BHT-212-CRO-4[1].PDF Rapair Manual Tail Rotor

BHT-212-CR&O

POST OFFICE BOX 482 • FORT WORTH, TEXAS 76101

COMPONENT REPAIR AND OVERHAUL MANUAL

VOLUME 4TAIL ROTOR/TAIL ROTOR DRIVE SYSTEM

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

NOTICE

FOR MODEL 212

BHT-212-CR&O

POST OFFICE BOX 482 • FORT WORTH, TEXAS 76101

COPYRIGHT NOTICE

COPYRIGHT 2003

BELL ® HELICOPTER TEXTRON INC.

AND BELL HELICOPTER TEXTRON

CANADA LTD.

ALL RIGHTS RESERVED

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

NOTICE

26 JULY 1993REVISION 5 — 28 NOVEMBER 2003

COMPONENT REPAIR AND OVERHAUL MANUAL

VOLUME 4TAIL ROTOR/TAIL ROTOR DRIVE SYSTEM

BHT-212-CR&O

PN

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

Bell Helicopter Textron Inc.P. O. Box 482

Fort Worth, Texas 76101-0482

PROPRIETARY RIGHTS NOTICE

These data are proprietary to Bell Helicopter Textron Inc. Disclosure, reproduction, or use ofthese data for any purpose other than helicopter operation and/or maintenance is forbiddenwithout prior written authorization from Bell Helicopter Textron Inc.

BHT-212-CR&O

64-00-0028 NOV 2003 Rev. 5 Page 1

CHAPTER 64 — TAIL ROTOR

CONTENTS — MAINTENANCE PROCEDURES

Paragraph Chapter/Section PageNumber Title Number Number

64-1 Tail rotor hub and blade system........................................... 64-00-00 5

TAIL ROTOR HUB AND BLADE ASSEMBLIES

64-2 Tail rotor hub and blade assemblies .................................... 64-00-00 764-3 Tail rotor hub and blades (212-010-701) ......................... 64-00-00 764-8 Tail rotor hub (212-010-701)............................................. 64-00-00 1164-16 Tail rotor hub and blades (212-011-701) .......................... 64-00-00 1764-21 Tail rotor hub (212-011-701)............................................. 64-00-00 2464-29 Pitch Horn (212-010-716 and 212-011-708)..................... 64-00-00 3564-32 Tail rotor blades................................................................ 64-00-00 3664-38 Pitch change link .............................................................. 64-00-00 4764-41 Pitch change components ................................................ 64-00-00 4764-44 Crosshead assembly ........................................................ 64-00-00 49

FIGURES

Figure PageNumber Title Number

64-1 Tail rotor hub and blades (212-010-701) ................................................................ 964-2 Balancing tail rotor hub and blades (212-010-701).................................................. 1064-3 Tail rotor hub (212-010-701) ................................................................................... 1364-4 Tail rotor yoke and trunnion damage limits .............................................................. 1464-5 Tail rotor hub bearing replacement .......................................................................... 1864-6 Installation — tail rotor blade retention bearings...................................................... 1964-7 Tool for staking tail rotor blade retention bearings 212-010-731 or 205-012-710.... 2064-8 Tail rotor hub and blades (212-011-701) ................................................................. 2164-9 Balancing tail rotor hub and blades (212-011-701).................................................. 2364-10 Tail rotor hub (212-011-701) .................................................................................... 2664-11 Tail rotor trunnion damage limits.............................................................................. 2764-12 Tool for staking tail rotor blade retention bearings................................................... 30A64-13 Tail rotor yoke blade bearing replacement............................................................... 3164-14 Tail rotor trunnion centering tool .............................................................................. 3264-15 Tail rotor yoke damage limits ................................................................................... 3364-16 Tail rotor trunnion housing damage limits ................................................................ 3464-17 Tail rotor blade pitch horn damage limits (212-010-716) ......................................... 3764-18 Tail rotor blade pitch horn damage limits (212-011-708) ......................................... 3864-19 Pitch horn bushing replacement .............................................................................. 4064-20 Deleted..................................................................................................................... 4164-21 Deleted..................................................................................................................... 4364-22 Tail rotor blade butt sealing...................................................................................... 4664-23 Tail rotor blade refinishing........................................................................................ 4864-24 Pitch change link damage and repair limits ............................................................. 5064-25 Pitch change components damage and repair limits ............................................... 5164-26 Lever bushing replacement...................................................................................... 52

BHT-212-CR&O

64-00-00Page 2 Rev. 5 28 NOV 2003

FIGURES (CONT)


64-27 Crosshead assembly damage and repair limits ....................................................... 5364-28 Static stop damage and repair limits........................................................................ 5464-29 Tail rotor yoke bearing work aid............................................................................... 55

CONSUMABLE MATERIAL LIST

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

ITEMNO. NOMENCLATURE

CAGE/FSCM/SOURCE

C-001 Grease, Aircraft General Purpose, MIL-G-81322 (Aeroshell No. 22 or Mobil No. 28) Commercial

C-031 Lubricating Oil, MIL-O-6082, Grade 1100, SAE 50 Commercial

C-040 Lubricating Oil, Light Machine (3 in 1 or equivalent) Commercial

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

C-104 Corrosion Preventive Compound, MIL-C-16173, Grade 2 Commercial

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

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

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

C-204 Epoxy Polyamide Primer, MIL-P-23377, MIl-P-85582, Type I. Refer to text for color. 22873

C-245 Coating, Polyurethane, MIL-C-85285 81349

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

C-305 Aliphatic Naphtha, TT-N-95, Type II Commercial

C-309 Methyl-Ethyl-Ketone (MEK), TT-M-261B, pH Insignificant (Alternate where MEK use prohibited: RHO SOLV 756) 83527

C-313 Adhesive, 299-947-099 or Metal Set A-4 orEA9340 orRP1258

97499904143356402684

C-317 Adhesive, Magnobond 6398 (299-947-100, Type II, Class 2) 2212197499

BHT-212-CR&O

64-00-0028 NOV 2003 Rev. 5 Page 3/4

CONSUMABLE MATERIAL LIST (CONT)

ITEMNO. NOMENCLATURE

CAGE/FSCM/SOURCE

C-318 Cleaning Compound, Alkaline Base, MIL-C-87936, pH Value 12 Max. (Detergent) Commercial

C-322 Adhesive, EC2216 04963

C-323 Epoxy Filler, 299-047-072, Type 1 orRP1257-3, EA960

9749906876

C-331 Adhesive, 299-947-125, Type IEA9309NA

9749933564

C-339 Alcohol, Ethyl, MIL-E-463 Commercial

C-340 Adhesive Tape for Nameplate, Film Type, Pressure (A/N 465 0.002 inch thick), (A/N 467 0.0031 inch thick), (Y9122 0.040 inch thick) 04963

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

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

C-386 Solvent, DuPont Prep-Sol 3919S 18873

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

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

C-407 Abrasive Pad, Nylon Web (Scotchbrite) L-P-0050, Type I, Class 1, Size 1 27713 or 76381

C-420 Masking Tape (12-inch Scotch Paper) No. 1000 2E760

C-422 Aluminum Wool, MIL-A-4864, Type II Commercial

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

C-424 Filler Putty, RP1257-3 02684

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

C-486 Cheesecloth (Bleached), CCC-C-440 Commercial

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

BHT-212-CR&O

TAIL ROTOR

64-1. TAIL ROTOR HUB AND BLADE are: Tail rotor hub and blade assembly, tailSYSTEM. rotor hub, and tail rotor blades.

The tail rotor hub and blade systemcomponents that are covered in this section

64-00-00Page 5/6

BHT-212-CR&O

TAIL ROTOR HUB AND BLADE ASSEMBLIES

64-2. TAIL ROTOR HUB AND BLADE 64-6. Assembly.ASSEMBLIES.

MATERIALS REQUIREDThis chapter provides maintenance, overhaul,and balancing information for tail rotor huband blade assemblies, 212-010-701 NUMBER NOMENCLATURE(paragraph 64-3) and 212-011-701(paragraph 64-16). C-104 Corrosion Preventive

Compound

64-3. TAIL ROTOR HUB AND BLADES(212-010-701). NOTE

Bolt shanks require corrosion64-4. Disassembly. preventive compound (C-104)

application prior to installation.NOTE

NOTEReview Mandatory RetirementSchedule in BHT-212-MM, and retireall items scheduled for retirement. Bolts (9) may be installed with heads

either inboard or outboard but allfour bolts shall be installed the

1. Remove nuts (2, figure 64-1), balance same.washer(s) (3) and washers (4).

1. Position blade grips over hub (1, figure2. Remove bolts (9) with washers (4) andremove blade (5). 64-1). Align hub bearings with holes in blade

and install bolts (9), washers (4), and nuts3. Remove nuts (12), washers (11), bolts (2). Torque nuts (2) 500 in.lbs. (56.49 Nm).(10), and pitch horn (6) from blade (5).Remove bolt (7) and washers (8) from pitch NOTEhorn (6). Repeat procedures for opposite

blade (5). Installation of balance washers, boltand torquing of nut will be

64-5. Inspection. accomplished during balancing ofhub and blade.

1. Refer to paragraph 64-10 for tail rotor hubinspection. 2. Install pitch horn (6) using bolts (10),

washers (11), and nuts (12). Torque nuts(12) 60 in.lbs. (6.7788 Nm). Repeat at other2. Refer to paragraph 64-18 for tail rotor

blade inspection. blade.

3. Refer to paragraph 64-20 for pitch horn 3. Balance tail rotor hub and assemblyinspection. (paragraph 64-7).

64-00-00Page 7

BHT-212-CR&O

64-7. Balancing (static). NOTE

Prior to storing arbor in kit case,MATERIALS REQUIRED after use, release setscrew and

allow internal spring-loaded damping

NUMBER NOMENCLATURE oil seal to move upward and seat.NUMBER NOMENCLATURE Do not retighten setscrew.C-405 Lockwire

6. Clean trunnion bore and cone seatsurfaces or rotor and position to locate data

SPECIAL TOOLS REQUIRED plates of hub upward. Place rotor on supportblocks with blocks contacting blade roots onflat outboard from blade bolts. Adjust blade

NUMBER NOMENCLATURE pitch to seat evenly on blocks.

7HEL075A Balancing kit 7. Remove pilot bushing (1) from storage

position on arbor (2).

7HEL087 Balancing kit 8. Position pilot bushing (3), large endupward, on arbor to align top surface(sensitivity setting reference surface) with the

1. Provide a work bench or flat top stand in 5 3/8 in. (136.525 mm) arbor scale position.a draft free area. Provide a hoist or other Temporarily secure with its setscrews (4).suitable means of suspension above thebench or in immediate area. 9. Insert arbor downward through trunnion

bore and seat bushing in cone of trunnion.2. Place two support blocks approximately5.0 in. (127 mm) high by 8.0 in. (203.2 mm) 10. Install pilot bushing (1), large endlong on bench top. Space parallel, 18 in. downward, on arbor lower end. Position(457.2 mm) apart. upward along arbor to engage trunnion bore

and seat in cone of trunnion. Secure by3. Remove 3165 arbor from 7HEL075A kit tightening both setscrews (5) evenly.case or 7HEL087 kit case and stand in avertical position supported in bore of kit case 11. With rotor resting on support blocks,block. adjust trunnion teeter position to visually align

arbor vertically. Maintain blade contact with4. Clean oil accumulation, if present, from blocks for pitch positioning.top end of arbor shaft and adjacent indicatorcollar (11, figure 64-2) with soft cloth or 12. Install base (6), hub extensiontissue. downward, on arbor lower end. Align length

of base with rotor span axis. Install upward5. Loosen retaining setscrew in indicator along arbor to position posts (7)collar, if tightened, and press indicator approximately 1/16 in. (1.58750 mm) belowdownward against light spring pressure to root and secure by tightening both setscrewsposition bottom surface approximately 0.005 (8) evenly.in. (0.127 mm) above black indicator disc. Apaper shim may be used. Lightly tighten 13. Carefully engage cable loop (9) of arborsetscrew to secure. Ensure indicator collar coupling with hoist hook and suspenddoes not contact indicator disc during any assembly clear of all obstructions withoutcondition of indicating movement. causing change to blade pitch or trunnion

position.

14. Loosen pilot bushing (3) setscrews andfirmly reseat bushing in cone of trunnion.Maintain seating pressure and secure by

64-00-00Page 8

BHT-212-CR&O

1. Hub2. Nut 23. Balance washer 34. Chamfered washer5. Blade 46. Pitch horn7. Balance bolt8. Balance washer9. Bolt

10. Bolt 611. Washer 1 1412. Nut13. Bolt holes 714. Bearings 10

10

9

212-R-64- 1

Figure 64-1. Tail rotor hub and blades (212-010-701)

moderately tightening both setscrews (4) objects, air drafts, or movement of nearbyevenly. personnel.

15. Recheck position of bushing top surface 19. Balance hub and blades chordwise usingto ensure arbor scale setting is maintained. a combination of AN960-416 and AN970-4Reset both pilot bushings if necessary to washers (12) as required (maximum of 10,maintain arbor setting and firm seating in any combination). Length of bolt (13) to betrunnion. AN4H-4A to AN4H-10A, as necessary, to

accommodate balance washers. See view A16. Ensure blades maintain clearance with accommodate balance washers. See view Afor balance indications. Torque bolt (13) 50posts of base. If friction of pitch change for balance indications. Torque bolt(13) 50

bearings cannot maintain blade position and to 70 in.lbs. (5.649 to 7.9086 Nm) and securepost clearance, allow both blades to pitch to to pitch horn using lockwire (C-405).trailing edge downward and rest on trailingposts. NOTE

17. Stabilize movements of suspended rotor If bolt is installed, at least oneand observe balance indicated by washer is required under bolthead.concentricity relationship of black indicatordisc (10) in top surface of arbor shaft with Alternate chordwise balance method:indicator collar (11). Acceptable balance is Use naion of and A

Use combinations of AN960-416 and AN970-4indicated when indicator collar remains withinedge limits of black indicator disc (view A). washers

symmetrically on 212-010-777 balance arms18. Ensure balance indications are not with AN4-4A thru AN4-11A bolts, length asaffected by interference from surrounding required, to accommodate washer stack and

MS21042L4 nut. Balance within 20 in.grams.Torque nut 60 in.lbs. (6.7788 Nm).

64-00-00Page 9

BHT-212-CR&O

212-010-777 BALANCE ARM

1. Pilot bushing (P/N 2529)2. Balance indicating arber (P/N 3165)3. Pilot bushing (P/N 32854. Setscrews5. Setscrews6. Base (P/N 3152)7. Post7. Post VIEW A8 Setscrews8. Setscrews BALANCE INDICATION9. Cable loop 10

10. Indicator disc11. Indicator collar12. Washers, chordwise balance13. Bolt 214. Washers, spanwise balance15. Blade attaching bolts BALANCED WITHIN EXCEEDS16. Balance arm for (212-010-701-23 LIMITS LIMITS

hub and blade assembly) SEE VIEW A 10

15

SENSITIVITY SETTING 2 12REFERENCE SURFACE 3 /

7 165 8 6

1 212-R-64-2

Figure 64-2. Balancing tail rotor hub and blades (212-010-701)

64-00-00Page 10

BHT-212-CR&O

21. Balance hub and blades spanwise by 64-10. Inspection.using combination of AN960-816, AN960-816L, AN970-8, and 212-010-764-1 washers NOTE(14), as required. Assemble with heaviestbalance washer next to chamfered washer. If records and/or physicalLength of bolt (15) to be NAS1308-34 to appearance of hub indicates hubNAS1308-36, as required to accommodate has been subjected to an accidentbalance washers. See view A for balance or incident outside realm of normal

usage, perform Conditionalindications. Torque nut 500 in.lbs. (56.49 unage paragraph 64-11. IfInspection, paragraph 64-11. IfNm). assembly does not require

conditional inspection, accomplishNormal Inspection, paragraph 64-12.

22. Recheck balance of hub and blades(steps 17. and 18.).

64-11. Conditional Inspection.

1. Visually inspect parts for apparent64-8. TAIL ROTOR HUB (212-010-701). damage or abnormal appearance.

2. Inspect parts for surface damage64-9. Disassembly. (paragraph 64-12).

3. DeletedNOTE

4. Check for bearing bolt hole deformation.Review Mandatory Retirement Bolt holes shall be round within 0.0005 in.Schedule (BHT-212-MM) and retire (0.0127 mm). Any deviation is cause forall items scheduled for retirement. replacing yoke.

If tail rotor h ub is bei n g 5. Inspect trunnion retention bolts and bladedisassembled for replacement of retention bolts for shear offset. Reject hubpart(s) instead of overhaul, assembly if any bolt shows shear offset.disassemble only to extentnecessary. 6. Inspect bearings for looseness in yoke.

Reject yoke if bearings are loose.

1. Remove trunnion halves (5 and 10, figure 7. Accomplish Normal Inspection,64-3) by removing nut (13), washers (2 and paragraph 64-12.12), bolt (1), indicator (3), shim (4), andbalance arm (11). Separate trunnion halves (5 64-12. Normal Inspection.and 10) and remove from yoke (7).

NOTENOTE

If an inspection is required which isTrunnion halves (5 and 10) are not Conditional, the yoke can beserialized and shall be replaced or magnetic particle inspected withoutretained as a matched set. removing bearings. Mask bearings to

prevent contamination.

2. Support hub on a suitable support having 1. Remove bearings (6 and 8,figure 64-3).clearance for bearings and press out bearings Remove tail rotor retention bearings (8) as(6 and 8). follows:

64-00-00Rev. 4 Page 11

BHT-212-CR&O

not to exceed 1.181 in. (29.9974CAUTION mm).

4. Inspect yoke (7, figure 64-3) and trunnionWHEN REMOVI NG OR halves (5 and 10) for mechanical andINSTALLING BEARINGS FROM corrosion damage (figure 64-4).YOKE ASSEMBLY, SUPPORTYOKE IN A MANNER TO AVOID 5. Inspect bolts (1) for cracks, corrosion,APPLYING EXCESSIVE BENDING and thread damage.LOADS.

