO

TIGHTEN LOOSE CONNECTIONS. REPLACE INDICATOR WITH ONE SYSTEM OK. WITH TEMPERATURE BULB AT
KNOWN TO BE SERVICEABLE. IS 20O TO 30OC (68O TO 86OF), CHECK
POINTER STEADY? FOR A RESISTANCE OF 96.5 TO
101.5 OHMS BETWEEN PINS A
YES NO AND B OF TEMPERATURE SEN−
SOR.

YES NO

SYSTEM OK. REPLACE TEMPERATURE SEN− SYSTEM OK. REPLACE TEMPERATURE SEN−
SOR. SOR.

CC0118_5
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Troubleshooting Chart

Figure 101 (Part 9)
66-61-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
1
XMSN OIL 2
WARN TEMP P118 J118 J900 P900 3
4
2 T R 5
AMP 6
DC
ESNTL XMSN OIL
BUS WARN PRESS
2 S T
AMP

LOWER CIRCUIT BREAKER PANEL

OIL XMSN

ORANGE
GREEN
TEMP J208 P208

WHITE
BLUE
NO. 2 2
DC PRI g
AMP
BUS
OIL XMSN
PRESS J207 P207
NO. 1 2 n
DC PRI AMP Q
BUS

UPPER CIRCUIT BREAKER PANEL P913 V W X Y

J913
P1 P214 J214 J900 P900
MAIN XMSN
S CC S
OIL HOT
Q

MAIN XMSN P901 V W X Y

R DD U
OIL PRESS J901

Q
CAUTION / ADVISORY PANEL
P11
J213
L
P213 t u v w
A Q
R BLUE
H WHITE
J ORANGE
M GREEN
F WHITE
P213 J213 J901 P901
G BLUE
B s P
P
C
r N
P GG4−1 P
P
D
J913
MAIN GEAR BOX OIL
TEMPERATURE / PRESSURE INDICATOR P913 N P
INSTRUMENT PANEL P
P109
WHITE
BLUE

0−5 VDC OUT Z

NON−FLIGHT INSTRUMENT DIMMER 7

8
NOTE 9
10
1. FOR WIRE NUMBERS REFER TO WIRING LEGEND
MANUAL.
WIRING
EFFECTIVITY SUPPLY
HELICOPTERS PRIOR TO 0419. OIL PRESSURE CB0119_1A
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram

(Helicopters Prior to 0419)
Figure 102 (Part 1 of 3) 66-61-00
Page 112
Jul 31/96
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

1
2
3 BLUE
4 WHITE
5 ORANGE
6 GREEN

OIL COOLER
J912
P912 S R

OIL TEMPERATURE
WARNING SWITCH P916 B A P909 B C D A BREATHER
121.50 2.80C
(2500 50F) OIL
PRESSURE
TRANSMITTER
OIL COOLER
BYPASS VALVE
OPENS BELOW
600 − 710C
(1400 − 1600F)
OPENS AT 35 PSID
DIFFERENTIAL
PRESSURE INDICATOR FILTER
12 3 PSID OIL
COOLER
BLOWER

OIL FILLER FILTER

BYPASS
OPEN 20 4
PSID

OIL LEVEL
SIGHT
LOW OIL PRESSURE
WINDOW
WARNING SWITCH
CHECK (14 2 PSI)
CHECK VALVE
VALVE

P918 3 2 1
LUBRICATION
PUMP PUMP PUMP RELIEF
VALVE
RELIEF
VALVE

P912 U T
J912
CHIP OIL
DETECTOR / TEMPERATURE
STRAINER SENSOR CHIP
DETECTOR/
STRAINER

P908 B A
7 WHITE DRAIN PLUG
8 BLUE
9
10

CB0119_2
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram
(Helicopters Prior to 0419) (Helicopters Prior to 0419)
Figure 102 (Part 2) 66-61-00 Figure 102 (Part 3) 66-61-00
Page 113/114
Jul 31/96
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
1
XMSN OIL 2
WARN TEMP P118 J118 P900 J900 3
4
2 T R 5
AMP 6
DC
ESS XMSN OIL
BUS WARN PRESS
2 S T
AMP

LOWER CIRCUIT BREAKER PANEL

XMSN

ORANGE
GREEN
OIL TEMP P208 J208

WHITE
BLUE
NO. 2 2
DC PRI g
AMP
BUS
PRESS
XMSN P207 J207
NO. 1 2 n
DC PRI AMP Q
BUS

UPPER CIRCUIT BREAKER PANEL P913 V W X Y

J913
P1 P214 J214 P900 J900
MAIN XMSN
S CC S
OIL HOT
Q

MAIN XMSN J901

R DD U
OIL PRESS P901 V W X Y

Q
CAUTION / ADVISORY PANEL
P11
J213
L
P213 t u v w
A Q
R BLUE
H WHITE
J ORANGE
M GREEN
F WHITE
P213 J213 P901 J901
G BLUE
B s P
P
C
r N
P GG4−3 P
P
D
J913
MAIN GEAR BOX OIL
TEMPERATURE / PRESSURE INDICATOR P913 N P
INSTRUMENT PANEL P
P109
WHITE
BLUE

0−5 VDC OUT Z

NON−FLIGHT INSTRUMENT DIMMER 7

8
NOTE 9
10
1. FOR WIRE NUMBERS REFER TO WIRING
MANUAL.
LEGEND
WIRING
EFFECTIVITY SUPPLY
HELICOPTERS 0419 − 0431. OIL PRESSURE CB0573
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram

(Helicopters 0419 - 0431)
Figure 103 (Part 1 of 3) 66-61-00
Page 115/116
Jul 31/96
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

1
2
3 BLUE
4 WHITE
5 ORANGE
6 GREEN

OIL COOLER
J912
P912 S R

OIL TEMPERATURE
WARNING SWITCH P916 B A P909 B C D A BREATHER
121.50 2.80C
(2500 50F) OIL
PRESSURE
TRANSMITTER
OIL COOLER
BYPASS VALVE
OPENS BELOW
600 − 710C
(1400 − 1600F)
OPENS AT 35 PSID
DIFFERENTIAL
PRESSURE INDICATOR FILTER
12 3 PSID OIL
COOLER
BLOWER