6. The tail rotor yoke and trunnion halvesa. If necessary, carefully cut away and shall be inspected by all the following steps

remove lip on one side of bearing using a fly using wet continuous method. Use ofcutter. Do not cut into yoke. fluorescent coated particles with ultraviolet

light is mandatory. The length of anyb. Position yoke on support (figure 64- indication shall be determined by the residual

29). Press old bearings from yoke as follows: method of magnetization.

c. Orient yoke with bearing lip side NOTEtoward support surface. Align yoke bearingswith two pins in support and clamp yoke A c arcenecioIf AC magnetic particle inspectionagainst support surface. equipment is used, use 60% of D.C.

d. Adjust leveling foot (swivel) and its amperes specified.adapter against yoke to attain zero gap. a. Thoroughly degrease tail rotor yoke.Remove or position clamp so as not tointerfere with work area. b. Place yoke longitudinally between

e. And of one contact heads of inspection equipment. Passe. Align drift over one pin and press old 2500 amperes of DC current through yoke.bearing into support pocket. Repeat this 2500 amperes of D current through yokeoperation to press out adjacent bearing. Inspection y , ,c. Inspect yoke, under black light,

completely for indications.f. Rotate yoke ends. Repeat operations7a through 7c to complete removal of allbearings. axis of coil perpendicular to plane of coil.2. Clean aged primer from yoke bore. Magnetize yoke using 12,500 ampere turns.2. Clean aged primer from yoke bore.

e. Inspect yoke, under black light,3. Inspect bearing bores for mechanical and e yoke under lightcompletely for indications.corrosion damage (figure 64-4). completely for indications.

f. Repeat steps d. and e. atNOTE approximately 8 in. increments of yoke.

Trunnion spline depth - 0.0727 in. g. After completion of inspection(1.84658 mm); length - 1.540 in. demagnetize yoke and check with pocket field(39.116 mm). Maximum spline wear indicator or compass to assurebetween 0.060 in. (1.524 mm) pins, demagnetization.

64-00-00Page 12 Rev. 4

BHT-212-CR&O

5. Trunnion Half6. Bearing7. Yoke8. Bearing9. Data Plate

10. Trunnion Half11. Balance Arm12. Washer13. Nut

212-R-64-3

Figure 64-3. Tail rotor hub (212-010-701)

64-00-00Page 13

BHT-212-CR&O

TRUNNION SETYOKE ASSEMBLY PIN 212-010-738 2P/N 212-010-704P/N 212-010-744 DAMAGE LOCATION SYMBOLS

TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

MECHANICAL AND 0.002 IN. (0.508 mm) 0.005 IN. (0.127 mm)CORROSION(Before and after repair)

MECHANICAL AND 0.005 IN. (0.127 mm) 0.010 IN. (0.254mm)CORROSION(Before and after repair)

MAXIMUM AREA PER 0.10 SQ. IN. (2.54 SQ. mm) 0.15 SQ. IN. (3.81 SQ. mm)

FULL DEPTH REPAIR A. IN. 1.27 SQ. mm) 0.05 SQ. IN. (1.27 SQ. mm)

NUMBER OF REPAIR AREAS One per segment Not critical

2 One per lug Two

EDGE CHAMFER 0.010 IN 254 mm) 0.010 IN. (0.254 508 mm)

2010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

BORE DAMAGE .002 IN. (0.508 mm) for 1/4 circumference

SPLINE DAMAGE Depth: One-third of splineLength: One-half of splineNumber: Three

NOTE

Repair area must be coated with brush LHE cadmium plating solumation (C-108).

Repair area must be coated with primer (C-204). 212-R-64-4

Figure 64-4. Tail rotor yoke and trunnion damage limits

64-00-00Page 14

BHT-212-CR&O

64-13. Repair. paper (C-423). Transfer information fromremoved plate to new data plate. Clean fayingsurface of hub and data plate by rubbing with

MATERIALS REQUIRED clean cheesecloth saturated with alphaticRefer to BHT-ALL-SPM for specification and naphtha (C-305). Wipe surfaces dry withsource. clean cheesecloth immediately following

cleaning.NUMBER NOMENCLATURE

c. Remove protective liner from one sideC-108 Brush Cadmium of film type tape (C-340), 0.002 in. (0.0508

Plating Solution mm) thick) and apply tape to data plate.Remove protective liner from opposite side of

C-204 Primer tape and position data plate on hub. Applyfirm contact pressure to data plate and cure

C-305 Aliphatic Naptha at 70 to 80°F (21 and 27°C) for a minimum 24C-340 Tape hours.

C-406 Aluminum Oxide Cloth d. Ensure gap between data plate andhub does not exceed 0.006 in. (0.1524 mm).

C-423 Abrasive Cloth or Trim excess tape, as required, from perimeterPaper of data plate.

C-464 India Stone e. Inspect data plate for loose edges,C-500 Crocus Cloth edge voids and noncure of adhesive.

5. Clean damage from bearing bore up to aSPECIAL TOOLS REQUIRED maximum depth of 0.002 in. (0.05088 mm),

not to exceed 1/4 total circumference (figure64-4).

NUMBER NOMENCLATURE

T101577-13 BackstopCAUTION

1. Replace bolts (1, figure 64-3).WHEN REMOVING OR

2. Replace nuts (13) and washers (2 and INSTALLING BEARINGS FROM12). YOKE ASSEMBLY, SUPPORT

YOKE IN A MANNER TO AVOID3. Polish out mechanical and corrosion APPLYING EXCESSIVE BENDINGdamage using fine to medium aluminum oxide LOADS.cloth (C-406) or fine India stone (C-464) andcrocus cloth (C-500) to obtain a smooth a. Roll stake bearing as follows:scratch-free surface. Coat all repair areasexcept trunnion splines with brush cadmiumplating solution (C-108). Repair depths, NOTEareas, and number of repairs shall not exceedlimits (figures 64-4). The 205-012-710-001 bearings may

be used as an alternate for 212-010-4. Replace data plate (9, figure 64-3) if 731-001 bearings. The 205-012-710-edge voids or loose edges are found. 001 bearings shall be installed in

sets of four. Do not mix bearings.a. Remove loose data plate.

b. Clamp yoke on support (figure 64-29)b. Abrade contact surface of new data and adjust leveling foot (swivel) and its

plate with medium grade abrasive cloth or adapter against yoke to attain zero gap.

64-00-00Rev. 4 Page 15

BHT-212-CR&O

Remove or position clamp so as not to are aligned and staking tool rollers are ininterfere with work area. contact with the groove in the bearing.

c. Install new bearings on alignment pinsin support. Apply wet unreduced primer (C- CAUTION204) to mating surfaces of bearing and yoke.Using tool drift, position bearings in yoke todimensions shown in figure 64-6 while primer UNDUE FORCE OF STAKINGis wet. Remove excess primer with clean TOOL INTO PREGROOVE OFcloth. Do not allow primer to contact bearing BEARING MAY CAUSE EXCESSIVEuniball. REDUCTION OF OUTER LIP

METAL THICKNESS.d. Remove yoke with bearings from

support and rotate yoke ends to accomplishinstallation of all bearings in yoke. Clamp g. Start the drill press and apply steadyyoke to support and repeat item 7b.yoke to support and repeat item 7b. hand pressure to the feed lever for aminimum of ten seconds. Raise drill press

chuck and staking tool. Check to determineitems 7g and 7h. the amount that the bearing has been staked

in comparison with figure 64-6.

CAUTION h. Lift yoke from support and changebackstop (T101577-13) and anvil to differentpockets in support. Repeat operations 7c

THE FIRST STAKING OPERATION through 7g for staking adjacent bearing.SHALL BE PERFORMED WITHDATA PLATE (PRECONED) SIDEOF YOKE UP AND FLANGED SIDE i. Rotate yoke ends and repeatOF STAKING ANVIL DOWN operations 7c through 7h to complete stakingOF STAKING ANVIL DOWN(FIGURE 64-5). on one side of yoke.(FIGURE 64-5).

8. Position yoke on support for staking j. Reposition the backstop (T101577-13)bearings in yoke as follows: with flange side up in support pocket. Invert

the yoke and stake the opposite side of thetwo alignment pins from bearing in the same manner. Repeat stakinga. Remove two alignment pins from

the bearing in small increments to attain the.008 in. (0.20 mm) maximum gap shown infigure 64-6.

b. Insert backstop (T101577-13) flangeside down into either pocket in support. Insertanvil into other pocket. k. Repeat applicable operations to

complete staking of the bearings on the

c. Position bearing to be staked on current side.backstop (T101577-13) with precone side upand assure backstop is centered with bearing. 9. Clean oil and excess primer from bearingRepeat item 7b. and housing.

d. Set drill press speed at 200 to 350 10. Check the bearing position in the yokerpm. to ensure that it is within the limits shown in

figure 64-6.e. Apply a small amount of lubricating oil

to staking tool roller. 11. Check the bearings by feel for smoothoperation. Check the bearing visually to

f. Lower the drill press chuck and the ensure that the ball was not scored by thestaking tool. Ensure bearing and staking tool staking tool.

64-00-00Page 16 Rev. 4

BHT-212-CR&O

I12. If yoke has been contacted by bearing 4. Disassemble and remove shim aswear indicator; paint yoke in area of wear necessary to provide a gap of 0.024 to 0.026indication. in. (0.6096 to 0.6604 mm) between yoke (7)

and each tip of indicator (3). Reassemble andtorque nuts 500 in.lbs. (56.49 Nm).

64-14. Assembly.5. Paint tail rotor hub (paragraph 64-15) if

MATERIALS REQUIRED required.

Refer to BHT-ALL-SPM for specification andsource. 64-15. Painting.

NUMBER NOMENCLATURE MATERIALS REQUIRED

C-104 Corrosion Preventive Refer to BHT-ALL-SPM for specification andCompound source.

NUMBER NOMENCLATURE1. Position trunnion half (5, figure 64-3), NUMBER NOMENCLATUREindicator (3) and shim (4) on data plate C-101 Corrosion Preventive(preconed) side of yoke (7) and trunnion half Compound(10) on opposite side. Ensure master spline oftrunnion halves are aligned. C-203 Lacquer

C-204 PrimerNOTE

C-305 Aliphatic NaphthaBolt shanks require corrosionpreventive compound (C-104)preventive compound (C-104) 1. Clean surface with alphatic naphtha (C-application prior to installation.application prior to installation. 305) and dry. Light sanding is permissible.

2. Install washer (2) under bolthead (1),insert bolts through wear indicator trunnion NOTEset and yoke. Position balance arm (11) onbolts (1), install washers (12) and nuts (13), After installation of bolts andtorque nuts 500 in.lbs. (56.49 Nm). torquing, coat boltheads, nuts, and

washers with corrosion preventive3. Shim indicator (3) as follows: compound (C-101).

a. Center trunnion within half degree (noflapping) measure gap between yoke (7) andtip of indicator (3).

64-00-00Rev. 4 Page 16A/16B

BHT-212-CR&O

2. Apply a mist coat of primer (C-204) to all 5. Cut lockwire and remove balance boltsurfaces except bearing. (21) and balance washers.

3. Paint all surfaces except bearings with 64-18. Inspection.two coats of lacquer (C-203).

64-16. TAIL ROTOR HUB AND BLADES NOTE(212-011-701). If records or physical appearance of

tail rotor hub and blade assemblyThe tail rotor hub assembly, 212-011-701, has indicates assembly was subject togrease lubricated roller element flapping an accident or incident outside realmbearings. of normal usage, perform conditional

inspection of tail rotor hub and64-17. Disassembly. blades. Refer to BHT-212-MM for

definition of accidents or incidentswhich require conditional inspection

NOTE be conducted.

Review Mandatory Retirement 1. Refer to paragraph 64-24 for tail rotor hubSchedule in BHT-212-MM, and retire inspection.all items scheduled from retirement.

2. Refer to paragraph 64-33 for tail rotorIf tail rotor hub and blades are being blade inspection.disassembled for replacement ofdefective part(s) instead of overhaul, 3. Refer to paragraph 64-30 for pitch horndisassemble only to extent inspection.necessary.

Identify bolts, washers, balance 64-19. Assembly.washers, blades, and nuts atlocation from which removed. MATERIALS REQUIREDHowever, if parts replacement orrepairs are required, hub and bladeassembly will require balancing. NUMBER NOMENCLATUREDisassemble hub and blade only toextent required to accomplish C-104 Corrosion Preventiveinspection and parts replacement. Compound

C-405 Lockwire1. Remove nuts (1 and 29, figure 64-8),washers, and bolts (10 and 12).

1. Install pitch horn (18, figure 64-8) on each2. Remove pitch horn (18) from rotor blade rotor blade as follows:as follows:

a. Position pitch horn (18, figure 64-8)a. Remove bolt (21) and balance washers between blade grips.

(19 and 20).

b. Remove two bolts (13). Remove pitch NOTEhorn (18). Bolt shanks require corrosion

preventive compound (C-104)3. Remove blade (7) from hub (15). application prior to installation.

4. Repeat steps 1. through 3. for oppositeside.

64-00-00Page 17

BHT-212-CR&O

MAKE FIRST STAKING IDRILL PRESS CHUCK

PRECONE SIDE OFTAIL ROTOR HUB YOKE UP

/-SEE DETAIL A

- STAKING TOOLS:ARBOR (T101577-3)BUSHING (T101577-5)ROLLERS (T101577-7)RETAINER (T101577-9)HOUSING (T101577-11)

TAIL ROTOR HUB YOKE(212-011-702-001)

= }-- STAKING TOOL ANVIL(BACKSTOP) (T101577-13). FOR

SEE FIGURE 64-6 -I FIRST OPERATION POSITIONFLANGED SIDE OF ANVIL(BACKSTOP) DOWN

iJ ---- ARBOR (T101577-3)

WOODRUFF KEY NO. 213

HOUSING (T101577-11)

ROLLER (R101577-7)

BUSHING (T101577-5) RETAINER (T101577-9)

WASHER (AN960-10)

SCREW (NAS1351-3-6) I

BACKSTOP (T101577-13)

ASSEMBLE TOOL AS ILLUSTRATED ABOVEFOR STAKING TAIL ROTOR BLADE RETENTION(PITCH CHANGE) BEARINGS IN TAIL ROTORHUB YOKE

DETAIL A

212-R-64-5

Figure 64-5. Tail rotor hub bearing replacement

64-00-00Page 18 Rev. 4

BHT-212-CR&O

BEARING MUST BECENTERED IN HOUSING

M/ SWITHIN 0.002 IN.A YOKE STAKED LIP (0.051 mm)A CHAMFER STAKEDUP

DIMENSIONS A AND B ! ,pt GAP BETWEEN YOKE ANDMUST BE EQUAL WITHIN STAKE I.P NOT TO0.004 IN. (0.102 mm) EXCEED 0.008 IN. 0.20 mm

1_ EXCEED 0.008 IN. 0.20 mam)

TAIL ROTOR HUB YOKE

.149 TO0.154 IN.(3.79 TO 3.91 mm)TYPICAL FOUR LOCATIONSTHIS SIDE OF YOKE

212-R-64-6

Figure 64-6. Installation- tail rotor blade retention bearings

b. Install two bolts (13), washers (14 and 11). Install chamfered washers (5 and 24)22) and nuts (23). Torque nuts (23) 150 with nuts (1 and 29).in.lbs. (16.947 mm).

c. Install bolts (21) and balance washers NOTE(19 and 20), as required. Torque bolt (21) 50 In o b wto 70 in.lbs. (5.649 to 7.9086 Nm). Secure torque of nut ance washers anbolt (21) to pitch horn (18) using lockwire (C- accomlishd during balancing of

'05 ' " * ' - ' ~accomplished during balancing of405). hub and blades.

2. Position blade grips over hub (15) with 4. Balance tail rotor hub and blades*V4 Balance tail rotor hub and bladesdata plate on blades outboard and yoke