OIL FILLER FILTER

BYPASS
OPEN 20 4
PSID

OIL LEVEL
SIGHT
LOW OIL PRESSURE
WINDOW
WARNING SWITCH
CHECK (14 2 PSI)
CHECK VALVE
VALVE

P918 3 2 1
LUBRICATION
PUMP PUMP PUMP RELIEF
VALVE
RELIEF
VALVE

P912 U T
J912
CHIP OIL
DETECTOR / TEMPERATURE
STRAINER SENSOR CHIP
DETECTOR/
STRAINER

P908 B A
7 WHITE DRAIN PLUG
8 BLUE
9
10

CB0119_2
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram
(Helicopters 0419 - 0431) (Helicopters 0419 - 0431)
Figure 103 (Part 2) 66-61-00 Figure 103 (Part 3) 66-61-00
Page 117/118
Jul 31/96
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
1
XMSN OIL 2
WARN TEMP P118 J118 P900 J900 3
4
2 T R 5
AMP 6
DC
ESS XMSN OIL
BUS WARN PRESS
2 S T
AMP

LOWER CIRCUIT BREAKER PANEL

XMSN

ORANGE
GREEN
OIL TEMP P208 J208

WHITE
BLUE
NO. 2 2
DC PRI g
AMP
BUS
PRESS
XMSN P207 J207
NO. 1 2 n
DC PRI AMP Q
BUS

UPPER CIRCUIT BREAKER PANEL P913 V W X Y

J913
P1 J214 P214 P900 J900
MAIN XMSN
S CC S
OIL HOT
Q

MAIN XMSN J901

R DD U
OIL PRESS P901 V W X Y

Q
CAUTION / ADVISORY PANEL
P11
P213 t u v w
L
J213
A Q
R BLUE
H WHITE
J ORANGE
M GREEN
F WHITE
J213 P213 P901 J901
G BLUE
B s P
P
C
r N
P GG4−3 P
P
D
J913
MAIN GEAR BOX OIL
TEMPERATURE / PRESSURE INDICATOR P913 N P
INSTRUMENT PANEL P
P109
WHITE
BLUE

0−5 VDC OUT Z

NON−FLIGHT INSTRUMENT DIMMER 7

8
NOTE 9
10
1. FOR WIRE NUMBERS REFER TO WIRING
MANUAL.
LEGEND
WIRING
EFFECTIVITY SUPPLY
HELICOPTERS 0432 − 9999. OIL PRESSURE CB0574
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram

(Helicopters 0432 - 9999)
Figure 104 (Part 1 of 3) 66-61-00
Page 119/120
Jul 31/96
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

1
2
3 BLUE
4 WHITE
5 ORANGE
6 GREEN

OIL COOLER
J912
P912 S R

OIL TEMPERATURE
WARNING SWITCH P916 B A P909 B C D A BREATHER
121.50 2.80C
(2500 50F) OIL
PRESSURE
TRANSMITTER
OIL COOLER
BYPASS VALVE
OPENS BELOW
600 − 710C
(1400 − 1600F)
OPENS AT 35 PSID
DIFFERENTIAL
PRESSURE INDICATOR FILTER
12 3 PSID OIL
COOLER
BLOWER

OIL FILLER FILTER

BYPASS
OPEN 20 4
PSID

OIL LEVEL
SIGHT
LOW OIL PRESSURE
WINDOW
WARNING SWITCH
CHECK (14 2 PSI)
CHECK VALVE
VALVE

P918 3 2 1
LUBRICATION
PUMP PUMP PUMP RELIEF
VALVE
RELIEF
VALVE

P912 U T
J912
CHIP OIL
DETECTOR / TEMPERATURE
STRAINER SENSOR CHIP
DETECTOR/
STRAINER

P908 B A
7 WHITE DRAIN PLUG
8 BLUE
9
10

CB0119_2
SA

Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram Main Gear Box Oil Temperature/Pressure Indicating System - Schematic Diagram
(Helicopters 0432 - 9999) (Helicopters 0432 - 9999)
Figure 104 (Part 2) 66-61-00 Figure 104 (Part 3) 66-61-00
Page 121/122
Jul 31/96
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL TEMPERATURE/PRESSURE INDICATING SYSTEM - MAINTENANCE PRACTICES

1. Oil Temperature Sensor Replacement.

A. Replace Oil Temperature Sensor (Figure 201).

(1) Remove access panel in baggage compartment.

(2) Drain main gear box. (Refer to SERVICING, CHAPTER 12.)

(3) Turn off all electrical power and disconnect electrical connector from oil temperature sensor.

(4) Remove sensor from main gear box lower housing.

(5) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing on replacement sensor.

(6) Install sensor in port on bottom of gear box lower housing and lockwire.

(7) Connect electrical connector to sensor and lockwire.

(8) Install access panel in baggage compartment.

(9) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

2. Oil Pressure Transmitter Replacement.

A. Replace Oil Pressure Transmitter (Figure 202).

(1) Remove left or right main gear box fairing.

(2) Turn off all electrical power and disconnect electrical connector from oil pressure transmitter.

(3) Remove oil pressure transmitter.

(4) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing on replacement oil pressure transmitter.

(5) Install oil pressure transmitter in port on aft side of main gear box and lockwire.

(6) Connect electrical connector to oil pressure transmitter and lockwire.

(7) Install main gear box fairing.

66-61-00
Page 201
Jul 31/93
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

PACKING
OIL TEMPERATURE
SENSOR

D
A FW
CB0120
SA

Oil Temperature Sensor - Replacement

Figure 201

66-61-00
Page 202
Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL PRESSURE
TRANSMITTER

PACKING

D
FW

CB0121
SA

Oil Pressure Transmitter - Replacement

Figure 202

66-61-00
Page 203/204
Jan 15/92
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL HOT WARNING SYSTEM- DESCRIPTION AND OPERATION

1. Description and Operation (Figures 1 and 2).

A main gear box oil temperature light marked MAIN XMSN OIL HOT is on the caution/advisory panel. The
warning light goes on when oil inlet temperature at the oil temperature warning switch, on the gear box rear
cover is about 105°C (221°F). The system is connected to the dc essential bus by a circuit breaker marked XMSN
OIL WARN TEMP.

P912 / J912

P900 / J900

P118 / J118 B

P1
P916

D
FW

OIL TEMPERATURE
WARNING SWITCH

A
P214 / J214 B

MAIN XMSN
OIL HOT

CAUTION/ADVISORY PANEL CB0122

SA

Main Gear Box Oil Hot Warning System - Location Diagram

Figure 1

66-62-00
Page 1
Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

XMSN OIL
WARN TEMP P916
DC
ESNTL 2 A
BUS AMP

MAIN XMSN
OIL HOT TRANSMISSION OIL
TEMPERATURE SWITCH

CC1991
SA

Main Gear Box Oil Hot Warning System - Simplified Schematic Diagram
Figure 2

66-62-00
Page 2
Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL HOT WARNING SYSTEM - TESTING AND TROUBLESHOOTING

1. Testing and Troubleshooting.

A. Operational Test.For operational test of the main gear box oil hot warning system, refer to Main Gear Box
Oil Temperature/Pressure Indicating System, Testing and Troubleshooting, 66-61-00.

66-62-00
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Jan 15/92
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL HOT WARNING SYSTEM - MAINTENANCE PRACTICES

1. Oil Temperature Warning Switch Replacement.

A. Replace Oil Temperature Warning Switch (Figure 201).

(1) Remove left or right main gear box fairing.

(2) Turn off all electrical power and disconnect electrical connector from switch.

(3) Remove oil temperature warning switch.

(4) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing on replacement switch.

(5) Install switch in port on aft side of main gear box and lockwire.

(6) Connect electrical connector to oil temperature warning switch and lockwire.

(7) Install main gear box fairing.

66-62-00
Page 201
Jun 31/93
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

OIL TEMPERATURE
WARNING SWITCH

A PACKING

D
FW

CB0123
SA

Oil Temperature Warning Switch - Replacement

Figure 201

66-62-00
Page 202
Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL LOW PRESSURE WARNING SYSTEM- DESCRIPTION AND OPERATION

1. Description and Operation (Figures 1 and 2).

A main gear box oil low pressure warning light marked MAIN XMSN OIL PRESS is on the caution/advisory
panel. The warning light will go on when oil pressure in the main gear box is sensed at the low oil pressure
warning switch below about 14 psi. The system is connected to the dc essential bus by a circuit breaker marked
XMSN OIL WARN PRESS.

66-63-00
Page 1
Jan 15/92
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
P912 / J912

P900 / J900

P118 / J118 B

P1
P918

D
FW

A
P214 / J214 B
MAIN XMSN
OIL PRESS

LOW OIL
PRESSURE
WARNING
SWITCH

CAUTION/ADVISORY PANEL CB0124

SA

Main Gear Box Oil Low Pressure Warning System - Location Diagram
Figure 1

66-63-00
Page 2
Jan 15/92
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

XMSN OIL P918

WARN
PRESS
1
DC
ESNTL 2 2
BUS AMP 3

MAIN XMSN
OIL PRESS TRANSMISSION OIL
PRESSURE SWITCH

CC1992
SA

Main Gear Box Oil Low Pressure Warning System - Simplified Schematic Diagram
Figure 2

66-63-00
Page 3/4
Jan 15/92
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL LOW PRESSURE WARNING SYSTEM - TESTING AND TROUBLESHOOTING

1. Testing and Troubleshooting.

A. Operational Test.For operational test of the main gear box oil low pressure warning system, refer to Main
Gear Box Oil Temperature/Pressure Indicating System, Testing and Troubleshooting, 66-61-00.

66-63-00
Page 101/102
Jan 15/92
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
MAIN GEAR BOX OIL LOW PRESSURE WARNING SYSTEM - MAINTENANCE PRACTICES

1. Oil Low Pressure Warning Switch Replacement.

A. Replace Oil Low Pressure Warning Switch (Figure 201).

(1) Drain main gear box. (Refer to SERVICING, CHAPTER 12.)

(2) Remove left main gear box fairing.

(3) Turn off all electrical power and disconnect electrical connector from pressure switch.

(4) Remove oil low pressure warning switch.

(5) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
and install packing on replacement switch.

(6) Install oil low-pressure warning switch in port on left side of main gear box rear cover and lockwire.

(7) Connect electrical connector to switch and lockwire.

(8) Service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(9) Install left main gear box fairing.

66-63-00
Page 201
Jul 31/93
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

LOW OIL PRESSURE

A WARNING SWITCH

A
D
FW

PACKING

CB0125
SA

Oil Low-Pressure Warning Switch - Replacement

Figure 201

66-63-00
Page 202
Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
GEAR BOX CHIP DETECTOR/OVERTEMP WARNING SYSTEM- DESCRIPTION AND OPERATION

1. Description and Operation (Figures 1 and 2).

The MAIN XMSN CHIP warning capsule on the caution/advisory panel goes on when metal chips are detected in
the oil sump of the main gear box. Once the capsule is switched on by the detector unit, a holding circuit will keep
the capsule on until power is removed by pulling the circuit breaker, or until the electrical system is shut down. The
chip detector system is connected to the dc essential bus by a circuit breaker marked CHIP DET MGB. The chip
detectors incorporate a fuzz burn-off feature, which eliminates small particles, about 0.001 x 0.001 x 0.200 in.
that could give false indications. The main gear box has a separate overtemp warning system. For description and
operation, refer to Main Gear Box Oil Hot Warning System, 66-62-00.

The INT GB CHIP/HOT and TAIL GB CHIP/HOT warning capsules on the caution/advisory panel go on when
metal chips are detected in the oil sump of the respective gear box. The intermediate and tail gear box warning
capsules will also go on whenever oil temperature goes above about 140°C (284°F). Once a capsule is switched
on by the detector unit, a holding circuit will keep the capsule on until power is removed by pulling the appro-
priate circuit breaker, or until the electrical system is shut down. The chip detector/overtemp system is connected
to the dc essential bus by a circuit breaker marked CHIP DET I/TGB. The chip detectors incorporate a fuzz burn-off
feature, which eliminates small particles, about 0.001 x 0.001 x 0.200 in. that could give false indications.