(paragraph 64-20).inboard.

~~~NOTE ~64-20. Balancing.Bolts (10 and 12) may be installed MATERIALS REQUIREDwith heads inboard or outboard. Refer to BHT-ALL-SPM for specification andHowever, all four shall be installed source.the same.

NUMBER NOMENCLATUREBolt shanks require corrosion NUMBER NOpreventive compound (C-104) C-031 Lubricating Oilapplication prior to installation.

C-040 Lubricating Oil3. Align hub blade bearings (16) with bladebolt holes. Install bolts (10 and 12) and (9 and C-405 Lockwire

64-00-00Rev. 4 Page 19

BHT-212-CR&O

SPECIAL TOOLS REQUIRED dashpot oil become necessary, fill balancearbor dashpot with lubricating oil (C-040) or

NUMBER NOMENCLATURE equivalent. One oil hole is located in side ofarbor approximately 1 11/16 in. (42.8625 mm)

7HEL087 Balancing kit below indicator bushing; another is located inopposite side approximately 2.5 in. (63.5 mm)from lower end of arbor. Remove both oil

1. Prepare balance kit for use as follows: hole screws, using 1/16 in. (1.58750 mm) hexwrench. Using a positive pressure, pump

a. Immediately prior to use of balance kit, action oil can, pump oil into lower arbor oilcarefully wipe all external and internal mating hole until oil appears at level of upper arborsurfaces with lint-free cloth or paper cleansing oil hole. Install lower and upper filler holetissue to remove old oil and accumulations of screws. If positive-press-type can is notfine dust or other foreign matter. Coat available, arbor dashpot may be filled throughcomponents (except spherical bearings) with upper hole only. Leave lower screw installedlubricating oil (C-031). This procedure will in arbor. In this case, repeat filling operationfacilitate installation of close-fitting pilot two or three times at 10 minute intervals toadapters, cones, and bushings on balancing ensure small air spaces are completely filled.arbors. Seizing of cones and bushings on Ensure filler hole screws are installedarbors is usually caused by fine particles of following filling or draining operation.dirt or other foreign matter, or by improperlubrication. 2. Provide a workbench or flat top stand in a

draft free area. Provide a suitable means tob. Should excessive oscillation of balance suspend arbor (3, figure 64-9) and tail rotor

indicator occur due to inadvertent loss of above workbench. Support arbor at cable looparbor dashpot oil, or should change of (1).

ARBOR, T101577-3


HOUSING, T101577-11

ROLLER, T101577-7

BUSHING, T101577-5 RETAINER, T101577-9

WASHER, AN960-10

SCREW, NAS1351-3-6

BACKSTOP, T101577-13

212-R-64-7

Figure 64-7. Tool for staking tail rotor blade retention bearings212-010-731 or 205-012-710

64-00-00Page 20

BHT-212-CR&O

1. Nut 7. Tail rotor blade2. Washer 8. Buffer3. Washer 9. Washer4. Washer 10. Bolt5. Washer 11. Washer

3 6. Washer 12. Bolt5 13. Bolt

14. Washer15. Tail rotor hub16. Tail rotor bearing17. Tail rotor balance bracket18. Tail rotor pitch horn

- 7 19. Washer20. Washer

28 21. Bolt22. Washer

26 23. Nut8 24. Washer

25 24 25. W 8 25. Washer26. Washer27. Washer

22 28. Washer

29. Nut21 20 19

18(dynamic method), refer to10

12

2 1715 14

13

NOTES

1 For instructions to install weights for16 tail rotor chordwise balancing with

Chadwick-Helmuth Vibrex equipment(dynamic method), refer toMaintenance Manual.

Bracket is an installation component.

212-R-64-8

Figure 64-8. Tail rotor hub and blades (212-011-701)

64-00-00Page 21

BHT-212-CR&O

3. Loosen retaining setscrew in indicator 12. Carefully engage cable loop (1) withcollar (2). Press indicator downward against hoist hook and suspend assembly clear of alllight spring pressure to position bottom obstructions without causing change to bladesurface approximately 0.005 in. (0.0127 mm) pitch or trunnion position on arbor.above black indicator disc (18). Lightlytighten setscrew. Ensure indicator collar (2) 13. Loosen setscrews (5) and firmly reseatdoes not contact indicator disc. plate (17) on hub assembly. Maintain seating

pressure and secure by moderately tightening4. Clean tail rotor hub (15) trunnion bore setscrew (5).and cone seat surfaces with soft cloth ortissue. 14. Recheck position of cone (16) to ensure

sensitivity setting of 5.125 in. (130.175 mm)5. Place two parallel wooden blocks on which was set at step 7. has not changed. Ifworkbench to support tail rotor hub and blade setting has changed and/or if arbor is notassembly. Place tail rotor hub and blade firmly seated on rotor hub trunnion, repeatassembly on wooden blocks with flat surface steps 5. through 13.of blades outboard of blade retention bolts incontact with wooden blocks and with heads of 15. Stabilize movements of suspended rotorrotor blade retention bolts (7) facing down. and observe balance indicated byAdjust blade pitch to cause blades to rest concentricity relationship of black indicatorevenly on blocks. Tail rotor hub name (data) disc (18) in top surface of arbor shaft withplate should be facing down. indicator collar (2). Acceptable balance is

indicated when indicator collar remains within6. Install pilot bushing (4) and plate (17) on edge limits of black indicator disc (view A,arbor (3). Do not tighten setscrews (5) at this figure 64-9).time.

16. Check balance indications are not7. Position cone (16) on balance indicating affected by interference from surroundingarbor (3) with top of cone (16) at 5.125 in. objects, air drafts, or movements of nearby(130.175 mm) mark on arbor (3). This is personnel.marked "Sensitivity Setting ReferenceSurface" on illustration. Tighten setscrews 17. Install washers (19 and 20, figure 64-8)(6). to balance hub and blade assembly

chordwise. Use a maximum of ten washers8. Position arbor (3) in hub and blade (19 and 20) of any combination. Use boltsassembly (15). (21) of correct length to accommodate

washers and obtain proper thread9. Install adapter (12) on arbor (3) and seat engagement. Bolts (21) may be AN44Aadapter on tail rotor hub trunnion. through AN4H10A. A minimum of one washer

(19 or 20) shall be under head of bolts (21),after chordwise and spanwise balance is

10. Install base (13) on arbor (3). Tighten within limits. Torque bolts (21) 50 to 70setscrews (14). in.lbs. (5.649 to 7.9086 mm). Secure two

bolts (21) to pitch horns (18) using lockwire11. Seat plate (17) against hub and blade (C-405).assembly. Seat pilot bushing (4) againstplate (17) and tighten setscrews (5). Install 18. Install washers (5, 9, 11, and 24) next tosliding bushing (20) in pitch horn. Install post rotor blades. Install washers (2, 3, 4, 6, 25,(19) on base (13, figure 64-9) and pitch horn 26, 27 and 28) as needed to obtain spanwise(11). Adjust pitch horn height on post to set balance, starting with heaviest washers nextrotor blade at 0° pitch. Install opposite post in to washers (5 and 24). Use bolts (10 and 12)same manner. Ensure both rotor blades are of correct length to accommodate washersat 0° pitch. and obtain proper thread engagement. Bolts

64-00-00Page 22

BHT-212-CR&0

18 1-5/16 IN.

1 (33.3375 mm)

WITHIN EXCEEDSBALANCED LIMITS LIMITS

BALANCE INDICATION SEE VIEW AVIEWA 18 13

DETAIL B5-1/8 IN (130.175 mm)SENSITIVITY SETTING 3REFERENCE 3

4

8 17 4

15

14 9

13SEE DETAIL B

1. Cable loop 11. Pitch horn2. Indicator collar 12. Adapter (3378) (7HEL087Kit)3. Arbor (3165) (7HEL087Kit) 13. Base (3152) (7HEL087Kit)4. Pilot bushing (2533) (7HEL087KIT) 14. Setscrew5. Setscrews 15. Tail rotor hub and blade assembly6. Setscrews 16. Cone (3380) (7HEL087Kit)7. Blade attaching bolt 17. Plate (2586) (7HEL087Kit)8. Spanwise balance washers 18. Indicator disc9. Chordwise balance washers 19. Post (2939) (7HEL087Kit)

10. Bolt 20. Sliding bushing

212-R-64-9

Figure 64-9. Balancing tail rotor hub and blade (212-011-701)

64-00-00Page 23

BHT-212-CR&O

(10 and 12) may be NAS1308-34 through 9. Remove inner races (8) from trunnionNAS1308-36. (11).

19. When balance indication (figure 64-9,view A) is within limits, torque nuts (1 and 29, 64-23. Inspection.figure 64-8) 500 to 550 in.lbs. (56.49 to62.139 Nm). MATERIALS REQUIRED

20. Remove two posts (19, figure 64-9). Refer to BHT-ALL-SPM for specification andSecure sliding bushings (20) to pitch horns source.(11).

NUMBER NOMENCLATURE21. Loosen setscrews (14). Remove base(13) and adapter (12). C-309 Methyl-Ethyl-Ketone

(MEK)22. Remove arbor (3) from tail rotor huband blade.

NOTE23. Loosen setscrews (6) and remove cone(16). If records or physical appearance of

tail rotor hub indicate assembly has24. Loosen setscrews (5) and remove pilot been subjected to an accident orbushing (4) and plate (17). incident outside realm of normal

usage, perform Conditional25. Loosen setscrew in indicator collar (2) Inspection, paragraph 64-24. If tailand allow internal, spring-loaded damping oil rotor hub does not requireseal to move upward and seat. Do not tighten Conditional Inspection proceed withsetscrew. Normal Inspection (paragraph 64-

25).26. Place all balance kit components instorage case. Position storage case instorage so arbor is upright to prevent 64-24. Conditional Inspection.seepage of oil around indicator.

1. Carefully inspect all detail parts visuallyfor any apparent damage or abnormal

64-21. TAIL ROTOR HUB (212-011-701). appearance.

64-22. Disassembly. 2. Inspect parts for surface damage (figures64-11, 64-15, and 64-16).

1. Remove four bolts (1, figure 64-10).3. Deleted.

2. Remove trunnion housing (5).

4. Deleted.3. Remove thrust plug (9).

4. Remove shim (10). 5. Inspect blade retention bolts forindication of shear offset. Reject hub and

5. Remove bearing (6). blade assembly if any bolts show shear offset.

6. Remove seal (7). 6. Inspect blade bearing races forlooseness in yoke. Reject yoke if bearings are

7. Remove similar parts from opposite side loose.of yoke (12).

7. Accomplish Normal Inspection8. Remove trunnion (11). (paragraph 64-25).

64-00-00Page 24 Rev. 4

BHT-212-CR&O

64-25. Normal Inspection. NOTE

. 1. Inspect bearing (6, figure 64-10) and Magnetic particle inspection may berace (8) for condition (BHT-ALL-SPM). conducted using either AC or DC

current. When using AC, use only2. Inspect static stop for damage limits 60% of DC amperes.(figure 64-28).

b. Magnetize yoke by placing between3. Perform a magnetic particle inspection of contacts and passing 2500 amperes throughtrunnion as follows: long axis of yoke. Inspect under black light for

indications.a. Using 1.0 in. (25.4 mm) diameter

central conductor through splines, place c. Place yoke in coil so long axis of yokeconductor between contact heads and pass is 90 °to direction of current flow through the1100 amperes through conductor. Inspect coil. Magnetize yoke using 12,500 ampereunder black light for indications, turns magnetizing force (for a 5 turn coil this

is 2500 amperes). Inspect under black lightb. Place trunnion in five turn coil with for indications. Repeat this inspection at 8 in.

long axis parallel to coil axis, apply 4200 (203.2 mm) increments to ensure adequateamperes. Inspect all surface for indications. inspection.

c. Demagnetize and clean trunnion d. Demagnetize yoke and cleanthoroughly. thoroughly.

4. Inspect trunnion (11, figure 64-11) as e. Remove masking material fromfollows: bearings.

a. Mount trunnion (11) on vee blocks on 64 Aa level workbench. Check brinelling depth 64- Assembly.with a dial indicator (figure 64-11). Falsebrinelling is acceptable to a maximum depth MATERIALS REQUIREDof 0.0015 in. (0.0381 mm) on trunnion race. Refer to BHT-ALL-SPM for specification andThere is no limit to number of false brinelling sosource.marks or quadrant of location. Do not attemptto polish out marks. Evidence of cracks,fretting, or spalling shall be cause for NUMBER NOMENCLATURErejection. C-001 Grease

5. Perform a magnetic particle inspection, C-304 Solventwet continuous method on yoke, as follows:

C-405 Lockwirea. If yoke is being inspected during

overhaul, remove blade bearings prior toinspection (paragraph 64-27). If yoke is being figure 64-10) with solvent (C-304) and air dryinspected at other than overhaul, bearings figure 64-10) with solvent (C-304) and air dry.inspected at other than overhaul, bearings Hand pack bearings with grease (C-001).should be masked using sealing wax or Hand pack bearings with grease (C-001).should be masked using sealing wax orequivalent.

64-00-00Rev. 4 Page 25

BHT-212-CR&O

0

1. Bolt 122. Steel washer3. Tail rotor balance bracket4. Lubrication fitting5. Trunnion bearing housing6. Bearing7. Seal8. Race 139. Thrust plug

10. Shim11. Trunnion12. Yoke13. Blade retention bearing

212-R-64-10

Figure 64-10. Tall rotor hub 212-011-701

64-00-00Page 26

BHT-212-CR&O

TRUNNION ASSEMBLY212-011-704-001

DAMAGE LOCATION SYMBOLS


CRACKS ALLOWED None None

MECHANICAL DAMAGE 0.002 IN. (0.0508 mm) 0.010 IN. (0.254 mm)

CORROSION DAMAGE 0.002 IN. (0.0508 mm) 0.010 IN. (0.254 mm)

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

NUMBER OF REPAIR AREAS One per segment One per segment

SPLINE DAMAGEDepth One-third of splineLength One-half of splineNumber Three

212-R-64-11 -1

Figure 64-11. Tail rotor trunnion damage limits (sheet 1 of 2)

64-00-00Page 27

BHT-212-CR&O

DIAL INDICATOR LOCATED

0.0015 IN. (0.0381 mm)MAX. DEPTH

TRUNNION

"V" BLOCK (2 PLACES)

FLAT SURFACE

212-R-64-11-2

Figure 64-11. Tail rotor trunnion damage limits (sheet 2)

64-00-00Page 28

BHT-212-CR&O

2. Install bearing (6), with stamped end of h. Position shim (10), prepared inbearing visible, and new seal (7) in each preceding step, same thrust plug (9) andhousing (5). same housing (5) on same side of yoke with

lubrication fitting (4) positioned as illustrated.3. Ensure races (8) are securely installed Install washers (2) and bolts (1). Torque boltson trunnion (11). 30 to 40 inch-pounds. (3.3894 to 4.5192 Nm).

4. Position one housing (5) on yoke (12). i. Prepare shim (10) for opposite end ofPosition housing and lubrication fitting (4) as trunnion (11) and install in same mannerillustrated. Install bolts (1) and washers (2). outlined in steps f. through h.Tighten bolts (1) to remove all gap in jointbetween housing and yoke. j. Secure heads of bolts (1) together in

pairs using lockwire (C-405).5. Position new shim (10) and thrust plug(9) on one end of trunnion (11). Position k. Remove hub from workaid.trunnion (11) in yoke (12).

NOTE6. Install new shim (10), thrust plug (9) andhousing (5) on opposite end of trunnion (11). Bracket (3) will be installed at tailInstall bolts (1) and washers (2). Tighten bolts rotor installation.(1) to snug position.

8. Lubricate hub two places at fittings (4)7. Center trunnion using workaid: with grease (C-001). Clean excess grease

from hub.a. If not previously accomplished,

fabricate workaid (shown on figure 64-14).64-27. Repair.

b. Place workaid on bench with pins (2)facing up. Remove insert (3). MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specification andc. Position yoke on workaid with pins (2)through two inboard blade retention bearings.

NUMBER NOMENCLATUREd. Loosen eight bolts (1, figure 64-10) to NUMBERallow trunnion to move. Position insert (3, C-204 Primerfigure 64-14) through trunnion and into hole inplate (1).

SPECIAL TOOLS REQUIREDe. Tighten eight bolts (1, figure 64-10) to

snug position but do not torque at this time.NUMBER NOMENCLATURE

f. Measure gap between housing (5) and T101577-13 Backstopyoke (12) with feeler gage and recorddimension.

1. Polish out mechanical and corrosiong. Remove bolts (1), washers (2), damage on parts shown on figures:

housing (5), thrust plug (9), and shim (10).Measure and record shim thickness. Peel 64-11 (trunnion)laminations from shim (10) to reduce 64-15 (yoke)thickness by 0.002 to 0.004 inch (0.0508 to 64-16 (housing)0.1016 mm) less than gap dimension 64-28 (static stop)recorded in step f. This will provide a pinch fiton trunnion when installed. Replace parts if limits are exceeded.

64-00-00Rev. 4 Page 29

BHT-212-CR&O

2. Inspect blade retention bearings (13, adapter against yoke to attain zero gap.figure 64-10) in yoke for play. Replace Remove or position clamp so as not tobearings if axial play of bearings exceed interfere with work area. `0.015 in. (0.381 mm).

g. Install new bearings on alignment pins

YOKE IN A MANNER TO AVOID h. Remove yoke with bearings fromAPPLYING EXCESSIVE BENDINGAPPLYING EXCESSIVE BENDING support and rotate yoke ends to accomplish

installation of all bearings in yoke. Clamp

3. If it is necessary to remove tail rotor yoke to support and repeat item 4b.blade retention bearings, carefully cut awayand remove lip on one side of bearing using afly cutter. Do not cut into yoke.

4. Position yoke on support (figure 64-29). CAUTIONPress old bearings from yoke as follows:

a. Orient yoke with bearing lip side THE FIRST STAKING OPERATIONtoward support surface. Align yoke bearings SHALL BE PERFORMED WITHwith two pins in support and clamp yoke DATA PLATE (PRECONED) SIDEagainst support surface. OF YOKE UP AND FLANGED SIDE

OF STAKING ANVIL DOWNb. Adjust leveling foot (swivel) and its (FIGURE 64-5).

adapter against yoke to attain zero gap.Remove or position clamp so as not to 5. Position yoke on support for stakinginterfere with work area. bearings in yoke as follows:

c. Align drift over one pin and press old a. Remove two alignment pins frombearing into support pocket. Repeat this support.operation to press out adjacent bearing.

b. Insert backstop (T101577-13) flanged. Rotate yoke ends. Repeat operations side down into either pocket in support. Insert

4a through 4c to complete removal of all anvil into other pocket.bearings.

c. Position bearing to be staked one. Roll stake bearing as follows: backstop (T101577-13) with precone side up

and assure backstop is centered with bearing.NOTE Repeat item 4b.

The 205-012-710-001 bearings may d. Set drill press speed at 200 to 350be used as an alternate for 212-010- rpm.731-001 bearings. The 205-012-710-001 bearings shall be installed in e. Apply a small amount of lubricating oilsets of four. Do not mix bearings. to staking tool roller.

f. Clamp yoke on support (figure 64-29) f. Lower the drill press chuck and theand adjust leveling foot (swivel) and its staking tool. Ensure bearing and staking tool

64-00-00Page 30 Rev. 4

BHT-212-CR&O

are aligned and staking tool rollers are in j. Reposition the backstop (T101577-13)contact with the groove in the bearing. with flange side up in support pocket. Invert

the yoke and stake the opposite side of the.................. .bearing in the same manner. Repeat stakingCAUTION the bearing in small increments to attain the

.008 in. (0.20 mm) maximum gap shown infigure 64-6.

UNDUE FORCE OF STAKINGTOOL INTO PREGROOVE OF k. Repeat applicable operations toBEARING MAY CAUSE EXCESSIVE complete staking of the bearings on theREDUCTION OF OUTER LIP current side.METAL THICKNESS.

6. Clean oil and excess primer from bearingg. Start the drill press and apply steady and housing.

hand pressure to the feed lever for aminimum of ten seconds. Raise drill press

chuck and staking too. Check to determine 7. Check the bearing position in the yoke tochuck and staking tool. Check to determinethe amount that the bearing has been staked ensure that it is within the limits shownin comparison with figure 64-6. figure 64-6.

h. Lift yoke from support and change 8. Check the bearings by feel for smoothbackstop (T101577-13) and anvil to different operation. Check the bearing visually topockets in support. Repeat operations 5c ensure that the ball was not scored by thethrough 5g for staking adjacent bearing. staking tool.

i. Rotate yoke ends and repeat 9. Install races (8, figure 64-10) on eachoperations 5c through 5h to complete staking end of trunnion (11) using thermal fit methodon one side of yoke. in BHT-ALL-SPM, omit stress relief.

ARBOR (T101577-3)


HOUSING (T101577-11)

ROLLER (R101577-7)

BUSHING (T101577-5) - RETAINER (T101577-9)

WASHER (AN960-10)

SCREW (NAS1351-3-6)

BACKSTOP(T101577-13)

ASSEMBLE TOOL AS ILLUSTRATED ABOVEFOR STAKING TAIL ROTOR BLADE RETENTION(PITCH CHANGE) BEARINGS IN TAIL ROTORHUB YOKE

212-R-64-12

Figure 64-12. Tool for staking tail rotor blade retention bearings

64-00-00Rev. 4 Page 30A/30B

BHT-212-CR&O

MAKE FIRST STAKINGDRILL PRESS CHUCKOPERATION WITH

PRECONE SIDE OFTAIL ROTOR HUB YOKE UP

SEE FIGURE 64-12

STAKING TOOLS:ARBOR (T101577-3)BUSHING (T101577-5)ROLLERS (T101577-7)RETAINER (T101577-9)HOUSING (T101577-11)

TAIL ROTOR HUB YOKE(212-011-702-001)

STAKING TOOL ANVIL(BACKSTOP) (T101577-13). FOR

SEE DETAIL A FIRST OPERATION POSITIONFLANGED SIDE OF ANVIL(BACKSTOP) DOWN

BEARING MUST BECENTERED IN HOUSINGWITHIN 0.002 IN.

A YOKE STAKED LIP (0.051mm)CHAMFER

DIMENSIONS A AND BMUST BE EQUAL WITHIN GAP BETWEEN YOKE AND0.004 IN. (0.102 mm) STAKE LIP NOT TO

EXCEED 0.008 IN. (0.20 mm)

B

TAIL ROTOR HUB YOKE

.149 TO 0.154 IN.(3.79 TO 3.91 mm)TYPICAL FOUR LOCATIONSTHIS SIDE OF YOKE

DETAIL A

212-R-64-13

Figure 64-13. Tail rotor yoke blade bearing replacement

64-00-00Rev. 4 Page 31

BHT-212-CR&O

12.00 IN. (304.8 mm)1.2203 IN. (30.99562 mm)

6.00 IN. (152.4 mm) 1.2188 IN. (30.95752 mm)

0.4980 IN. (12.6492 mm)0.4970 IN. (12.6238 mm)

0.500 IN.(12.7 mm)

0.50 IN.(12.7 mm)

2.25 IN.(57.15 mm)

TYP

5.5020 IN. (139.7508 mm)5.5015 IN. (139.7381 mm)

11.0040 IN. (279.5016 mm)11.0035 IN. (279.4889 mm)

15 °

150

0.4990 IN. (12.6746 mm) 1.2185 IN. 30.9499mm)0.4985 IN. (12.6619 mm) DIA. 1.2180 IN. (30.9372 mm)

DIA.0.12 IN.

(3.098 mm) TYP 0.19IN.(4.826mm)TYP

(60.452 mm) 4.00 IN. (101.6 mm)---

NOTES

1. Plate 3/4 x 4.5 x 12 inch (19.05 x114.3 x 304.8 mm) 4130 steel.

2. Pin, steel rod 0.4985 to 0.4990 inch(12.6619 to 12.6746 mm) diameter4130 steel.

3. Insert, steel rod 1.2180 to 1.2185 3inch (30.9372 to 30.9499 mm)diameter, 4130 steel.

Figure 64-14. Tall rotor trunnion centering tool 212-R-64-14

64-00-00Page 32

BHT-212-CR&O

YOKE ASSEMBLY212-0011-702-001


TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED



CORROSION DAMAGE 0.002 IN. (0.0508 mm) 0.005 IN. (0.172 mm)

MAXIMUM AREA PER 0.10 SQ. IN. (64.52 SQ. mm) 0.15 SQ. IN. (96.78 SQ. mm)FULL DEPTH REPAIR

NUMBER OF REPAIR AREAS One per segment

EDGE CHAMFER 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

BORE DAMAGE 0.002 IN. (0.0508 mm) for one-fourth circumference

THREAD DAMAGEDepth One-third of threadLength 0.25 IN. (6.35 mm)Number One per segment

NOTE

Maximum acceptable axial play in blade retention bearings is 0.015 inch (0.381 mm). Bearing looseness in yokeis not acceptable. 212-R-64-15

Figure 64-15. Tail rotor yoke damage limits

64-00-00Page 33

BHT-212-CR&O

f/// -a -THIS DAMAGEI ( )l I I99 LIMIT APPLICABLE

\\ )/I ^^^^ TO BOTH OUTSIDE"1' .. 3 -',;/:' . ? 9 AND INSIDE DIAMETERS.

BOTH ENDS

TRUNNION HOUSING212-011-709-001


991 r^'\'\'i'\ [--TYPE OF DAMAGE MAXIMUM DAMAGE AND REPAIR DEPTH

CRACKS ALLOWED None None None

MECHANICAL DAMAGE 0.002 IN. (0.0508 mm) 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm)

CORROSION DAMAGE 0.002 IN. (0.0508 mm) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

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

NUMBER OF REPAIR AREAS One per segment One per segment One per segment

BORE DAMAGE 0.002 IN. (0.0508 mm) for one-fourth circumference

EDGE CHAMFER 0.030 IN. (0.762 mm)

NO DAMAGE TO LUBRICATIONFITTING IS ACCEPTABLE 212-R-64-16

Figure 64-16. Tail rotor trunnion housing damage limits

64-00-00Page 34

BHT-212-CR&0

64-28. Painting. 64-30. Inspection.

MATERIALS REQUIRED 1. Inspect pitch horn for cracks usingfluorescent penetrant method (BHT-ALL-

Refer to BHT-ALL-SPM for specification and SPM). Replace if cracked.source.

2. Inspect pitch horn threads for corrosionNUMBER NOMENCLATURE or damage. Replace if threads are damaged

or corroded.C-203 Lacquer

3. Inspect pitch horn, 212-010-716, asC-204 Primer follows:follows:

C-305 Aliphatic NaphthaC-305a. Inspect for damage or corrosion (figure

64-17). Replace if limits are exceeded.1. Clean hub with alphatic naphtha (C-305).Do not allow naphtha to contaminate b. Inspect hole of sliding bushing forbearings. corrosion and wear. Replace pitch horn if

corroded or if diameter of hole exceeds2. Mask off bearings. 0.5005 in. (12.7127 mm).

3. Apply spray coat of primer (C-204). c. Inspect fixed bushing for loosenessand wear. Replace pitch horn if bushing is

4. Paint with . loose. Replace bushing if inner diameterexceeds 0.313 in. (7.9502 mm).

5. Remove masking tape.4. Inspect pitch horn, 212-011-708, asfollows:

64-29. PITCH HORN (212-010-716 AND212-011-708). a. Inspect for damage or corrosion (figure

64-18). Replace if limits are exceeded.Two different type pitch horns are used in thetail rotor assembly. The 212-010-716 pitch b. Inspect hole of sliding bushing forhorn is used with 212-010-701 tail rotor hub. corrosion and wear. Replace pitch horn ifThe 212-011-708 pitch horn is used with 212- corroded or if diameter of hole exceeds 0.438011-701 tail rotor hub. Both pitch horns are in. (11.1252 mm).covered in the following paragraphs. Whereinspection or repair procedures differexplanations are in accompanying text andillustrations.

64-00-00Rev. 4 Page 35

BHT-212-CR&O

c. Inspect fixed bushing for looseness and e. Pitch horn, 212-010-716; machine facewear. Replace pitch horn if bushing is loose. of bushing to obtain dimensions shown inReplace bushing if inner diameter exceeds view A, figure 64-19.0.313 in. (7.9502 mm).

f. Pitch horn, 212-011-708; machine face64-31. Repair. of bushing to obtain dimensions shown in

view B, figure 64-19.

MATERIALS REQUIREDMATERIALS REQUIRED 64-32. TAIL ROTOR BLADES.

NUMBER NOMENCLATURENUMBER NOMENCLATURE ^64-33. Conditional Inspection.C-201 Primer

C-203 Lacquer NOTE

C-204 Primer If records and/or physicalappearance of tail rotor blade

C-406 Aluminum Oxide Cloth indicate blade has been subjected toan accident or incident outside therealm of normal usage, perform

1. Polish out allowable mechanical damage Conditional Inspection as follows: Ifor corrosion using fine to medium grades of assembly does not requirealuminum oxide cloth (C-406). Remove Conditional Inspection, accomplishcorrosion damage twice depth of pit. Polish Normal Inspection, paragraph 64-34.out mechanical damage deep enough toremove traces of damage. Do not exceed 1. Major overspeed inspection.limits of figures 64-17 and 64-18.

a. Check for bond separation anywhere2. Apply chemical film treatment to repaired on the blade. If any separations exist,areas (BHT-ALL-SPM). replace blade.

3. Refinish repaired areas with one spray b. If any movement of tip or root endcoat of primer (C-204) and one spray coat of balance weights has occurred, replace blade.light gray lacquer (C-203).

c. Check retention bushings for evidence4. Replace fixed bushing in pitch horn as of looseness. If any bushing is loose, replacefollows: blade.

a. Press bushing from pitch horn. d. If blades pass above inspectionrequirements and no other discrepancies

b. Inspect bushing bore in pitch horn for exist, blade is serviceable.damage. If damage exceeds 0.002 in.(0.0508 mm) for one-fourth of circumference 2. Sudden stoppage or hard landingreplace pitch horn. inspection.

c. Coat replacement bushing with a. Check for bond separation anywhereunreduced primer (C-201). Press bushing on blade. If any separations exists, replaceinto pitch horn while primer is still wet. blade.

d. Ream bushing 0.3120 to 0.3125 in. b. If any movement of root end weights(7.9248 to 7.9375 mm). has occurred, replace blade.

c. If one blade of a pair has beendamaged badly enough that metal has been

64-00-00Page 36

BHT-212-CR&O

PITCH HORN212-010-716


TYPE OF DAMAGE MAXIMUM DEPTH AND REPAIR AREAS ALLOWED

MECHANICAL(Before and after repair) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

CORROSION(Before repair) 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm)(After repair) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

MAXIMUM AREA PER 0.050 SQ. IN. (32.26 SQ. mm) 0.100 SQ. IN. (64.52 SQ. mm)NONOVERLAPPINGFULL DEPTH REPAIR

NUMBER OF One TwoNONOVERLAPPINGREPAIR AREAS

NOTES

1. All edges may be radiused or chamfered to a depth of 0.030 inch (0.762 mm) to remove nicks or dents.

2. Repair areas shall be treated with chemical film material (C-100).

3. No cracks allowed.212-R-64-17

Figure 64-17. Tail rotor blade pitch horn damage limits (212-010-716)

64-00-00Page 37

BHT-212-CR&O



TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED



CORROSION(Before repair) 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm)(After repair) 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

MAXIMUM AREA PER 0.050 SQ. IN. (32.26 SQ. mm) 0.10 SQ. IN. (64.52 SQ. mm)NONOVERLAPPINGFULL DEPTH REPAIR

NUMBER OF One One per segmentNONOVERLAPPINGREPAIR AREAS

EDGE CHAMFER 0.030 IN. (0.762 mm) 0.030 IN. (0.762 mm)by 45 by 45

THREAD DAMAGEDepth: One-third of threadLength: 0.10 IN. (2.54 mm)Number: One per segment

NOTES

1. Maximum acceptable dimension for hole for sliding bushing is 0.4380 inch (11.1252mm).

2. Inspect fixed bushing for secure installation. Loose bushings are not acceptable.

3. No cracks allowed. 212-R-64-18

Figure 64-18. Tail rotor blade pitch horn damage limits (212-011-708)

64-00-00Page 38

BHT-212-CR&O

64-00-0028 NOV 2003 Rev. 5 Page 39

torn or any bond lines have been separated, bothblades shall be replaced.

d. If one blade of a pair has been damagedslightly by denting, replace blade. The other blade maybe continued in service after inspection and anynecessary repair by an authorized overhaul facility.

3. Accomplish Normal Inspection, paragraph 64-34.

64-34. Normal Inspection

MATERIALS REQUIRED

1. Check for looseness of blade bolt bushing. Anylooseness of blade bolt bushing is cause for bladereplacement. Check blade bushing ID. If ID exceeds0.5005 in. (12.7127 mm), bushing shall be replaced byan authorized blade overhaul facility.

2. Inspect tail rotor blades in accordance with BHT-212-MM.

3. Damage necessitating replacement.

a. Any damage in excess of that outlined in step1. is cause for blade replacement.

b. Tail rotor blades sustaining the followingdamage shall be scrapped.

(1) Water in honeycomb core.

(2) Any blade which has reached maximumservice life.

(3) If one or more cracks develop and extendfrom a previously repaired area.

(4) Holes in skin larger than allowed forpatching.

(5) Any corrosion penetrating entirelythrough skin.

(6) If spar is worn completely through at tip.

(7) Edge voids deeper than 0.50 in. (12.7mm) at tip end of any of root end doublers or gripplates.

(8) Edge voids in leading edge or trailingedge of doublers 0.250 in. (6.35 mm) or more in depthand show indications of corrosion in void.

4. Inspect buffer pads around blade bolt holes forwear, tears, or debonding.

64-35. Repair — Tail Rotor Blades

MATERIALS REQUIRED

1. Repair rotor blade minor damage. Refer to BHT-212-MM for procedure.

NUMBER NOMENCLATURE

C-313 Adhesive

C-317 Adhesive

C-322 Adhesive

C-323 Filler

C-331 Adhesive

C-424 Putty

Refer to BHT-ALL-SPM for specification and source.

NUMBER NOMENCLATURE

C-339 Alcohol

C-363 Adhesive

C-423 Abrasive Cloth or Paper

BHT-212-CR&O

64-00-00Page 40 Rev. 5 28 NOV 2003

Figure 64-19. Pitch horn bushing replacement

BVIEW

212-R-64-19

0.670 TO 0.680 IN(17.010 TO 17.272 mm)


VIEW APITCH HORN212-010-716

0.750 IN(19.05 mm)

0.645 TO 0.647 IN(16.383 TO 16.4338 mm)

0.610 TO 0.620 IN(15.494 TO 15.748 mm)

BHT-212-CR&O

64-00-0028 NOV 2003 Rev. 5 Page 41

Figure 64-20. Deleted

BHT-212-CR&O

64-00-00Page 42 Rev. 5 28 NOV 2003

Figure 64-21. Deleted

BHT-212-CR&O

64-00-0028 NOV 2003 Rev. 5 Page 43

2. Blades with one or more holes in the skin, orwhich otherwise do not meet the inspection limitsdescribed in BHT-212-MM, may be sent to anauthorized blade repair facility for evaluation ofpossible repair.

3. Replace buffer pads around blade bolt holes asfollows:

a. Remove damaged or worn buffer pad with aputty knife or similar instrument, do not gouge blade.Sand off adhesive to bare metal. Sand in a spanwisedirection only with 400 grit abrasive cloth or paper(C-423) to achieve a surface finish of 32 RMS orbetter.

b. Wipe area around hole with a clean clothdampened with MEK (C-309). Wipe dry with cleancloth.

c. Install new buffer pad, centered around bolthole, one at each bolt hole. Bond buffer pads to bladeusing adhesive (C-317), apply 5 to 10 psi pressure(34.475 to 68.95 kPa) to buffer pads.

d. Cure under pressure at 75°F (23°C) for 24hours or one hour at 180°F (82°C).

64-36. Blade butt sealing

MATERIALS REQUIRED

1. Inspect all butt area bondlines placing emphasison those areas illustrated in figure 64-22.

DO NOT ALLOW ANY METHYL-ETHYL-KETONE TO ENTER BLADE. DO NOTSATURATE BOND LINES WITH MEK ASIT WILL SOFTEN THE ADHESIVE.

2. If cracks are suspected, remove paint insuspected area(s) using a clean cloth dampened withMEK (C-309).

3. Dry exposed sections of the butt block with aclean cloth.

4. Apply a thin film of adhesive (C-313) to bondlinesdepicted on figure 64-22, view C-C, areas A and B.

5. Apply a small bead of adhesive (C-313) to innerchannel bondlines shown on figure 64-22.

6. Swab inner diameter of leading edge drain holewith a thin film of adhesive (C-313) to ensure adequatesealing exists.

NOTE

Cure time for adhesive (C-313) at 70 to90°F (21 to 32°C) is 24 hours. The curemay be accelerated by applying heat 145 to155°F (63 to 68°C) for 30 minutes.

7. Refinish reworked area of tail rotor blade (BHT-212-MM).

NOTE

The blades shall be balanced with tail rotorhub and blade assembly prior to helicopterinstallation and operation.

NUMBER NOMENCLATURE

C-309 Methyl-Ethyl-Ketone (MEK)

C-313 Adhesive

BHT-212-CR&O

64-00-00Page 44 Rev. 5 28 NOV 2003

64-37. Refinishing

MATERIALS REQUIRED

1. Refinish tail rotor blades as follows:

a. Protect blade bearings and data plate withmasking tape.

b. Thoroughly wipe surface to be repainted withsolvent (C-386). Allow solvent to wet area for a fewminutes, then wipe dry with clean cheesecloth(C-486).

c. Thoroughly sand area to be painted with 400grit, or finer abrasive cloth or paper (C-423) until auniform matte finish is obtained.

d. Wash sanded surface using nylon webabraisve pad (C-407) and cleaning compound (C-318)to obtain a water break-free surface. Rinse with water.Repeat steps b. through d. as required to obtain awater break-free surface.

NOTE

From completion of this step through finalpaint, surface of blades which are to bepainted shall not be handled with barehands.

e. If bare metal is exposed, prepare area to bepainted by applying a brush or spray coating of cleaner(C-344). Allow cleaner to remain in contact with themetal surfaces for one to three minutes, thenthoroughly rinse with water and verify a water break-free surface.

f. Apply one spray coat of primer (C-204) tocover sanded area.

NOTE

Primer shall be overcoated between 1 and8 hours. If 8 hours is exceeded, repeatsteps b. through f.

g. Apply one to two light spray coats ofpolyurethane coating (C-245). Allow 30 minutes to 8hours air drying time between coats. If 8 hours isexceeded, initial coat shall be sanded and reprimedwith urethane compatible primer prior to overcoating.

h. After air drying for a minimum of 6 hours,mask areas (figure 64-23) not to be painted withmasking tape.

NOTE

If topcoat air dries for longer than 8 hours atroom temperature, all topcoated surfaces tobe striped shall be thoroughly sanded with400 grit or finer abrasive cloth or paper(C-423) and reprimed with urethanecompatible primer prior to striping.

i. Stripe by applying one or two light spray coatsof polyurethane coating (C-245). Allow 30 minutes to 8hours air dry between coats.


NUMBER NOMENCLATURE

C-204 Primer

C-245 Polyurethane Coating

C-318 Cleaning Compound

C-344 Cleaner

C-386 Solvent

C-407 Abrasive Pad

C-420 Tape


C-486 Cheesecloth

BHT-212-CR&O

64-00-0028 NOV 2003 Rev. 5 Page 45

j. After air drying for a minimum of 8 hours,feather out paint lines on leading edge with 400 grit orfiner abrasive cloth or paper (C-423) to assure asmooth transition from metal to paint.

k. Stencil the following on both sides of tail rotorblade tip using urethane coating gloss black No.17038. The letters shall be 0.250 in. (6.35 mm) high.Spacing between lines shall be 0.062 in. (1.5748 mm).

l. Remove masking tape from blades.

NOTE

Only tail rotor blades with same paintscheme shall be utilized in tail rotor hub andblade assembly.

m. Static balance tail rotor hub and bladeassembly (paragraph 64-7 or 64-22).

64-38. PITCH CHANGE LINK

64-39. Inspection

1. A 212-001-058-001 pitch change link clevisexhibiting crack indications shall be inspected usingthe wet continuous magnetic particle inspectionmethod consisting of:

a. A head shot of 1000 amps

b. A coil shot of 1500 amps

2. Inspect for cracks using a 10X magnifying glassand a black light. No cracks are permissible. If nocracks are found, demagnetize and clean part.

3. A 212-001-058-101 pitch change link clevisexhibiting crack indications shall be inspected usingfluorescent penetrant method (BHT-ALL-SPM).

64-40. Repair

MATERIALS REQUIRED

1. Polish out acceptable damage, removing no morematerial than necessary to blend repair smoothly intosurrounding surface. Mechanical damage shall bepolished only deep enough to remove traces ofdamage. Corrosion damage should be polished out totwice the depth of deepest pit, provided maximum limitis not exceeded (figure 64-24).

2. Use 400 to 600 grit abrasive cloth or paper(C-423) to remove damage to a scratch-free surface.Do not attempt repairs by using a grinding wheel.

3. No thread or surface damage is acceptable ifrepair will interfere with thread engagement.

4. Replace any bent, dented, or distorted link parts,or any parts having cracks.

5. Apply brush cadmium plate to repaired surfaceswhich have plating removed (BHT-ALL-SPM).

6. Mask threaded areas and fill and drain barrel anddrilled hole in clevis with an epoxy zinc coating orepoxy polyamide primer (BHT-ALL-SPM).

7. Apply a protective coating of primer (C-204) to allrepaired surfaces which have had plating removed(BHT-ALL-SPM).

DO NOT USE FOR HANDLING

HELICOPTER


NUMBER NOMENCLATURE

C-204 Primer


BHT-212-CR&O

64-00-00Page 46

Figure 64-22. Tail rotor blade butt sealing

VIEW C-C

INNER GRIPPLATE

C

C

BAREA

AREA A AREA B

BONDLINES (TYPICAL)APPLY ADHESIVE (C-313)

212-R-64-22

AREA A

LEADING EDGE DRAIN HOLE,SWAB ID WITH ADHESIVEFILM (C-313)

BONDLINE (TYPICAL)APPLY ADHESIVE (C-313)

APPLY ADHESIVE (C-313)BEAD TO INNER CHANNELBONDLINES

BHT-212-CR&O

64-00-0028 NOV 2003 Rev. 5 Page 47

64-41. PITCH CHANGE COMPONENTS

64-42. Inspection

1. Inspect components for mechanical or corrosiondamage (figure 64-25).

2. Inspect idler and lever for cracks usingfluorescent penetrant method (BHT-ALL-SPM).

3. Inspect tail rotor retaining nut for cracks usingmagnetic particle inspection method (BHT-ALL-SPM).

4. Inspect bearings in idler and lever for roughnessand wear.

5. Inspect bushings in lever for looseness and wear.Replace lever if bushings are loose. Replace bushingsif inside diameter exceeds 0.3135 in. (7.9629 mm) or ifelongation exceeds 0.002 in. (0.0508 mm).

6. Inspect threaded rod of pitch link assembly forcracks using magnetic particle inspection method(BHT-ALL-SPM).

64-43. Repair

MATERIALS REQUIRED

1. Repair pitch change components in accordancewith limits shown in figure 64-25.

2. Remove all mechanical and corrosion damagewithin limits with abrasive cloth or paper (C-423) toobtain a smooth scratch-free surface.

3. Mask off bushing bores and slider portion ofcontrol tube.

4. Apply two spray coats of primer (C-204) torepaired area.

5. Replace any cracked components.

6. Replace any component that exceedsmechanical or corrosion limits.

7. Replace bushings in lever as follows:

a. Press bushings from lever. Clean aged primerfrom bushing bores in lever.

b. Inspect bushing bores in lever for damage.Replace lever if damage exceeds 0.002 in. (0.0508mm) for one-fourth of circumference.

c. Coat replacement bushings with unreducedprimer (C-201). Press bushings into lever while primeris still wet.Refer to BHT-ALL-SPM for specification and source.

NUMBER NOMENCLATURE

C-201 Primer

C-204 Primer


BHT-212-CR&O

64-00-00Page 48 Rev. 5 28 NOV 2003

Figure 64-23. Tail rotor blade refinishing

(48.26 TO 50.8 mm)

OMIT PAINT IN THIS AREA

WHITE

FEATHER EDGES OF PAINT(LINES IN FEATHERED EDGES

TOPCOAT ARE PERMISSIBLE)FORMED BY LAYERS OF

1.9 TO 2.0 IN

4.0 IN(101.6 mm)

BLACK

4.0 IN(101.6 mm)

WHITE

4.0 IN(101.6 mm)

BLACK

4.0 IN(101.6 mm)

WHITE

4.0 IN(101.6 mm)

BLACK

7.0 IN(177.8 mm)

WHITE212-R-64-23

BHT-212-CR&O

d. Line ream bushings 0.3125 to 0.3130 C-204 Primerin. (7.9375 to 7.9502 mm) as shown on figure64-26. C-423 Abrasive Cloth or

Papere. Machine faces of bushings equally to

obtain 0.938 to 0.940 in. (23.8252 to 23.876 Repair crosshead assembly componentsmm) dimension shown on figure 64-26. Faces in accordance with figure 64-27.of bushings shall be perpendicular tocenterline of bushings within 0.001 in. (0.254 2. Remove all mechanical and corrosionmm) after machining. damage within limits with abrasive cloth or

paper (C-423) to obtain a smooth scratch-free64-44. CROSSHEAD ASSEMBLY. surface.

3. Apply two spray coats of primer (C-204)64-45. Inspection, to repaired area.

1. Inspect crosshead assembly for 4. Replace any cracked components.mechanical and corrosion damage (figure 64-27). 5. Replace any components exceeding

mechanical or corrosion damage limits.2. Inspect crosshead assembly for cracksusing magnetic particle inspection method 6. Replace pitch link bearing if axial or(BHT-ALL-SPM). radial play of bearing exceeds wear limits