66-64-00
Page 1/2
Jul 31/96
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

P503

B C

P910

P117 / J117

NO.1 RELAY P502

PANEL
P105

P106

P400 / J400
D
FW D
NO.2 RELAY FW
PANEL
P315 / J315 MAIN GEAR BOX
CHIP DETECTOR /
STRAINER RH MAIN GEAR BOX
A CHIP DETECTOR /
P911 STRAINER LH

P913 / J913
B C
P901 / J901
E D
P313 / J313

LOWER CIRCUIT
BREAKER PANEL
P1 P212 / J212

INT GB
CHIP / HOT

MAIN XMSN TAIL GB

CHIP CHIP / HOT

TAIL GEAR BOX INTERMEDIATE

CHIP / TEMPERATURE GEAR BOX CHIP /
CAUTION/ADVISORY PANEL DETECTOR TEMPERATURE DETECTOR CB0126
SA

Gear Box Chip Detector/Overtemp Warning System Gear Box Chip Detector/Overtemp Warning System
Figure 1 (Part 1 of 2) Figure 1 (Part 2)
66-64-00 66-64-00
Page 3/4
Jan 15/92
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
P911
P1 A
INT GB
CHIP/TEMP a

TAIL GB b
CHIP/TEMP
C
B
MAIN
XMSN Z
CHIP MAIN GEAR BOX
CHIP DETECTOR
P910

CAUTION/ADVISORY A
PANEL

B1 B2
CHIP DET
MGB
DC
X1 X2 C
ESNTL
2
BUS B
AMP
A2 A1
MGB
K3/1R MAIN GEAR BOX
CHIP DETECTOR
NO. 1 RELAY P503
PANEL
A

B1 B2 THERMAL SWITCH
CHIP DET CLOSED >1320 TO 1480C
IGB/TGB (2690 TO 2990F)
DC
ESNTL X1 X2
2 C
BUS AMP
B
A2 A1
TGB
K5/2R TAIL GEAR BOX
CHIP DETECTOR
P502

B1 B2 THERMAL SWITCH
CLOSED >1320 TO 1480C
(2690 TO 2990F)
X1 X2
C
B
A2 A1
IGB
K4/2R INTERMEDIATE
GEAR BOX
CHIP DETECTOR
NO. 2 RELAY PANEL
CB0579
SA

Gear Box Chip Detector/Overtemp Warning System -

Simplified Schematic Diagram
Figure 2 66-64-00
Page 5/6
Jul 31/96
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
GEAR BOX CHIP DETECTOR/OVERTEMP WARNING SYSTEM - TESTING AND TROUBLESHOOTING

1. Testing and Troubleshooting.

A. Prepare for Operational Test.

(1) Special Tools and Equipment.

(a) Iron Wire, 0.001-inch diameter, Zapper Check Kit, 1C136, Technical Development Company
(TEDECO), 24 East Glenolden Ave., Glenolden, PA 19036.

B. Operational Test (Figures 101 and 102).

NOTE: If troubleshooting because of a chip caution light going on in flight, go to Trouble No. 1, 2, or 3.

(1) On lower circuit breaker panel, make certain CHIP DET MGB and I/TGB circuit breakers are pushed in.

(2) Connect source of external dc power.

(3) Disconnect connector P911 from left main gear box chip detector.

(4) Connect jumper wire between pins A and B of connector P911.

RESULT:

- MAIN XMSN CHIP capsule on caution/advisory panel should go on.

CORRECTIVE ACTION:

- If MAIN XMSN CHIP caution capsule does not go on, go to Trouble No. 4.

(5) Disconnect jumper wire between pins A and B.

RESULT:

- MAIN XMSN CHIP caution capsule should remain on.

CORRECTIVE ACTION:

- If MAIN XMSN CHIP caution capsule does not remain on, check for ground at contact A2 of relay K3
on No. 1 relay panel. If there is no ground, repair ground. If there is ground, replace relay K3.

(6) Remove chip detector. (Refer to Maintenance Practices, Main Gear Box Chip Detector/Strainer Replace-
ment.) Clean chip detector using dry-cleaning solvent, Fed. Spec P-D-680, Type II, dry shop air, and
cheesecloth. Test chip detector, refer to step (23).

(7) Pull out and push in CHIP DET MGB circuit breaker on lower circuit breaker panel.

(8) Disconnect connector P910 from right main gear box chip detector.

66-64-00
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Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(9) Connect jumper wire between pins A and B of connector P910.

RESULT:

- MAIN XMSN CHIP caution capsule should go on.

CORRECTIVE ACTION:

- If MAIN XMSN CHIP caution capsule does not go on, check for ground at pin B of connector P910.
If there is no ground, repair ground. If there is ground, repair/replace wiring between pin A of
connector P910 and pin of connector P901.

(10) Remove chip detector. (Refer to Maintenance Practices, Main Gear Box Chip Detector/Strainer
Replacement.) Clean chip detector using dry-cleaning solvent, Fed. Spec P-D-680, Type II, dry shop
air, and cheesecloth. Test chip detector, refer to step (23).

(11) Disconnect connector P502 from intermediate gear box chip detector.

(12) Connect jumper wire between pins A and B of connector P502.

RESULT:

- INT GB CHIP/HOT caution capsule should go on.

CORRECTIVE ACTION:

- If INT GB CHIP/HOT caution capsule does not go on, go to Trouble No. 5.

(13) Disconnect jumper wire between pins A and B.

RESULT:

- INT GB CHIP/HOT caution capsule should remain on.

CORRECTIVE ACTION:

- If INT GB CHIP/HOT caution capsule does not remain on, check for ground at contact A2 of relay
K4 on No. 2 relay panel. If no ground, repair ground. If there is ground, replace relay K4.

(14) Pull out and push in CHIP DET I/TGB circuit breaker on lower circuit breaker panel.

(15) Connect jumper wire between pins C and B of connector P502.

RESULT:

- INT GB CHIP/HOT caution capsule should go on.

CORRECTIVE ACTION:

- If INT GB CHIP/HOT caution capsule does not go on, repair/replace wiring between pin C of
connector P502 and pin of connector P400.

66-64-00
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Jan 15/92
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(16) Drain intermediate gear box and remove chip detector, including valve assembly. (Refer to Mainte-
nance Practices, Intermediate Gear Box Chip Detector Replacement.) Clean chip detector and valve
assembly using dry-cleaning solvent, Fed. Spec P-D-680, Type II, dry shop air, and cheesecloth. Install
chip detector probe in valve and test chip detector, refer to step (23).

(17) Disconnect connector P503 from tail gear box chip detector.

(18) Connect jumper wire between pins A and B of connector P503.

RESULT:

- TAIL GB CHIP/HOT caution capsule should go on.

CORRECTIVE ACTION:

- If TAIL GB CHIP/HOT caution capsule does not go on, go to Trouble No. 6.

(19) Disconnect jumper wire between pins A and B.

RESULT:

- TAIL GB CHIP/HOT caution capsule should remain on.

CORRECTIVE ACTION:

- If TAIL GB CHIP/HOT caution capsule does not remain on, check for ground at contact A2 of relay
K5 on No. 2 relay panel. If there is no ground, repair ground. If there is ground, replace relay K5.

(20) Pull out and push in CHIP DET I/TGB circuit breaker on lower circuit breaker panel.

(21) Connect jumper wire between pins C and B of connector P503.

RESULT:

- Tail GB CHIP/HOT caution capsule should go on.

CORRECTIVE ACTION:

- If TAIL GB CHIP/HOT caution capsule does not go on, repair/replace wiring between pin C of
connector P503 and pin of connector P400.

(22) Drain tail gear box and remove chip detector, including valve assembly. (Refer to Maintenance Prac-
tices, Tail Gear Box Chip Detector Replacement.) Clean chip detector and valve assembly using dry-
cleaning solvent, Fed. Spec P-D-680, Type II, dry shop air, and cheesecloth. Install chip detector probe
in valve and test chip detector, refer to step (23).

CAUTION: SEE WARNING CONTAINED IN STANDARD PRACTICES - COMSUMABLE MATERIALS,

20-50-00, WHEN USING FLAMMABLE MATERIALS.

NOTE: Intermediate and tail gear box chip detector probes should be installed in valves prior to
testing.

(23) Test main, intermediate, and tail gear box chip detectors as follows:

66-64-00
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Nov 15/01
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(a) Apply 28 vdc to pin A of applicable chip detector with test lamp in series with pin A and power
source.

(b) Connect ground to pin B.

(c) Short out chip detector contacts with a clean screwdriver. On main gear box chip detectors, test
chip detector with screwdriver held across each of three gaps (blue-gray color separators). Hold
screwdriver in place.

RESULT:

- Test light should go on.

CORRECTIVE ACTION:

- If test light does not go on, replace chip detector.

(d) Remove screwdriver and keep 28 vdc connector to pin A for 1 minute.

(e) Disconnect 28 vdc from pin A and short out chip detector contacts within 1 minute, using a
0.001-inch-diameter iron wire from Zapper Check Kit, 1C136, Technical Development Company
(TEDECO).

RESULT:

- Wire should burn-off.

CORRECTIVE ACTION:

- If wire does not burn-off, clean chip detector contacts and repeat test. If after three attempts,
wire does not burn-off, replace chip detector.

(f) If testing intermediate or tail gear box chip detectors, do this:

1 Install chip detector probe in valve.

2 Apply 28 vdc to pins A and C of chip detector, with test lamp in series with pin C and power
source. Make sure ground is still connected to pin B.

3 Place chip detector assembly, up to packing groove on valve, in hot oil bath of gear box oil.
Keep chip detector in oil for 15 minutes at 148°C (299°F) or until test lamp goes on.

RESULT:

- Test lamp should go on.

CORRECTIVE ACTION:

- If test lamp does not go on, replace chip detector valve assembly.

4 Disconnect 28 vdc power.

(g) Remove ground and test lamp.

66-64-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
(h) Install chip detector in gear box with new packing and service gear box, if necessary. Refer to
Maintenance Practices.

66-64-00
Page 104A/104B
Nov 15/01
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TROUBLE NO. 1 TROUBLE NO. 2
MAIN XMSN CHIP CAUTION CAPSULE INT GB CHIP/HOT CAUTION CAPSULE
GOES ON DURING FLIGHT. GOES OUT DURING FLIGHT.

DISCONNECT CONNECTOR P910 DISCONNECT CONNECTOR P502

AND P911 FROM MAIN GEAR BOX FROM INTERMEDIATE GEAR BOX
CHIP DETECTORS. CHIP DETECTOR.

PULL OUT AND PUSH IN CHIP DET PULL OUT AND PUSH IN CHIP DET
MGB CIRCUIT BREAKER ON I/TGB CIRCUIT BREAKER ON
LOWER CIRCUIT BREAKER PANEL. LOWER CIRCUIT BREAKER PANEL.
DOES CAUTION CAPSULE GO DOES CAUTION CAPSULE GO
OFF? OFF?

YES NO YES NO

REMOVE AND INSPECT BOTH CHECK FOR SHORTS BETWEEN REMOVE AND INSPECT CHIP CHECK FOR SHORTS BETWEEN
LEFT AND RIGHT CHIP PIN A OF CONNECTORS P910 AND DETECTOR FOR METAL PARTICLE PIN A AND C OF CONNECTOR
DETECTORS FOR METAL P911 AND PIN m OF CONNECTOR CONTAMINATION. P502 AND PIN FF OF CONNECTOR
PARTICLE CONTAMINATION. P105. P106.
YES NO
YES NO YES NO YES NO

DO A SERVICEABILITY CHECK OF TEST CHIP DETECTORS. REFER REPAIR / REPLACE WIRING. REPLACE RELAY K3 ON NO.1 DO A SERVICEABILITY CHECK OF TEST CHIP DETECTOR. REFER TO REPAIR/REPLACE WIRING. REPLACE RELAY K4 ON NO.2
MAIN GEAR BOX. TO OPERATIONAL TEST, STEP RELAY PANEL. INTERMEDIATE GEAR BOX. OPERATIONAL TEST, STEP (23). RELAY PANEL.
(23). DOES CHIP DETECTOR TEST OK?

YES NO

REPLACE GEAR BOX REPLACE CHIP DETECTOR.

S76A_47127.1 (C27)
SA

Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart
Figure 101 (Part 1 of 9) Figure 101 (Part 2)
66-64-00 66-64-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TROUBLE NO. 3
TAIL GB CHIP / HOT CAUTION CAPSULE
GOES ON DURING FLIGHT.