(BHT-ALL-SPM).

64-46. Repair.7. Replace counterweight link if axial orradial play of bearing exceeds 0.020 in.

MATERIALS REQUIRED (0.508 mm).Refer to BHT-ALL-SPM for specification andsource.

NUMBER NOMENCLATURE

64-00-00Rev. 4 Page 49

BHT-212-CR&O

LINK ASSEMBLY209-011-713


I


NICKS, DENTS, 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.030 IN. (0.762 mm)AND CORROSION

MAXIMUM AREA PER 0.50 SQ. IN. 0.25 SQ. IN. N.C.FULL DEPTH REPAIR (322.6 SQ. mm) (161.3 SQ. mm)

NUMBER OF REPAIR AREAS One per tang One per segment One

EDGE CHAMFER 0.020 IN. (0.508 mm) 0.040 IN. (1.016 mm) 0.040 IN. (1.016 mm)

THREAD DAMAGE: Depth: One third of threadLength: One quarter inch (6.35 mm)Number: Two 212-R-64-24

Figure 64-24. Pitch change link damage and repair limits

64-00-00Page 50

BHT-212-CR&O

IDLER209-011-711

CONTROL TUBE LEVER209-011-710 209-011-712

AREA A AREA B AREA C AREA D


NICKS, SCRATCHES, 0.010 IN. 0.020 IN. 0.005 IN. 0.002 IN.AND CORROSION (0.254mm) (0.508 mm) (0.127 mm) (0.0508 mm)

CORROSION 0.005 IN. 0.010 IN. 0.005 IN. 0.002 IN.(0.127 mm) (0.254 mm) (0.127 mm) (0.0508 mm)

AREA OF 0.25 SQ. IN. 0.50 SQ. IN. 0.05 SQ. IN. 0.05 SQ. IN.FULL DEPTH REPAIR (16.13 SQ. mm) (322.6 SQ. mm) (32.26 SQ. mm) (32.26 SQ. mm)

NUMBER OF REPAIR AREAS One per segment One per segment Two One per tang

EDGE CHAMFER 0.030 IN. 0.060 IN. 0.020 IN. 0.010 IN.(0.762 mm) (1.524 mm) (0.508 mm) (0.254 mm)

THREAD DAMAGE:DEPTH: One-third of threadLENGTH: One-tenth inch (0.254 mm)NUMBER: Two 212-R-64-25-1

Figure 64-25. Pitch change components damage and repair limits (sheet 1 of 2)

64-00-00Page 51

BHT-212-CR&O

GEARBOX HOUSING209-011-720


MECHANICAL 0.010 IN. (0.254 mm)

CORROSION 0.005 IN. (0.127 mm) before repair

0.010 IN. (0.254 mm) after repair

MAXIMUM AREA FOR 0.01 SQ. IN. (6.45 SQ. mm)FULL DEPTH REPAIR

NUMBER OF REPAIRS Not critical212-R-64-25-2

Figure 64-25. Pitch change components damage and repair limits (sheet 2)

0.938 TO 0.940 IN.(23.8252 TO 23.876 mm)

0.3125TO 0.3130 IN.(7.9375 TO 7.9502 mm)

212-R-64-26

Figure 64-26. Lever bushing replacement

64-00-00Page 52

BHT-212-CR&0

COUNTERWEIGHT LINK212-010-711

COUNTERWEIGHT SUPPORT212-010-739

BELLCRANK CROSSHEAD212-010-709 212-010-775


AREA A AREA B AREA C

I I


NICKS, SCRATCHES, DENTS 0.005 IN. (0.127 mm) 0.010 IN. (0.254 mm) 0.002 IN. (0.0508 mm)AND CORROSION

MAXIMUM AREA PER 0.05 SQ. IN. 0.10 SQ. IN. 0.05 SQ. IN.FULL DEPTH REPAIR (32.26 SQ. mm) (64.52 SQ. mm) (32.26 SQ. mm)

NUMBER OF REPAIR AREAS One per lug One One per segment

EDGE CHAMFER 0.010 IN. (0.254 mm) 0.020 IN. (0.508 mm)

THREAD DAMAGE: SPLINE DAMAGE:

Depth: One-third of thread Depth: One-third of splineLength: One-quarter inch Length: One-third of splineNumber: One per segment Number: Two 212-R-64-27

Figure 64-27. Crosshead assembly damage and repair limits

64-00-00Rev. 4 Page 53 I

BHT-212-CR&O

STATIC STOP212-011-713-103



CRACKS ALLOWED None None None

MECHANICAL 0.002 In. (0.05 mm) 0.005 In. (0.13 mm) 0.010 In. (0.25 mm)

CORROSION 0.002 In. (0.05 mm) 0.005 In. (0.13 mm) 0.010 In. (0.25 mm)

MAXIMUM AREA PER 0.050 Sq. In. 0.050 Sq. In. 0.100 Sq. In.FULL DEPTH REPAIR (32.26 mm2 ) (32.26 mm2 ) (64.52 mm2 )

NUMBER OF REPAIR AREAS One per lug One per segment One

EDGE CHAMFER 0.010 In. (0.25 mm) 0.010 In. (0.25 mm) 0.020 In. (0.51 mm)

SPLINE DAMAGEDEPTH 1/3 of splineLENGTH 1/2 of splineNUMBER Two splines

212-R-64-28

Figure 64-28. Static stop damage and repair limits

64-00-00Page 54 Rev. 4

BHT-212-CR&O

ANVIL (BRG INSTL)SEE VIEW A

T101577-13BACKSTOP ADAPTERSEE VIEW B

SEE VIEW C

CL-8-SLF-S

SUPPORTSEE VIEW D SEE VIEW E 2 1

NOTES

A Leveling foot stud to be installed in thislocation for use with 212-011-702 yoke assy.

Leveling foot stud to be installed in thislocation for use with 212-010-744 yoke assy.

212-R-64-29-1

Figure 64-29. Tail rotor yoke bearing work aid (Sheet 1 of 3)

64-00-00Rev. 4 Page 55

BHT-212-CR&O

~-ANVIL (FLAT) ADAPTER~(==S ' I(BRG INSTL) (SWIVEL)

MATL STEEL MATL STEELLTS 90-.125 KSI TS : 90-125 KSI

2.12 IN. DIA(53.85 mm) \

2.30 IN. DIA(58.42 mm)

8 0 ' T YP0.17 IN.

(4.32 mm) TYP - 0.30 IN. 0.06 IN. (1.52 mm)

(7.62 mm) X 45TYP\ 1.09 IN. / 0.06 IN. (152 mm) 1.50 IN. DIA

(0.127 TO 0.381 mm) (48.819 mm)0.005 TO 0.015 IN. R TYP(0.127 TO 0.381 mm) VIEW B

(2.03 mm) TYP MATL : STEEL - (DRILLSTOCK)

Figure 64-29. Tail rotor yoke bearing work aid (Sheet 2)

64-00-00Page 56 Rev. 4

BHT-212-CR&O

16.00 IN.(406.40 mm)

5.90 IN.(149.86 mm) 9.998 IN.

(253.949 mm)

0.062 IN(1.575 mm)

(26.67 mm)

3.000 TO .2.00 IN.(3.001 IN. 50.80 mm)

(76.20 TO ( 38.10 mm)76.22 11.002 IN.

(279.45 mm)

0.25 IN. (6.35 mm) HOLE THRU

HOLE X 2.50 IN. (63.50 mm) DP CSK 100' X 0.560 IN. (14.22 mm) DIA(12.649 TO 12.70 mm)

1.55 IN. SF 1.645 IN. (41.78 mm) DIA X 0.06 IN. (1.52 mm) COR R(39.37 mm) C BORE 2.17 TO 2.20 IN.DIA X 0.03 IN (0.76 mm) COR R

(55.12 TO 55.88 mm) IN'DIA X 0.03 IN. {0.76 mm) COR R(55.12 TO 55.88 mm)

CSK 90 X 0.53 IN. (13.46 mm) DIA0 TO C BORE 0.50 IN. (12.70 mm) -13 UNC 2 B0.81 TO 0.82 IN. THRU PER MlL-S-7742120.57 TO 20.82 mm)

2.25 IN.0.50 IN. R (57.15 mm)(12.70 mm) 3.80 IN.

(96.52 mm)

SUPPORTMATL STEELTS = 90-125 KSI

UNLESS OTHERWISE TS= 90-125 KSISPECIFIED:TOLERANCES.XX ±.03.XXX ±.010ANGLES ±1/2 °

MACHINE FINISHES125/

212-R-64-29-3

Figure 64-29. Tail rotor yoke bearing work aid (Sheet 3)

64-00-00Rev. 4 Page 57/58

BHT-212-CR&O

CHAPTER 65 - TAIL ROTOR DRIVE SYSTEM

CONTENTS - MAINTENANCE PROCEDURES

Paragraph Chapter/Section PageNumber Title Number Number

65-1 Tail rotor drive system ........................... 65-00-00 5

TAIL ROTOR DRIVESHAFT HANGER

65-2 Tail rotor driveshaft hanger ...................... 65-00-00 765-3 Overhaul ....................................... 65-00-00 765-9A Replacement -- coupling temperature

indicator "TEMP-PLATES" ..................... 65-00-00 10A65-10 Painting -- tail rotor driveshaft hanger

assemblies (212-040-600-001 and -009with magnesium hanger and 204-040-617-005) ....................................... 65-00-00 11

INTERMEDIATE (42°) GEARBOX

65-11 Intermediate (42°) gearbox ....................... 65-00-00 1765-12 Deleted ....... ................................. 65-00-00 1765-21 Intermediate gearbox quills. ...................... 65-00-00 2665-22 Input quill ...................................... 65-00-00 2665-29 Output quill .................................... 65-00-00 43

TAIL ROTOR (90° ) GEARBOX

65-36 Tail rotor gearbox ................................ 65-00-00 5565-37 Overhaul ....................................... 65-00-00 5565-46 Input quill ...................................... 65-00-00 71

FIGURES


65-1 Tail rotor drive system components ................................... 665-2 Tail rotor driveshaft hanger ........................................... 1265-3 Tail rotor driveshaft coupling wear pattern ............................ 1465-4 Tail rotor driveshaft hanger wear limits ................................ 1565-5 Tail rotor driveshaft coupling "TEMP-PLATES" installation ............ 1665-6 Intermediate (42°) gearbox............................................ 1965-7 Intermediate gearbox case damage limits ............................. 2165-8 Intermediate gearbox processing requirements ........................ 22A65-9 Intermediate gearbox pinion identification ............................. 2465-10 Intermediate gearbox input quill ....................................... 28

65-00-00Rev. 4 Page 1

BHT-212-CR&O

FIGURES (Cont)


65-11 Intermediate gearbox input quill wear limits ........................... 3265-12 Gear and pinion wear patterns ........................................ 3465-13 Quill coupling teeth wear patterns..................................... 3765-14 Quill roller bearing wear pattern ....................................... 3865-15 Quill sleeve damage limits ............................................ 3965-16 DELETED ............................................................. 4265-17 Intermediate gearbox output quill ..................................... 4565-18 Intermediate gearbox coupling wear pattern .......................... 4765-19 Intermediate gearbox output wear limits .............................. 4965-20 DELETED ............................................................. 5465-21 Tail rotor gearbox ..................................................... 5765-22 Tail rotor gearbox wear limits ......................................... 6165-23 Gear and pinion wear pattern ......................................... 6265-24 Tail rotor gearbox corrosion damage limits ............................ 6465-25 Roller bearing inspection .............................................. 6665-26 Tail rotor gearbox output shaft damage limits ......................... 6765-27 Tail rotor gearbox shims and studs dimensions ....................... 6865-28 Tail rotor gearbox input quill .......................................... 7365-29 Tail rotor gearbox input quill wear limits .............................. 7565-30 Input quill coupling teeth wear pattern ................................ 76

TABLES

Table PageNumber Title Number

65-1 Magnetic particle inspection ........................................... 80

65-00-00Page 2 Rev. 4

BHT-212-CR&0

CONSUMABLE MATERIAL LIST

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

ITEM CAGE/FSCM/NO. NOMENCLATURE SOURCE

C-001 Grease, Aircraft General Purpose, MIL-G-81322 (AeroshellNo.22 or Mobil No.28) Commercial

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

C-010 Lubricating Oil, Turbine Engine, MIL-L-7808 Commercial

C-011 Lubricating Oil, Turbine Engine, MIL-L-23699 Commercial

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

C-100 Chemical Film Material (Alodine 1200 or 1201) MIL-C-81706,Class 1A, Form II (Dip Tank) or III (Brush-on). Apply perMIL-C-5541. Commercial

C-103 Chromic Acid (Brush-On Solution) Chromic Acid and CalciumSulfate Commercial

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

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

C-112 Cadmium Chromate Conversion Coating Micro Bronze No. 1or 76071

Enthox 280 or 02258Alumigold orNo. 6 CD orDalic 5005

C-114 Corrosion Treatment (A mixture of items C-113, C-212 andwater or items C-115, C-212 and water)

C-116 Chromic Acid (Technical), O-C-303-1 Commercial

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

C-202 Epoxy (Super-Koropon) Primer 22873

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

C-204 Epoxy Polyamide Primer, MIL-P-23377, MIL-P-85582, Type I.Refer to text for color. Commercial

C-210 Epoxy Paint, White Catalyzed Color No. 17875 per FED-STD-595 Commercial

C-211 Shellac, TT-S-300, Type 1, Grade B, Body 2 Commercial

C-298 Adhesive, Epoxy, Devcon 2-Ton Commercial

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

C-305 Aliphatic Naphtha, TT-N-95, Type II Commercial

65-00-00Rev. 4 Page 3

BHT-212-CR&0

CONSUMABLE MATERIAL LIST (Cont)

ITEM CAGE/FSCM/NO. NOMENCLATURE SOURCE

C-308 Adhesive, Sealant, 299-947-107, Type III, Class 7, MIL-S- 974998802, Class B2 or 83527

Proseal 890 83574

C-309 Methyl-Ethyl-Ketone (MEK), TT-M-261B, pH Insignificant Commercial(Alternate where MEK use prohibited: RHO SOLV 756) 83527

C-317 Adhesive, Magnabond 6398 (299-947-100, Type II, Class 2) 22121 or97499

C-318 Cleaning Compound, Alkaline Base, MIL-C-87936, pH Value12 Max. (Detergent) Commercial

C-334 1.1.1-Trichloroethane, MIL-T-81533 (Vapor) or O-T-620(Cold) Commercial

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

C-407 Abrasive Pad, Nylon Web (Scotchbrite) L-P-0050, Type I, 27713 orClass 1, Size 1 76381

C-409 Use C-500

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

C-427 Barrier Material, Greaseproofed and Waterproofed, Flexible,MIL-B-121 Commercial

C-432 Nitric Acid, O-N-350 Commercial

C-434 Plating Tape, No. 420 26066

C-436 Paint Remover, Alkaline Type, General, MIL-R-81294 or 80244MIL-R-8633A or 81349Turco No. 5469 61102

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

C-490 Cork Stopper, LL-S-731, Type I, Grade A, Class 2 (Sizespecified in text) Commercial

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

65-00-00Page 4 Rev. 4

BHT-212-CR&O

TAIL ROTOR DRIVE SYSTEM

65-1. TAIL ROTOR DRIVE SYSTEM. (1), intermediate (42°) gearbox (2), and tailrotor (90° ) gearbox (3).

Principle components of the tail rotor drivesystem (figure 65-1) is the tail rotor driveshaft

65-00-00Page 5

BHT-212-CR&O

2. Intermediate gearbox

212-R-65-1

Figure 65-1. Tail rotor drive system components

65-00-00Page 6Page 6

BHT-212-CR&O

TAIL ROTOR DRIVESHAFT HANGER

65-2. TAIL ROTOR DRIVESHAFT 65-5. Cleaning.HANGER.

MATERIALS REQUIRED65-3. OVERHAUL.

NUMBER NOMENCLATURE65-4. Disassembly.

C-304 Solvent

NOTE C-436 Paint Remover

If hanger is being disassembled forreplacement of part(s), instead of 1. Wash all parts, except bearings, withoverhaul, disassemble only to extent solvent (C-304). Dry with filtered, compressednecessary. air.

1. Remove retainer ring (1, figure 65-2), 2. Clean bearing by wiping with dry, lint-freeplate (2), and spring (3) from outer coupling cloth. Do not allow bearings to spin while(8). drying.

2. Remove nut (16), washers (5), bolt (4), 3. Remove paint from hanger with paintand retainer plate (6). remover (C-436). Rinse with clean water.

NOTE 65-6. Conditional Inspection.

For ease of maintenance, blockouter coupling to remain in outboard NOTE(extended) position. This willstabilize outer coupling during If records or physical appearance ofdisassembly and assembly. hanger indicates component was

subjected to an accident or incident3. Slide rear coupling (15) from splined shaft outside realm of normal usage,(11). Remove inner and outer couplings (7 perform Conditional Inspection asand 8) from forward end of splined shaft. follows. If no evidence is found,Remove seal (10) from outer coupling (8). accomplish Normal Inspection,

paragraph 65-7.3A. Observe condition of grease. If greaseis very viscous (thick) and has a strong 1. Visually inspect curvic faces of outer andpungent odor, replace outer coupling (8) and rear couplings (8 and 15, figure 65-2) forinner coupling (7). distortion or evidence of overheating.lf I

overheat conditions are noted, refer to4. Support inner race of bearing (13) and paragraph 65-7.press out shaft (11).

2. Visually inspect mounting ears of hanger5. Remove retainer ring (12) and press (14) for cracks or distortion.bearing from hanger (14).

3. Visually inspect teeth of spherical faces of6. Discard bearing at overhaul. inner and outer couplings (7 and 8) for cracks

or galling.

4. Check bearing (13) for freedom andsmoothness of rotation.

65-00-00Rev. 3 Page 7

BHT-212-CR&O

5. Inspect detail parts for cracks by NOTEmagnetic particle or fluorescent penetrantmethods as applicable (paragraph 65-7) Wear limits are provided to show(BHT-ALL-SPM). required fit between mating parts. It

is not intended all dimensions bechecked as a prescribed overhaulprocedure. However, parts exhibiting

If inspection reveals cracks or evidence of wear or physicaldistortion indicative of excessive damage shall be checkedloads in any one detail part, entire dimensionally.assembly shall be consideredunserviceable and nonreparable. NOTE

6. Accomplish Normal Inspection (paragraph Overtemperature indicator dots on65-7). temperature indicator TEMP-

PLATES are of a white or light graycolor and turn black when exposed

65-7. Normal Inspection. to an overtemperature condition.Chemical contamination can also

1. Visually inspect all parts for damage or cause the indicating dots to turnexcessive wear. black.

2. Inspect inner coupling (7, figure 65-2) for 5. Inspect outer coupling (8, figure 62-5)acceptable wear patterns (figure 65-3). temperature indicator TEMP-PLATES (9) for

evidence of overtemperature indication. If3. Inspect following parts by magnetic overtemperature indication is noted, performparticle (Code M) or fluorescent penetrant coupling overtemperature inspection as(Code F) (BHT-ALL-SPM), as applicable. follows:Demagnetize parts after magnetic inspection.

a. Inspect outer coupling cadmium platingfor being discolored (circumferential tan or

Figure Nomenclature Code light brown band) or blistered. If cadmiumIndex No. plate discoloration or blistering is found,65-2, 4 Bolt M replace outer coupling and inner coupling.65-2, 6 Retainer plate F65-2, 7 Inner coupling M b. Inspect gear teeth of outer coupling65-2, 8 Outer coupling M and inner coupling for being discolored65-2, 11 Shaft M (brown or blue) in the normally bright contact65-2, 14 Hanger (see note) F/M patterns. If discoloration is found, replace65-2, 15 Rear coupling M outer coupling and inner coupling.

c. Inspect outer coupling and innercoupling under 5x to 10x magnification for

NOTE teeth exhibiting signs, of metal smearing ortearing in the contact patterns. If smearing or

Perform fluorescent penetrant tearing is found replace outer coupling andinspection on magnesium hangers inner coupling.(14) and magnetic particle inspectionon steel hangers (14). d. Inspect grease from couplings for being

very viscous (thick) and having a strong4. Inspect parts dimensionally and replace pungent odor. If grease is found to be viscousparts which exceed inspection limits (figure (thick) and having a strong pungent odor,65-4). replace outer coupling and inner coupling.

65-00-00Page 8 Rev. 3

BHT-212-CR&O

NOTE 7. Hold bearing (13) outer race and turninner race by hand and simultaneously loade0 If TEMP-PLATES are to be replaced, bearing by pressing axially on inner race.

replace TEMP-PLATES after Obvious roughness, catching, or binding arecompleting entire inspection and cause to discard bearing.repair procedures and couplingshave been determined serviceable Deletedand prior to assembly. 9. Inspect hanger (14) for mechanical and

corrosion damage as follows:5A. Inspect outer coupling (8) temperatureindicator TEMP-PLATES (9) for deterioration, a. Hanger (14) is unserviceable anddebonding or discoloration of epoxy coating nonreparable if evidence of overheating isthat prevents interpretation of indicating dots. present.If deterioration, debonding, or discoloration of b iInspect hanger for corrosion damage.epoxy is found, replace TEMP-PLATES in Superficial corrosion damage is acceptable ifaccordance with paragraph 65-9A. corrosion is removed and hanger cadmium

plate is touched up.6. Inspect bearing (13) for evidence ofoverheating such as discoloration of bearing c. Inspect lubrication in bearing and(blue to blue/black in color), multicolor hanger.appearance of hanger (14) which darkensadjacent to bearing. Any of the aboveconditions are cause to discard bearing.Brown color of bearing shield is normal and isnot evidence of overheating.

65-00-00Rev. 3 Page 8A/8B

BHT-212-CR&O

10. Inspect inner coupling (7) for wear in 65-9. Assembly.area contacted by seal (10). Rough surfaceand/or wear that would cause lubricant MATERIALS REQUIREDleakage is not acceptable.

NUMBER NOMENCLATURE11. Inspect spring (3), bolt (4), retainer plate(6), retainer rings (1 and 12), plate (2), and C-001 Greasenut (16) for mechanical and corrosion

C-015 Lubricant (Tube Pack)damage. Any damage which will affectfunction is not acceptable.

65-8. Repair. AUTION

MATERIALS REQUIRED IF COUPLING SHAFT (11, FIGURE65-2), FORWARD INNERCOUPLING (7), OR REAR

NUMBER NOMENCLATURE COUPLING (15) IS TO BEREPLACED, ENSURE MESHING

Plan-108 Brush u m SPLINES HAVE 26 SPLINES ANDPlating Solution NOT 24 SPLINES.NOT 24 SPLINES.C-464 India Stone

THE 212-040-602-1 AND -5C-500 Crocus Cloth S H A F T S AR E NOT

INTERCHANGEABLE WITH 212-040-602-3 AND -7 SHAFTS. THE

1. Replace all unserviceable parts and seals 212-040-602-3 AND -7 SHAFTSon assembly. ARE LONGER AND HAVE A

SMALLER OUTSIDE DIAMETER TOACCOMMODATE 204-040-623-3

1 2. Replace coupling seal (10, figure 65-2) BEARING.and bearing (13) upon assembly.

1. Support inner race of bearing (13) and3. Dress splines of inner and outer couplings press shaft (11) into bearing.(7 and 8) with India stone (C-464), asnecessary, to blend out burrs, small nicks, or NOTEscratches.

Bearing journal of shaft (11) must becentered on inner race of bearing

4. Polish nicks, burrs, or scratches on (13) within 0.003 to 0.016 in. (0.0762exterior surfaces with crocus cloth (C-500). to 0.4064 mm).

5. Treat repaired cadmium plated surfaces 2. Support hanger (14) and press bearingand shaft into hanger. Secure bearing withwith brush cadmium plating solution (C-108) retainer ring (12).retainer ring (12).(BHT-ALL-SPM).

6. Replace parts which exceed allowablewear limits.

7. Replace temperature indicator TEMP-PLATES if necessary. Refer to paragraph 65-9A.

65-00-00Rev. 3 Page 9

BHT-212-CR&O

NOTE internal splines for full length of exposedsplines. A workaid may be fabricated (figure

A workaid may be fabricated (figure 65-2, detail C) to obtain depth of grease.65-2, detail B) to aid installation ofseal (10, figure 65-2).

NOTE

3. Install seal (10) into outer coupling (8)seal groove as follows: Ensure inner coupling (7) is correct

for tail rotor driveshaft hangera. Apply a light coat of lubricant (tube coupling, overall length is 2.07 to

pack) (C-015) to outer circumference of seal 2.08 in. (52.578 to 52.832 mm).(10). Coupling for 42° and 90° gearbox is

1.87 to 1.88 in. (47.498 to 47.752

b. Install seal (10) into outer coupling (8) mm) long.seal groove with lip of seal toward internalsplines to outer coupling (8), as shown in 5. Install nner coupling (7), with small endfigure 65-2, detail A. through seal (10). Bottom out inner coupling

against seal.

NOTE 6. Assemble retainer plate (6) and rearcoupling (15) onto splined end of inner shaft

Seal (10) will be partially seated and (11). Install inner and outer coupling (7 andinner coupling (7) will be used as a 8), retainer plate (6) on opposite end of innerbackup, in reverse (see detail A) to shaft (11). Install bolt (4) through retainerfully seat outer circumference edge plate (6) with bolt head toward coupling end,of seal into outer coupling seal with washers (5) and nut (16). Torque nut 50groove. to 70 in.lbs. (5.649 to 7.9086 Nm) and secure

with cotter pin.c. Using inner coupling (7) as a backup

and placed (detail A), firmly press down (hand 7. Place spring (3) onto alignment probe onpressure only) on outer coupling (8), rear side of cover plate (2). Position springsimultaneously tuck outer circumference edge and cover on outer coupling (8), compressof seal (10) with workaid into outer coupling spring and install retainer ring (1). Ensure(8) seal groove, retainer ring is fully seated.

d. Continue pressing around seal (10)with workaid until seal (10) is fully seated. NOTERemove inner coupling (7) from outercoupling (8). Refer to paragraph 65-10 for

painting of 212-040-600-001 and -4. Hand pack internal splines of outer 009 tail rotor driveshaft hangercoupling (8) with lubricant (tube pack) (C-015) assemblies.to 0.12 in. (3.048mm) deep over top of

65-00-00Page 10 Rev. 4

BHT-212-CR&O

NOTE CONTAMINATION. ANYCONTAMINATION COULD ALLOW

If hanger bearing (13) has been THE TEMP-PLATES TO COME OFFreplaced during overhaul of hanger O R I N D I C A T E F A L S Eassembly and is new, do not TEMPERATURES.lubricate bearing with a hand greasegun. The bearing has been 2. Prepare outer coupling surface forlubricated at the factory and bonding by scrubbing surface clean with aadditional lubricant may damage cloth moistened with an authorized cleaner,bearing seal. such as MEK (C-309) to remove all

contamination. Before the cleaner solvent8. Lubricate hanger bearing (13) with hand dries, wipe the surface dry with a clean cloth.grease gun, using grease (C-001), Mobil 28 The cleaned surface should be at least 0.50only. inch (12.70 mm) larger than the TEMP-

PLATES. Refer to figure 65-5 for location of9. The tail rotor hanger will be tagged with TEMP-PLATES on outer coupling.date of lubrication and an entry made incomponent historical record, if hanger is to be 3. Accomplish a water break-free test onreturned to stock. the prepared bonding surface by applying

distilled or demineralized water from a10. When tail rotor hanger is installed on suitable dispenser (such as a squeeze bottle).helicopter, an entry will be made in helicopter The water must flow into a continuous filmlog and flex couplings lubrication log. without gathering into distinct water droplets

within 25 seconds after application on the65-9A. REPLACEMENT - COUPLING surface. Wipe dry with a clean cloth. Ensure

the bonding surfaces are not subsequentlyTEMPERATURE INDICATOR TEMP- contaminated.contaminated.PLATES.

4. If the coupling bonding surface will notMATERIALS REQUIRED meet the water break-free test requirements

and the cleaning materials are notRefer to BHT-ALL-SPM for specification and contaminated, clean coupling bondingsource. surfaces as follows.

NUMBER NOMENCLATURENOTE

C-298 Epoxy AdhesiveFollow the manufacturers

C-309 Methyl-Ethyl-Ketone recommendations for proper water(MEK) mixtures.

C-318 Cleaning CompoundCleaning Compound a. Using an authorized alkaline cleaningC-436 Paint Remover compound (C-318) and cloth, scrub the

coupling bonding surface clear. Followcleaning with a thorough water rinse.

1. Remove epoxy coating and TEMP-PLATES using paint remover (C-436). Repeat b. Thoroughly dry coupling surfaces.process until no trace of epoxy is present.

c. Repeat water break-free test as statedabove.

CAUTION

BONDING SURFACE AND TEMP-PLATES MUST BE FREE OF ALL

65-00-00Rev. 4 Page 10A

BHT-212-CR&O

CAUTIONNOTE

****,**s«*"« s... Use of any epoxy adhesive otherthan Devcon 2-Ton is not

IN ORDER TO PREVENT authorized.CONTAMINATION OF THE TEMP-PLATES ADHESIVE BACKING, 8. Prepare Devcon 2-Ton epoxy adhesiveENSURE THAT WORK AREA AND epoxy adhesive (C-298) as follows:HANDS ARE THOROUGHLYCLEANED BEFORE WORKINGWITH TEMP-PLATES. a. Pour equal amounts of epoxy Part A

and Part B into a solvent proof container.

DO NOT PRESS OR RUB THE b. Vigorously mix Part A and Part B with aTEMP-PLATES WITH BARE brush such as an artist brush.FINGERS DURING INSTALLATIONON THE COUPLING AS THIS WILL c. A few drops of authorized thinner, suchCONTAMINATE THE SURFACES. as MEK (C-309), may be added to the epoxyAPPLY EPOXY COATING TO THEAPPLY EPOXY COATING TO THE during the mixing operation to reduce theTEMP-PLATES IMMEDIATELYTEMP-PLATES IMMEDIATELY viscosity to a level that permits uniform brushFOLLOWING INSTALLATION OF application of the epoxy mixture. Do not thinTHE TEMP-PLATES ON this mixture such that it runs when applied toCOUPLING. COUPLING. a vertical surface. The final viscosity of the

epoxy should be similar to a heavily bodied5. Carefully prebend the temperature paint. Too thin a mixture may seep into theindicator TEMP-PLATES to match the V temperature indicator TEMP-PLATE andcontour of coupling surface. Do not crease cause the indicator dots to turn black in whichthe TEMP-PLATES sharply. event, the TEMP-PLATE must be removed

and replaced. Working time for the mixture isNOTE approximately 15 minutes.

Working one TEMP-PLATE at a 9. Using a soft-bristled brush, uniformlytime, repeat steps 6 and 7 until all apply the epoxy coating over the TEMP-TEMP-PLATES are installed on PLATES to a thickness of approximatelycoupling. 0.002 to 0.004 inch (0.0508 to 0.1016 mm)

similar to a coat of paint. The coating should6. Remove protective backing from the be uniform in appearance, totally cover theTEMP-PLATE and carefully position onto the surface of the TEMP-PLATES and extendsurface prepared in step 2. approximmately 0.25 inch (6.35 mm) beyond

the edges of the TEMP-PLATES.7. Using a clean cloth or cotton swab, workthe TEMP-PLATE into the contour of thecoupling. A thoroughly cleaned firm rubber CAUTION(edge of a block type eraser) workaid may beutilized to work TEMP-PLATE into full contactwith the coupling surface. Ensure the TEMP- DO NOT EXPOSE THE EPOXYPLATE is in full contact with the coupling COATING TO OIL, GREASE,surface. Do not press or rub the TEMP- CLEANING SOLVENT OR OTHERPLATE with bare fingers. CHEMICALS DURING CURE.

65-00-00Page 10B Rev.3

BHT-212-CR&O

10. Allow epoxy coating to cure at room MATERIALS REQUIRED (CONT)temperature approximately 60 to 100°F (15.6to 38°C) for a minimum of six hours prior to NOMENhelicopter operation. For best results, allow NUMBERNOMENCLATUREepoxy to cure overnight prior to operatinghelicopter or exposure to oil or grease. C-204 Primer

C-305 Aliphatic NaphthaNOTE

An alternate source of heat can be 1. Touch up exposed magnesium surfacesused if the temperature does not on hanger (14, figure 65-2) with chromic acid Iexceed 180°F (82°C). (C-103) (BHT-ALL-SPM).

11. After one hour epoxy curing time at 2. Mask off bearing, seal, and couplings.room temperature, the epoxy coating total Clean hanger in area to be painted with cleancuring time can be accelerated by placing the cheesecloth wetted with aliphatic naphtha (C-coupling in a temperature controlled oven for 305). Wipe dry with clean cheesecloth beforeone to two hours at a temperature of 150 to naphtha evaporates180°F (66 to 82°C).

12. Follow the 3. Apply two spray coats of primer (C-204)12. Following the cure, the TEMP-PLATES 22.9 u) thickness.should conform to the contour of the couplingand be free of lifted edges. Indicating dots onTEMP-PLATES must remain the original white NOTEor light gray with no full or partial blackdiscoloration. Apply aluminized lacquer spray coat

not less than thirty minutes and not13. Accomplish an adhesion test on each more than eight hours, after epoxyTEMP-PLATE installation. Press a 1.00 inch primer is applied.(25.4 mm) wide strip of high adhesion tapeonto the TEMP-PLATE and epoxy overcoat. 4. Spray on first coat of aluminized, colorThe tape should extend beyond the edge of No. 17178 lacquer (C-203) 0.4 to 0.6 milthe epoxy overcoat. Grasp one end of the thickness. Allow to dry for thirty minutes totape at approximately 90 degrees from the one hour and apply second coat.surface and remove tape in one abruptmotion. Lifting or peeling of the epoxy coating NOTEor TEMP-PLATE is not acceptable. If lifting orpeeling is detected, remove and replace If second coat of lacquer cannot beTEMP-PLATE by repeating procedure. applied within time limits noted in

step 5., second coat may be delayed14. Repeat procedure for all tail rotor drive for up to seventy-two hours, butouter couplings. surface to be painted shall be

cleaned with a tack rag prior to65-10. PAINTING - TAIL ROTOR applying second coat.DRIVESHAFT HANGER ASSEMBLIES (212-040-600-001 AND -009 WITH MAGNESIUM 5. Allow last coat of aluminized lacquer toHANGER AND 204-040-617-005). dry for forty-eight hours and remove masking

tape.

MATERIALS REQUIRED 6. Deleted.

NUMBER NOMENCLATURE

C-103 Chromic Acid

C-203 Lacquer

65-00-00Rev.3 Page 11

BHT-212-CR&O

15

3 14

13

12

^^^^. KwslM'\' --4 GREASE GROOVES IN~7 (204-040-623-003 BEARING\\ 1. Retainer ring 9. Deleted

SEE DETAIL A 5. Washer 13. Bearing6. Retainer plate 14. Hanger7. Inner coupling 15. Rear coupling8. Outer coupling 16. Nut

NOTE

A Location of Temperature

WORKAID

SEE DETAIL B

SEAL (10) PARTIALLY SEATED SEAL (10 FULLY SEATED

~INTERNA L IF Iffr -OUTER COUPLING (8)SPLINES INSTALLED INVERTED

INNER COUPLING (7) USED ON INNER COUPLINGAS BACK-UP TO PUSH LIPOF SEAL (10) UP

DETAIL A SEE DETAIL C

Figure 65-2. Tail rotor driveshaft hanger (Sheet 1 of 2)

65-00-00Page 12 Rev.3

BHT-212-CR&O

1.0 IN. (25.4 mm) RADIUS

8 IN. (203.20 mm)

2.0 IN.(50.8 mm)

7.0 IN. (177.80 mm)

0.125 IN. |(3.18mm) 0.25 IN.

1.0 IN. (2 5.4 mm) (6.35 mm)

NOTE

Make from plexiglass or similar material, remove all sharp edges.

DETAIL B

1.05 IN. 0.27 IN. (6.80 mm)(26.67 mm

0.25 IN. (6.35 mm)

HANDLE LENGTH IS OPTIONAL

0.1 IN.(2.54 mm)RADIUS

. (31.75 mm)

0.05 IN.COUPLING (1.27mm) 0.312 IN.TAIL ROTOR RADIUS (7.92 mm)DRIVESHAFT

Make locally from 1/4 in. (6.35 mm) plastic, or similar material.

DETAIL C212-R-65-2-2

Figure 65-2. Tail rotor driveshaft hanger (Sheet 2)

65-00-00Page 13

BHT-212-CR&O

time.A Acceptable pattern typical of low operating

B Acceptable pattern typical of couplings whichhave operated with normal misalignment for alonger period of time than that shown In A.

C Acceptable pattern denoting operation athigher torque than that shown in A and B.

D Acceptable pattern showing a pitted tooth.This condition Is acceptable on all teeth.

E Pattern shows a more severe condition oftooth pitting than that shown In D. There Isno metal projecting above the normal face ofthe tooth, indicating that the pitted area ispolishing over. This condition may exist on allteeth. Couplings with pits larger than 1/32inch (0.79375 mm) diameter should be re-placed. 212-R-65-3

Figure 65-3. Tail rotor driveshaft coupling wear pattern

65-00-00Page 14

BHT-212-CR&O

7

8

64

MIN. MAXITEM NOMENCLATURE INCHES mm INCHES mm

1 Outer Coupling - Internal Spline Between pins 1.8290 46.4566 1.8360 46.6344(Use 0.1309 IN. (3.32486 mm)diameter pins)

2 Inner Coupling - External Spline Over pins 2.1590 54.8386 2.1740 55.2196(Use 0.1080 IN. (2.7432 mm)diameter pins)

3 Inner Coupling and Rear Between pins 1.1465 29.1211 1.1578 29.40812Coupling - Internal Splines(Use 0.0960 IN. (2.4384 mm)diameter pins)

4 Shaft - External Spline Over pins 1.4424 36.63696 1.4465 36.7411(Use 0.0960 IN. (2.4384 mm)diameter pins)

5 Shaft - Bearing Seat(212-040-602-1 and 5) 1.3776 34.99104 1.3784 35.01136(212-040-602-3 and 7) 1.3476 34.22904 1.3484 34.24936

6 Bearing - Inner Diameter(204-040-623-1 and 5) 1.3775 34.9885 1.3781 35.00374(204-040-623-3) (Regreasable) 1.3477 34.23158 1.3481 34.24174

7 Bearing - Outer Diameter 2.4403 61.98362 2.4409 61.99886

8 Hanger - Inner Diameter 2.4401 61.97854 2.4409 61.99886

NOTE

1 Maximum depth of wear 0.005 inch (0.127 mm) measured from unworn face of tooth. 212-R-65-4

Figure 65-4. Tail rotor driveshaft hanger wear limits

65-00-00Page 15

BHT-212-CR&O

HANGER

204-040-604-005 COUPLINGREF

6000-1 TEMP-PLATE (RED BORDER)2 REQD-180 DEGREES APARTEQUALLY SPACED WITHIN 0.3 IN. (7.62 mm)

IDENTIFICATION/ ( 0.74± 0.030 IN.PLATE (18.79±0.762 mm)

212-R-65-5

Figure 65-5. Tail rotor driveshaft coupling TEMP-PLATES installation

65-00-00Page 16 Rev.3

BHT-212-CR&0

INTERMEDIATE (42° ) GEARBOX

65-11. INTERMEDIATE (42°) GEARBOX. 2. Release pin (24) which secures chain tocase and remove cap (26). Remove packing(25) from cap. Discard packing.

65-12. DELETED

3. Remove retainer ring (19), glass (21),and indicator (22). Use suitable tool to

65-13. Disassembly. remove glass. Carefully remove packing (20)from glass. Discard packing.

SPECIAL TOOLS REQUIRED4. Remove six nuts (14) and washers (15).

NUMBER NOMENCLATURE Cut sealant between case (6) and input quill(16). Remove sealant from three jackscrew

T101308 Jackscrew holes and install three T101308 jackscrews inBacklash threaded holes in sleeve of quill. Heat

T101350 Backlash clamp housing warm to touch with heatgun.TurnT102030-3 Backlash clamp jackscrews evenly to pull input quill from

case.204-040-001-17 Puller tool (Sightglass)PAT-5S or Equivalent

NOTE

NOTE Note moved to 65-16

Prior to disassemble, it is 5. Deleted - Moved to paragraph 65-16recommended that a backlash checkbe accomplished and readingsrecorded. 5A. Deleted - Moved to paragraph 65-16

NOTE 6. Refer to paragraph 65-21 for input quill

If records and/or physical procedures.appearance of intermediate gearboxindicate assembly has been 7. Remove output quill (1) by samesubjected to an accident or incident procedure described in step 4. Removeoutside realm of normal usage,perform Conditional Inspection, fromparagraph 65-15.

8. Remove three screws (5) and shim plateIf intermediate gearbox is beingIf intermediate gearbox is being (4). Remove three screws (11) and removedisassembled, for replacement of (4). Remove three screws (11) and removepart(s) instead of overhaul, shim plate (10). Identify shim plates fordisassemble only to extent reinstallation in same location. Shim platesnecessary. shall be removed for fluorescent penetrant

inspection or corrosion stripping.

1. Remove chip detector (17, figure 65-6)and drain oil from case. Remove packing (18) 9. Refer to paragraph 65-29 for output quill

I from chip detector, and discard packing. procedures.

65-00-00Rev. 4 Page 17

BHT-212-CR&0

65-14. Cleaning normal usage, perform ConditionalInspection as follows. If gearboxdoes not require Conditional

MATERIALS REQUIRED Inspection, accomplish NormalRefer to BHT-ALL-SPM for specification and Inspection (paragraph 65-16).source.

1. Inspect gearbox and gearbox records toNUMBER NOMENCLATURE determine whether gearbox has been

subjected to an accident or incident outsideC-010 Lubricating Oil the realm of normal usage which would

Lubricating Oil require conditional inspection. Refer to BHT--011 Lubricating Oil 212-MM, for definition of accidents or

C-105 Corrosion Preventive incidents which require that conditionalinspection be conducted.

C-304 Solvent2. If conditional inspection is not required,

C-436 Paint Remover proceed with normal inspection, paragraph

C-486 Cheesecloth 65-16.

3. Check gearbox for free rotation and1. Clean all parts with solvent (C-304). backlash of gears. Backlash should not vary

more than 0.002 inch (0.0508 mm), when2. Dry parts with low pressure, filtered air or checked at different points around gear.cheesecloth (C-486) Do not allow drybearings to spin. 4. Perform fluorescent penetrant inspection

of gearbox case (16, figure 65-6) (BHT-ALL-3. Remove sealant from gearbox case (6, SPM).figure 65-6) with plastic scraper.

NOTENOTE

If inspection reveals cracks orParts requiring fluorescent penetrant distortion, gearbox shall beinspection shall be stripped of all considered unserviceable andfinishes. nonrepairable.

4. Remove all paint and primer from 5. Accomplish Normal Inspection,gearbox case using paint remover (C-436). paragraph 65-16.

5. When parts are not to be usedimmediately after cleaning, gently agitate 65-16. Normal Inspectionparts in corrosion preventive (C-105) and airdry. Apply protective coat of approved 1. Inspect gearbox case (6, figure 65-6) forlubricating oil (C-010) or lubricating oil (C- damage which would cause it to be011). nonserviceable or nonreparable.

65-15. Conditional In n 2. Inspect studs and washer seats (9 and 8)65-15. Conditional Inspection for looseness, damage, and corrosion.

NOTE 3. Inspect gearbox case quill ports for4.4100 to 4.415 inches (112.014 to 112.141

If records and/or physical mm) inside diameter.appearance of gearbox indicateassembly has been subjected to an 4. Inspect oil filler cap (26, figure 65-6) andaccident or incident outside realm of adapter (23) for damage and wear.

65-00-00Page 18 Rev. 4

BHT-212-CR&0

5. Inspect oil level sight glass (21) for a. Inspect outer coupling cadmium platingcracks, crazing, scratches, or discoloration. for being discolored (circumferential tan orInspect indicator (22) for stained or peeled light brown band) or blistered. If cadmiumpaint. plate discoloration or blistering is found,

replace outer coupling and inner coupling.6. Inspect chip detector (17) for obviousdamage. b. Inspect gear teeth of outer coupling

and inner coupling for being discolored7. Inspect gearbox case for corrosion and (brown or blue) in the normally bright contactfor elongated mounting bolt holes (figure 65- patterns. If discoloration is found, replace7). outer coupling and inner coupling.

8. Perform fluorescent penetrant inspection c. Inspect outer coupling and innerof gearbox case (BHT-ALL-SPM). coupling under 5x to 10x magnification for

teeth exhibiting signs of metal smearing or9. Inspect shim plate (10, figure 65-6) for tearing in the contact patterns. If smearing ordamage and wear. tearing is found, replace outer coupling and

inner coupling.

NOTE d. Inspect grease from couplings forbeing very viscous (thick) and having a strong

If inspection reveals cracks or pungent odor. If grease is found to be viscousdistortion, gearbox case shall be (thick) and having a strong pungent odor,considered unserviceable and replace outer coupling and inner coupling.nonrepairable.

10. Inspect chip detector (17) for obvious NOTEdamage.

If "TEMP-PLATES" are to bereplaced, replace "TEMP-PLATES"

NOTE after completing entire inspectionand procedures and couplings have

Overtemperature indicator dots on been determined serviceable andtemperature indicator "TEMP- priortoassembly.PLATES" are of a white or light graycolor and turn black when exposed 12. Inspect outer couplings (13 and 28)to an overtemperature condition. temperature indicator "TEMP-PLATES" forChemical contamination can also deterioration, debonding or discoloration ofcause the indicating dots to turn epoxy coating that prevents interpretation ofblack. indicating dots. If deterioration, debonding, or

discoloration of epoxy is found, replace11. Inspect outer couplings (13 and 28) "TEMP-PLATES" in accordance withtemperature indicator "TEMP-PLATES" or paragraph 65-9A.evidence of overtemperature indication. Ifovertemperature indication is noted, performcoupling overtemperature inspection asfollows:

65-00-00Rev. 4 Page 18A/18B

BHT-212-CR&O

1. Output quill2. Nut3. Washer (2)4. Shim plate5. Screw6. Case7. Data plate8. Washer seat9. Stud

10. Shim plate 2811. Screw12. Packing13. Coupling 1914. Nut 2015. Washer (2) 21 2516. Input quill17. Chip detector 2418. Packing19. Ring 220. Packing 1721. 'Glass22. Indicator23. Oil filler adapter 524. Pin25. Packing \26. Cap27. Chain28. Coupling

15