DISCONNECT CONNECTOR P503

FROM TAIL GEAR BOX CHIP DE−
TECTOR.

PULL OUT AND PUSH IN CHIP DET

I / TGB CIRCUIT BREAKER ON
LOWER CIRCUIT BREAKER
PANEL. DOES CAUTION CAPSULE
GO OFF?

YES NO

REMOVE AND INSPECT CHIP DE− CHECK FOR SHORTS BETWEEN

TECTOR FOR METAL PARTICLE PIN A AND C OF CONNECTOR
CONTAMINATION. P503 AND PIN CC OF CONNEC−
TOR P106.
YES NO
YES NO

DO A SERVICEABILITY CHECK OF TEST CHIP DETECTOR. REFER TO REPAIR / REPLACE WIRING. REPLACE RELAY K5 ON NO. 2 RE−
TAIL GEAR BOX. OPERATIONAL TEST, STEP (23). LAY PANEL.
DOES CHIP DETECTOR TEST OK?

YES NO

REPLACE GEAR BOX. REPLACE CHIP DETECTOR.

S76A_47127_2 (C27)
SA

Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart

Figure 101 (Part 3)
66-64-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TROUBLE NO. 4
MAIN XMSN CHIP CAUTION CAPSULE
WILL NOT GO ON.

CHECK THAT CHIP DET MGB CIR−

CUIT BREAKER IS IN.

YES NO

PUSH TEST BUTTON ON CAUTION / PUSH IN CIRCUIT BREAKER. IF

ADVISORY PANEL. DOES CAP− CIRCUIT BREAKER POPS, CHECK
SULE GO ON? SYSTEM FOR SHORT CIRCUIT.
REPAIR / REPLACE COMPONENTS
YES NO OR WIRING AS REQUIRED.

CHECK FOR 28 VDC AT PIN A OF REPLACE BULB.

CONNECTOR P911.

YES NO

CHECK FOR GROUND AT PIN B CHECK FOR 28 VDC AT PIN n OF

OF CONNECTOR P911. CONNECTOR P105.
YES NO YES NO

CHECK FOR 28 VDC AT PIN k OF REPAIR / REPLACE GROUND. WITH POWER OFF, CHECK FOR WITH POWER OFF, CHECK FOR
CONNECTOR J213. CONTINUITY BETWEEN PIN A OF CONTINUITY BETWEEN PIN n OF
CONNECTOR P911 AND PIN m OF CONNECTOR P105 AND CHIP DET
YES NO CONNECTOR P105. MGB CIRCUIT BREAKER.

YES NO YES NO

WITH POWER OFF, CHECK FOR WITH POWER OFF, CHECK FOR
CONTINUITY BETWEEN PIN k OF CONTINUITY BETWEEN PIN k OF
CONNECTOR P213 AND PIN Z OF CONNECTOR J213 AND PIN p OF REPLACE RELAY K3 ON NO. 1 REPAIR / REPLACE WIRING. REPLACE CHIP DET MGB CIRCUIT REPAIR / REPLACE WIRING BE−
CONNECTOR P1. CONNECTOR P105. RELAY PANEL. BREAKER. TWEEN PIN n OF CONNECTOR
P105 AND CHIP DET MGB CIRCUIT
YES NO YES NO BREAKER.

REPAIR / REPLACE CAUTION / AD− REPAIR / REPLACE WIRING. REPLACE RELAY K3 ON NO. 1 REPAIR / REPLACE WIRING.
VISORY PANEL. RELAY PANEL.

S76A_47127.3 (C27)
SA

Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart
Figure 101 (Part 4) Figure 101 (Part 5)
66-64-00 66-64-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TROUBLE NO. 5
INT GB CHIP / HOT CAUTION CAPSULE
WILL NOT GO ON.

CHECK THAT CHIP DET I / TGB

CIRCUIT BREAKER IS IN.

YES NO

PUSH TEST BUTTON ON CAU− PUSH IN CIRCUIT BREAKER. IF

TION / ADVISORY PANEL. DOES CIRCUIT BREAKER POPS, CHECK
CAPSULE GO ON? SYSTEM FOR SHORT CIRCUIT.
REPAIR / REPLACE COMPONENTS
YES NO OR WIRING AS REQUIRED.

CHECK FOR 28 VDC AT PIN A OF REPLACE BULB.

CONNECTOR P502.

YES NO

CHECK FOR GROUND AT PIN B CHECK FOR 28 VDC AT PIN GG OF

OF CONNECTOR P502. CONNECTOR P106.

YES NO YES NO

CHECK FOR 28 VDC AT PIN a OF REPAIR / REPLACE GROUND. WITH POWER OFF, CHECK FOR WITH POWER OFF, CHECK CHIP
CONNECTOR P1. CONTINUITY BETWEEN PIN A OF DET I / TGB CIRCUIT BREAKER
CONNECTOR P502 AND PIN FF FOR CONTINUITY.
YES NO OF CONNECTOR P106.
YES NO
YES NO

REPAIR / REPLACE CAUTION / AD− WITH POWER OFF, CHECK FOR

VISORY PANEL. CONTINUITY BETWEEN PIN a OF
CONNECTOR P1 AND HH OF CON− WITH POWER OFF, CHECK FOR REPAIR / REPLACE WIRING. REPAIR / REPLACE WIRING BE− REPLACE CIRCUIT BREAKER.
NECTOR P106. CONTINUITY BETWEEN PIN GG TWEEN CHIP DET I / TGB CIRCUIT
OF CONNECTOR J2 ON NO. 2 RE− BREAKER AND PIN GG OF CON−
YES NO LAY PANEL AND X1 OF RELAY K4 NECTOR P106.
AND PIN FF OF CONNECTOR J2
AND X2 OF RELAY K4.

YES NO
WITH POWER OFF, CHECK FOR REPAIR / REPLACE WIRING.
CONTINUITY BETWEEN PIN HH
OF CONNECTOR J2 ON NO. 2 RE−
LAY PANEL AND CONTACT B2 OF
RELAY K4 AND BETWEEN CON− REPLACE RELAY K4. REPAIR / REPLACE WIRING.
TACT B1 AND X1 OF RELAY K4.