~~~ 9 8

10

12 ll

NOTE

Location of temperature indicator TEMP-PLATES.

13

212-R-65-6

Figure 65-6. Intermediate (42°) gearbox

65-00-00Rev.3 Page 19

BHT-212-CR&0

65-17. Repair b. Stud hole damage: Remove damagedor loose studs. Use suitable tool to grip studand turn out slowly and evenly to avoid

MATERIALS REQUIRED seizure and breakage. If stud hole threads areRefer to BHT-ALL-SPM for specification and damaged, repair or replace case as required.source. If corrosion or other damage has not

penetrated past first thread, rework case asNUMBER NOMENCLATURE follows (BHT-ALL-SPM):

C-100 Chemical Film Material (1) Machine or drill out damagedthread. Do not exceed depth of one thread.

C-105 Corrosion Preventive Clean out diameter shall equal major thread

C-108 Brush Cadmium diameter.Plating Solution

(2) Break all sharp edges, except inC-112 Cadmium Chromate area of threads. Clean out small vent hole in

Conversion Coating bottom of threaded hole. Treat bare surfaceswith chemical film material (C-100).

C-116 Chromic Acid

C-204 Primer (3) Replace stud (BHT-ALL-SPM).

C-308 Adhesive (4) Fill all counterdrilled holes withadhesive (C-308) flush with top of case.

C-423 Abrasive cloth orPaper c. Repair minor scratches, nicks, and pits

C-432 Nitric Acid on noncritical surfaces with abrasive cloth orpaper (C-423).

C-494 Inkd. Cases with corrosion damage within

acceptable limits must be treated byNOTE immersion in a hot chromic acid bath

consisting of 20 to 24 ounces (591.4 toReplace case if structural damage to 709.68 ml) of chromic acid (C-116) per gallonstud threads or mounting bolt holes (3.7584 liters) of water at 200°F (93°C) for asare elongated so repair limits are long as corrosion is present. It is mandatoryexceeded. that all corrosion products be removed.

Corrosion removal process must be controlledto ensure that machined dimensions are1. Replace parts which exceed allowable to ensure that machined dimensions aremaintained and that cadmium plating is notremoved from studs. After chromic acid bath,rinse case with water to remove chromic acid

2. Repair corrosion damage on the case as and dry with filtered compressed air and applyfollows (figure 65-7): corrosion preventive (C-105).

a. Flange repair: Machine off upper face 3. Replace unserviceable oil filler capto a minimum flange thickness of 0.40 inch adapter (23, figure 65-11). Install new adapter(10.16 mm) (dimension B, figure 65-7) coated with primer (C-201).provided this leaves no pits in excess of0.010 inch (0.254 mm) deep and affected 4. If original cadmium plating on case shimarea does not exceed inspection limits. plate (20) has worn through, replate asRework case using a 0.875 inch (22.225 mm) follows:diameter spotface with 0.062 inch (1.5748mm) corner radius. Machined surface finish a. Cadmium plate shim plates usingshall be 63 RMS or better. brush cadmium plating solution (C-108).