YES NO

REPLACE RELAY K4. REPAIR / REPLACE WIRING.

S76A_47127.4 (C25)
SA

Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart
Figure 101 (Part 6) Figure 101 (Part 7)
66-64-00 66-64-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
TROUBLE NO. 6
TAIL GB CHIP / HOT CAUTION CAPSULE
WILL NOT GO ON.

CHECK THAT CHIP DET I / TGB

CIRCUIT BREAKER IS IN.

YES NO

PUSH TEST BUTTON ON CAU− PUSH IN CIRCUIT BREAKER. IF

TION / ADVISORY PANEL. DOES CIRCUIT BREAKER POPS, CHECK
CAPSULE GO ON? SYSTEM FOR SHORT CIRCUIT.
REPAIR / REPLACE COMPONENTS
YES NO OR WIRING AS REQUIRED.

CHECK FOR 28 VDC AT PIN A OF REPLACE BULB.

CONNECTOR P503.

YES NO

CHECK FOR GROUND AT PIN B CHECK FOR 28 VDC AT PIN GG OF

OF CONNECTOR P503. CONNECTOR P106.

YES NO YES NO

CHECK FOR 28 VDC AT PIN b OF REPAIR / REPLACE GROUND. WITH POWER OFF, CHECK FOR WITH POWER OFF, CHECK CHIP
CONNECTOR P1. CONTINUITY BETWEEN PIN A OF DET I / TGB CIRCUIT BREAKER
CONNECTOR P503 AND PIN CC FOR CONTINUITY.
YES NO OF CONNECTOR P106.
YES NO
YES NO

REPAIR / REPLACE CAUTION / AD− WITH POWER OFF, CHECK FOR

VISORY PANEL. CONTINUITY BETWEEN PIN b OF
CONNECTOR P1 AND PIN EE OF WITH POWER OFF, CHECK FOR REPAIR / REPLACE WIRING. REPAIR / REPLACE WIRING BE− REPLACE CIRCUIT BREAKER.
CONNECTOR P106. CONTINUITY BETWEEN PIN GG TWEEN CHIP DET I / TGB CIRCUIT
OF CONNECTOR J2 ON NO. 2 RE− BREAKER AND PIN GG OF CON−
YES NO LAY PANEL AND X1 OF RELAY K5 NECTOR P106.
AND PIN CC OF CONNECTOR J2
AND X2 OF RELAY K5.

YES NO
WITH POWER OFF, CHECK FOR REPAIR / REPLACE WIRING.
CONTINUITY BETWEEN PIN EE OF
CONNECTOR J2 ON NO. 2 RELAY
PANEL AND CONTACT B2 OF
RELAY K5 AND BETWEEN CON− REPLACE RELAY K5. REPAIR / REPLACE WIRING.
TACT B1 AND X1 OF RELAY K5.

YES NO

REPLACE RELAY K5. REPAIR / REPLACE WIRING.

S76A_47127.5 (C25)
SA

Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart Gear Box Chip Detector/Overtemp Warning System - Troubleshooting Chart
Figure 101 (Part 8) Figure 101 (Part 9)
66-64-00 66-64-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
P502
CHIP
P117 J117 A
DET MGB
2 K
AMP

DC P313 J313 P315 J315 J400 P400 THERMAL SWITCH

ESNTL SGP502-1 CLOSED >1320 TO 1480C
BUS U p a
GND502-1 (2690 TO 2990F)
CHIP DET B
I / TGB J313 P313

2 L W C
AMP

INTERMEDIATE GEAR BOX

LOWER CIRCUIT BREAKER PANEL CHIP DETECTOR
P503

P1 P213 J213 A

MAIN XMSN CHIP Z k

P212 J212 THERMAL SWITCH

SGP503-1 CLOSED >1320 TO 1480C
TAIL GB CHIP / HOT b D T g b (2690 TO 2990F)
GND503-1
B

C
INT GB CHIP / HOT a C

TAIL GEAR BOX

CAUTION / ADVISORY PANEL (SEE DETAIL A) CHIP DETECTOR
INSTRUMENT PANEL P901 J901 J913 P913 P911
SGP911-1
i i A

j j
J901 P901 J913 P913 THERMAL SWITCH
GND901-1 CLOSED >1320 TO 1480C
i i (2690 TO 2990F)
SGP911-2 B
P106 HH GG FF EE CC P105 p m n

j j J2 / 2R J2 / 1R C
SGXK3-2
GND901-1
MAIN GEAR BOX LEFT
SGXK7-2 SGXK7-1
EFFECTIVITY: HELICOPTERS 0375-0418. CHIP DETECTOR
SGXK3-3

GND / 1R
DETAIL A

SGXK4-2
P910
SGXK7-5

SGXK10-6

SGXK4-3
SGXK23-2
A
SGXK23-3
SGXK4-1
NOTE XK3 / 1R
XK4 / 2R THERMAL SWITCH
B3 B2 B1 A3 A2 A1 X2 X1 B3 B2 B1 A3 A2 A1 X2 X1 XK5 / 2R B3 B2 B1 A3 A2 A1 X2 X1
FOR WIRE NUMBER REFER TO WIRING CLOSED >1320 TO 1480C
MANUAL. (2690 TO 2990F)
B

EFFECTIVITY
INTERMEDIATE GEAR TAIL GEAR BOX MAIN GEAR BOX MAIN GEAR BOX RIGHT
HELICOPTERS PRIOR TO 0466. BOX CHIP DETECTOR CHIP DETECTOR CHIP DETECTOR CHIP DETECTOR
RELAY K4 / 2R RELAY K5 / 2R RELAY K3 / 1R
NO. 2 RELAY PANEL NO. 1 RELAY PANEL CC0033B
SA

Gear Box Chip Detector/Overtemp Warning System - Schematic Diagram Gear Box Chip Detector/Overtemp Warning System - Schematic Diagram
Figure 102 (Part 1 of 2) Figure 102 (Part 2)
66-64-00 66-64-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

GEAR BOX CHIP DETECTOR/OVERTEMP WARNING SYSTEM - MAINTENANCE PRACTICES

1. Main Gear Box Chip Detector/Strainer Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Chip Detector Remover/Installer, 76700-20203-041

B. Replace Chip Detector/Strainer (Figure 201).

NOTE: There are two chip detector/strainers on the main gear box. Replacement procedures are the same
for both.

(1) Remove left or right main gear box fairing.

(2) Turn off all electrical power and disconnect electrical connector from chip detector.

(3) Remove bolt, washer, and retainer from gear box.

(4) Turn outer liner and chip detector/strainer about 58°, using chip detector remover/installer, 76700-
20203-041. Remove chip detector/strainer from main gear box.

(5) If necessary, replace outer liner as follows:

(a) Drain main gear box. (Refer to SERVICING, CHAPTER 12.)

(b) Turn outer liner until tab on liner is lined up with pin on side of gear box housing.

CAUTION: TO PREVENT PIN FROM FALLING INTO GEAR BOX HOUSING, REACH INSIDE
LINER AND GRASP PIN AS IT IS PRESSED OUT.

(c) Remove old sealing compound and carefully press pin out of housing and liner.

(d) Remove outer liner from chip detector port and remove packing.

(e) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to new
packing and install packing in groove on replacement outer liner.

(f) Install outer liner in chip detector port, lining up bolthole in gear box housing.

(g) Carefully insert new pin in housing flush to 0.010 inch above spotface of housing.

(h) Check that liner does not pull out and that it turns freely from stop to stop (about 65°).

(i) Fill spotface in housing with sealing compound, MIL-S-8802, Class B.

(6) Apply same type lubricating oil, as used to service gear box per Servicing, 12-10-00, lightly to packing
on replacement chip detector/strainer.

66-64-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

(7) Insert chip detector/strainer into outer liner with alignment pins lined up. Turn outer liner and chip
detector/strainer about 58° to line up boltholes, using chip detector remover/installer, 76700-20203-
041.

(8) Place retainer in position over alignment pins and install bolt and washer to secure retainer. Torque
self-locking bolt to 110 inch-pounds.

(9) Connect electrical connector to chip detector.

(10) If outer liner was replaced, service main gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(11) Install left or right main gear box fairing.

2. Intermediate Gear Box Chip Detector Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Drain Attachment, H538A-3, Technical Development Corp.

B. Replace Chip Detector (Figure 202).

(1) Remove screws and remove tail cone end fairing.

(2) Turn off all electrical power and disconnect electrical connector from chip detector.

NOTE: If only the sensor plug is being replaced, it is not necessary to drain the intermediate gear box.
The valve closes when the sensor plug is removed.

(3) Drain intermediate gear box using drain attachment. (Refer to SERVICING, CHAPTER 12.)

(4) Remove chip detector.

(5) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and install on chip detector.

(6) Install chip detector in port on bottom of intermediate gear box. Torque chip detector to 95 inch-pounds
and lockwire chip detector.

(7) Connect electrical connector to chip detector.

(8) Service intermediate gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(9) Install tail cone end fairing and secure with screws.

3. Tail Gear Box Chip Detector Replacement.

A. Prepare for Replacement.

(1) Special Tools and Equipment.

(a) Drain Attachment, H538A-3, Technical Development Corp.

66-64-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

A RETAINER

D
FW PACKING
A

B CHIP DETECTOR / ALIGNMENT

STRAINER PIN

D
FW BOLT, WASHER
(TORQUE 110 IN. LBS)

NOTE
LEFT SIDE SHOWN
RIGHT SIDE (TYPICAL)

PIN
OUTER
LINER

D
FW
PACKING

ALIGNMENT PIN CB0127

SA

Main Gear Box Chip Detector/Strainer - Replacement

Figure 201
66-64-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

INTERMEDIATE
GEAR BOX

PACKING

A CHIP DETECTOR VALVE

(TORQUE TO
95 IN. LBS)
SENSOR
PLUG
ELECTRICAL
CONNECTOR

CS0319
SA

Intermediate Gear Box Chip Detector - Replacement

Figure 202
B. Replace Chip Detector (Figure 203).

(1) Unscrew and remove tail gear box fairing.

(2) Turn off all electrical power and disconnect electrical connector from chip detector.

NOTE: If only the sensor plug is being replaced, it is not necessary to drain the tail gear box. The valve
closes when the sensor plug is removed.

(3) Drain tail gear box using drain attachment. (Refer to SERVICING, CHAPTER 12.)

(4) Remove chip detector.

(5) Coat new packing lightly with same type lubricating oil, as used to service gear box per Servicing,
12-10-00, and install on chip detector.

(6) Install chip detector in port on bottom of tail gear box. Torque chip detector to 95 inch-pounds and
lockwire chip detector.

(7) Connect electrical connector to chip detector.

(8) Service tail gear box with proper oil. (Refer to SERVICING, CHAPTER 12.)

(9) Install tail gear box fairing and secure with screws.

66-64-00
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 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2

TAIL
GEAR
BOX

PACKING

CHIP DETECTOR
(TORQUE TO VALVE
95 IN. LBS)
SENSOR
PLUG

ELECTRICAL
CONNECTOR
CS0320
SA

Tail Gear Box Chip Detector - Replacement

Figure 203

66-64-00
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.
 S-76B
MAINTENANCE MANUAL, SA 4047-76B-2
CHIP DETECTOR RELAYS- DESCRIPTION AND OPERATION

1. Description and Operation.

The three chip detector relays, K3/1R on the No. 1 relay panel and K4/2R and K5/2R on the No. 2 relay panel,
receive electrical power from the dc essential bus through circuit breakers marked CHIP DET MGB, and CHIP DET
I/TGB. When a chip too large to be burned off is sensed within any of the three chip detectors the relay for the
chip detector is energized. Once energized, electrical power passes through a set of contacts within that relay to
light the appropriate chip detector caution capsule on the caution/advisory panel. Once a caution light is switched
on by one of the chip detectors, a holding circuit will keep the light on until power is removed by pulling the
appropriate circuit breaker, or until the electrical system is shut down. For a location diagram and simplified
schematic of the chip detector system, refer to Gear Box Chip Detector/Overtemp System, 66-64-00. For relay
removal/installation, refer to No. 1 and No. 2 Relay Panel Typical Relay - Maintenance Practices, 39-40-05 and
39-40-06.

66-64-01
Page 1/2
Mar 31/95
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This Document Contains Technical Data Controlled by the EAR. See WARNING and classifications on first page.