65-00-00Page 20 Rev. 4

BHT-212-CR&O

Required dimensions shall be met after etched on part adjacent to applicableplating (BHT-ALL-SPM). mounting surface.

b. If original shim plate is missing or (2) Subtract dimension etched ormixed with other shim plates, determine stamped on case from 3.4670 to 3.4675required dimensions of replacement shim inches (88.0618 to 88.0745 mm) to giveplate as follows: required shim thickness, after plating.

(1) Examine case for referencedimension which is metal stamped or vibro-

65-00-00Rev. 4 Page 20A/20B

BHT-212-CR&O

AREA A

SEE VIEW A

DETAIL VIEW A

DIMENSION B

SIDE VIEW VIEW LOOKING AFT

0.290 IN.(7.366 mm)MAXIMUM ACCEPTABLEELONGATION OFMOUNTING BOLT HOLES

NOTES

1. Corrosion pitting on upper machined face at four mounting bolt holes is acceptable provided it is nomore 0.020 inch (0.508 mm) deep, no more than 20 percent of total area is pitted, no more than 10percent of the area under washer is pitted and minimum thickness of flange in pitted area is no less than0.430 inch (10.992 mm).

2. Cases having damage exceeding inspection limits may be reworked by machining off upper face to aminimum flange thickness of 0.400 inch (10.16 mm) (see dimension B above) provided this leaves nopits in excess of 0.010 inch (0.254 mm) deep and affected area does not exceed limits given above.

3. Rework case using a 0.875 inch (22.225 mm) diameter spot face with 0.062 inch (1.5748 mm) cornerradius. Machined surface finish must be 63 RMS or better.

4. Corrosion pitting in area A is acceptable provided it is no more than 0.030 inch (0.762 mm) deep and nomore than forty percent of area within any one inch square (25.4 square mm) nor twenty percent oftotal area A at either bore is pitted. Structural damage to threaded holes for studs is acceptableprovided damage does not extend past first thread. 212-R-65-7-1

Figure 65-7. Intermediate gearbox case damage limits (Sheet 1 of 2)

65-00-00Rev. 4 Page 21

BHT-212-CR&O

1.25 IN. 212-040-506-1 CASE ASSY(31.75 mm)

AREAS OF ACCEPTABLE CORROSION PITTING ON LOWER SURFACES0.56 IN OF CASE MOUNTING PADS DIMENSIONAL LIMITS APPLY TO AFFECTED

(14.22 mm)AREAS AFTER CORROSION HAS BEEN POLISHED OUT.

FOR -1 CASE ASSY MADEFROM -15 MACHINING

45° TYP

0.25 IN. (6.35 mm) TYP0.28 IN. (7.11 mm) R MIN TYP

FOR -1 CASE ASSY MADEFROM -3 OR -9 MACHINING

BOTTOM VIEW

Maximum depth of acceptable corrosion pitting is 0.015 inch (0.381 mm)measured from machined surface of mount pad after all pitting has beenpolished out.

Maximum depth of acceptable corrosion pitting is 0.030 inch (0.762 mm)measured from machined surface of mount pad after all pitting has beenpolished out.

NOTES

1. Corrosion pitting on either pad may extend over no more than 50% ofany one square inch of area in which pitting is allowed or, as anaggregate total, cover more than 30% of the area.

2. Polish out corrosion pitting removing minimum material to produce asurface finish of 63 microinches or better. Fillet radii to be 0.125 inch(3.175 mm) minimum.

3. Cases with corrosion damage within acceptable limits must be treatedby immersion in chromic acid bath in accordance with instructions givenin BHT-ALL-SPM for magnesium parts to remove all corrosion products.

4. Chemical film treat corroded areas in accordance with BHT-ALL-SPMfor magnesium parts.

5. Apply (2) coats of MIL-P-23377 polyamide epoxy primer in accordancewith instructions given in BHT-ALL-SPM.

212-R-65-7-2

Figure 65-7. Intermediate gearbox case damage limits (Sheet 2)

65-00-00Page 22 Rev. 4

BHT-212-CR&0

3

INNER COUPLING OUTER COUPLING SLEEVE204-040-603 204-040-604 212-040-502

4

VIEW A

B VIEW B

CASE212-040-506

NOTES

1 Cadmium plate will be applied to this area only.

2 Do not apply cadmium plate in hole.

3 Epoxy primer and acrylic lacquer will be applied to this area only.

4 Primer and final finish will not be applied to this area. 212-R-65-8

Figure 65-8. Intermediate gearbox processing requirements

65-00-00Rev. 4 Page 22A/22B

BHT-212-CR&0

(3) Grind new blank shim to required MATERIALS REQUIRED (CONT)thickness and apply brush cadmium platingsolution (C-108). Using ink (C-494) orequivalent, identify new shim plate by etching NUMBER NOMENCLATUREserial number of applicable case on shim C-423 Abrasive Cloth orplate. Also etch thickness on shim plate. PaperNeutralize etching ink with water and commonbaking soda after etching.

1. Position original shim plates (4 and 10,5. Repair oil filler cap as required (BHT- figure 65-6) or replacement shim plates on212-MM). case (6). Install each shim plate with three

screws (5 and 11).6. Replace oil level sight glass (21), ifcracked, crazed, scratched, or discolored and 2. Use heat lamp at each input and outputreplace indicator (22), if stained or if paint is port to heat gearbox case (6).peeled (BHT-212-MM).

7. All parts repaired shall be reinspected NOTEprior to use. Replace all parts which arecracked, broken, warped, distorted, have Teeth of pinion on input quill andmalformed threads, or which cannot be output quill are cut opposite eachrepaired. Replace all seals, gaskets, other (figure 65-9).packings, standard hardware, and all locking

devices, on reassembly. 3. Place packing (12, figure 65-6) on sleeveof each quill. Coat packing and mating

8. Apply brush brush cadmium plating surfaces of quill sleeves and gearcase with* solution (C-108) and chemical film material gearbox oil. Insert input quill (16) in forward(C-100) to required areas of parts from which porfinish was removed during inspection andrepair (BHT-ALL-SPM). NOTE

9. Apply supplementary chromate Only the output quill has an oilconversion coating, on cadmium plated parts, collector cone.by swabbing or brushing for 30 seconds(maximum). Refer to BHT-ALL-SPM. 4. Install washers (15) and nuts (14) on

studs and tighten evenly. Ensure only10. Replace coupling "TEMP-PLATES" if aluminum washers (3) and (15) are in contact Inecessary (Paragraph 65-9A). with quill sleeve. Torque 50 to 70 inch-lbs.

(5.649 to 7.9086 Nm).65-18. Assembly

5. Install output quill (1) in same mannerusing washers (3) and nuts (2). Exercise care

MATERIALS REQUIRED to engage gear and pinion teeth whenRefer to BHT-ALL-SPM for specification and installing second quill to avoid damage.source.

NOTENUMBER NOMENCLATURE

C-305 Aliphatic NaphthaCheck backlash and torque checkC-305 Aliphatic NaphthaC-35 nuts (2 and 14) when gearboxC-309 Methyl-Ethyl-Ketone stabilizes at room temperature.

(MEK)

C-317 Adhesive

65-00-00Rev. 4 Page 23

BHT-212-CR&0

6. Check for backlash using T101350 clamp denotes vented cap shall beand T102030-3 clamp. Take reading from installed.center of dowel pin in T102030 clamp (pinlocation is marked 212). Backlash 0.004 to0.010 inch (0.1016 to 0.254 mm). Check in and install on cap (26) and install oil fillerthree places approximately 120 ° apart,

In any one assembly, adapter (23). Secure chain (27) to case withrecord readings. In any one assembly,backlash reading shall not vary more than0.002 in. (0.0508 mm) when checked at threeplaces around gear. A greater variation NOTEindicates a warped gear. Check gears andreject out of tolerance parts. Deleted

I8. Lubricate and install packing (20) onCAUTION sight glass (21) and lubricate with gearbox oil.

Position indicator plate (22) in case with tangin notch. Install glass (21) with recessed side

DO NOT ALTER SHIM PLATES ON inboard. Install ring (19).CASE OR QUILL SLEEVES TOOBTAIN BACKLASH. IF BACKLASHIS NOT WITHIN LIMITS, PARTS 9. Place gasket (18) on chip detector (17)ARE IMPROPERLY ASSEMBLED, and install in case. Torque 120 to 150 inch-OR ARE DIMENSIONALLY lbs. (13.5576 to 16.947 Nm).INCORRECT.

NOTENOTE

Chip detector will be secured toHalf-inch (12.7 mm) diameter white adjacent mounting bolthead whendot on cap (26) and on case (6) gearbox is installed on helicopter.

212-R-65-9

INPUT OUTPUT

Figure 67-9. Intermediate gearbox pinion identification65-00-00Page 24 Rev. 4

BHT-212-CR&0

10. Prepare data plate (7) for installation. d. Position plate on gearbox. Use fixtureand rubber bands to maintain approximatelyten psi pressure on plate during cure period

{»CAUTION of 24 hours. Clean off any adhesive outsidebond region with cheesecloth moistened withMEK (C-309) before adhesive cures.

STAMPING DIRECTLY ON 12. Seal and paint intermediate gearboxSURFACE OF INSTALLED DATA (paragraph 65-19).PLATE IS PROHIBITED.

13. Deleteda. Data plate information shall include

initials of facility performing overhaul ormodification, date of overhaul or 65-19. Sealing and paintingmodifications, and part number. Totaloperating time since new shall be included, if MATERIALS REQUIREDapplicable. Stamp date of overhaul ormodification in area adjacent to Refer to BHT-ALL-SPM for specification andmanufacturers data. If there is not sufficient source.space to stamp new data on old plate, makenew data plate and transfer pertinent data NUMBER NOMENCLATUREfrom old plate to new plate.

C-210 Paint

b. If required, locally manufacture C-245 Coating, Polyurethanereplacement data plate from 0.032 inch(0.8128 mm) thick, soft aluminum sheet, C-246 Primercondition 0, QQ-A-250/8B. Make plate 1.0inch (25.4 mm) wide and 2.0 inch (50.8 mm) C-308 Adhesivelong. C-309 Methyl-Ethyl-Ketone

11. Install data plate (7) as follows: (MEK)

a. Position data plate on gearbox andform data plate to have contact with gearboxover its entire lower surface.

If gearbox is to be run-in on a run-instand, skip painting and sealing until

b. Clean data plate and gearbox in area after run insction (paragraphwhere plate will be bonded by abrading lightly 65-20)with 400 grit abrasive cloth or paper (C-423).Remove residue with clean cloth moistened 1. Clean external surfaces of case and quillwith alphatic naphtha (C-305). After cleaning, sleeve flanges with MEK (C-309) and cleanwear clean, dry, white gloves, when handling clothscloths. Do not allow cleaning agent to contactparts to prevent contamination. oil or grease seal.oil or grease seal.

c. Mix adhesive (C-317), 33 parts B to100 parts A. Mix the two parts thoroughly. Pot NOTElife is 30 to 50 minutes after mixing. Apply athin coat of mixed adhesive to plate and to Mix sealing compound according togearbox in area where plate will be bonded. directions on container and apply toPlace four mil thread in adhesive on data gearbox with pressure gun or woodplate. Two pieces of thread positioned spatula. If necessary, smoothlengthwise on plate serve as spacer and sealant with bare finger wetted withcontrol bondline thickness. water.

65-00-00Rev. 4 Page 25

BHT-212-CR&0

2. Fill groove between case and quill NOTEsleeves and around bearing retaining nutswith adhesive (C-308). Allow to cure for 72 The following paragraphs providehours at room temperature. overhaul information for. the input

and output quill of the intermediategearbox. Refer to paragraph 65-293. Remove oil filler cap. Mask filler cap gearbox. Refer to paragraph 65-29for input quill overhaul. Refer toadapter, chip detector, oil level sight glass, r p 65 utput quillparagraph 65-37 for output quillcouplings, and seals at outboard ends of overhaul.

quills, and data plate.

4. Spray paint gearbox with primer (C-246), 65-22. INPUT QUILLcoat 0.4 to 0.9 mil thickness.

65-23. DisassemblyNOTE

Apply coating of coating (C-245), as SPECIAL TOOLS REQUIREDpe r m a n u f a c t u r i n grecommendations, not less than NUMBERNOMENCLATUREthirty minutes and not more thanfour hours after epoxy primer is T101307 Wrenchapplied.

T101333 Pressing bar

5. Deleted T101334 Pressing bar

NOTE T101564 Holding fixture

T101600 WrenchDeleted

6. Deleted NOTE

7. Use brush to apply 1/2 inch (12.7 mm) If input quill is being disassembleddiameter dot of white catalyzed epoxy paint for replacement of part(s) instead of(C-210) to oil cap and to gearbox case. Dot overhaul, disassemble only to extenton case should be placed on boss below oil necessary.cap adapter and directly above chip detector.

NOTE

65-20. Run-in and test For ease of maintenance, blockouter coupling to remain in outboard

It is recommended that intermediate gearbox, (extended) position. This willafter overhaul, be test run, and inspected in stabilize outer coupling duringaccordance with Bell Helicopter Textron BHT- disassembly and assembly.PUB-77-003, Run-in and Test Manual that isfurnished with run-in test stand. In the event a 1. Remove retainer ring (9, figure 65-10),run-in stand not available, the functional test plate (8), centering spring (7), and lock springspecified in BHT-212-MM, may be (6). Remove spacer (5). Remove retainer (4);accomplished as minimum acceptable a 1/4-20 threaded bolt may be used toalternate test. facilitate removal of retainer (4). Install bolt in

center of retainer and pull on bolt to withdrawretainer from inner coupling. Remove packing

65-21. INTERMEDIATE GEARBOX QUILLS (3) from retainer.

65-00-00Page 26 Rev. 4 Page 26A/26B deleted.

BHT-212-CR&O

2. Hold outer coupling (11) with T101307 1. Clean quill parts with solvent (C-304)wrench; position square adapter through with exception of bearings which are cleanedwrench and remove coupling retaining bolt with 1.1.1-trichloroethane (C-334).(2). Remove washer (1).

2. Use clean, lint-free cloth or low pressure,3. Remove couplings (10 and 11) from filtered, compressed air to dry parts. Do notpinion (25). spin bearings while drying.

4. Separate couplings (10 and 11) and 3. If not used immediately after cleaning,remove seal (14) from coupling (11). coat bearings with gearbox oil to prevent

corrosion damage. Do not handle unoiled5. Position T101564 holding fixture on bearings with bare hands.sleeve (18) with T101600 wrench, positionedon nut (15). Remove nut (15). Remove 4. Remove sealant from quill sleeve withpacking (16) and press seal (14) out of nut. plastic scraper.

I Discard packing and seal.5. Remove paint from quill sleeve with paint

6. Press pinion (25) out of sleeve (18). remover (C-436) and rinse with clean water.Remove retaining ring (26) and roller bearing(27) using T101333 pressing bar. Press 6. If not used immediately after cleaning,duplex ball bearing (17) out of sleeve using gently agitate parts in corrosion preventiveT101334 pressing bar. (C-105) and air dry. Apply protective coat of

gearbox oil.

NOTE

65-25. Conditional InspectionDuplex bearings are a matched set,both bearings have same serialnumber. Keep duplex bearingstogether as a set. NOTE

7. Input quill 212-040-003-009, remove If records and/or physicalretainer ring (22) and plug (23) from pinion appearance of input quill indicate(25). Remove packing (24). assembly has been subjected to an

accident or incident outside realm of8. Remove three screws (21) and shim normal usage, perform Conditionalplate (20). Identify shim plate for installation Inspection as follows. If input quillon same sleeve.. does not require Conditional

Inspection, accomplish Normal65-24.Cleaning Inspection (paragraph 65-26).65-24. Cleaning

1. Visually inspect pinion (25, figure 65-10)MATERIALS REQUIRED teeth for damage and evidence of overload

Refer to BHT-ALL-SPM for specification and pattern.source. 2. Visually inspect couplings (10 and 11) for

cracked or chipped teeth.NUMBER NOMENCLATURE

C-105 Corrosion Preventive 3. Deleted - Refer to Normal inspection (65-26).

C-304 Solvent3A. Deleted - Refer to Normal inspection.

C-334 1.1.1 -Trichloroethane

C-436 Paint Remover 4. Inspect bearings for roughness orsurface impressions produced by a heavy

65-00-00Rev. 4 Page 27

BHT-212-CR&0

:', /..... ...

sleeve (18) after assembly.5214 SEE DETAILS B & C

1. Washer 8. Plate 15. Nut / 22. Retainer ring2. Retaining bolt 9. Retainer ring 16. Packing 23. Plug3. Packing 10. Inner coupling 17. Duplex ball bearing 24. Packing4. Retainer 11. Outer coupling 18. Sleeve A 25. Pinion5. Spacer 12. Deleted 19. Clinch nut 26. Retaining ring6. Lock spring 13. Seal 20. Shim plate 27. Roller bearing7. Centering spring 14. Seal 21. Screw 212-R-65-101

Figure 65-10. Intermediate gearbox input quill (sheet 1 of 2)

I65-00-00Page 28 Rev. 4

BHT-212-CR&0

WORKAID

SEAL (13) PARTIALLY SEATED rL SEAL (13) FULLY SEATED

INNER COUPLING (10) USED INVERTED ON INNER

AS BACK-UP TO PUSH LIP COUPLINGOF SEAL (13) UP

DETAIL A

0.880 0.818-- INCH INCH

(22.352 mm) (20.777mm)

DETAIL B DETAIL C204-040-607-7 204-040-607-5SPRING RETAINER SPRING RETAINERFOR INPUT QUILL FOR OUTPUT QUILL

212-R-65-10-2

Figure 65-10. Intermediate gearbox input quill (sheet 2)

65-00-00 |Rev. 4 Page 29 1

BHT-212-CR&0

blow or pressure or rollers skidding instead of cause the indicating dots to turnrolling. black.

5. Perform magnetic particle inspection of 4. Inspect outer coupling (11, figure 65-10)pinion (25) and couplings (10 and 11) (BHT- temperature indicator "TEMP-PLATES" forALL-SPM). evidence of overtemperature indication. If

overtemperature indication is noted, perform6. Perform fluorescent penetrant inspection coupling overtemperature inspection asof sleeve (18) (BHT-ALL-SPM). follows:

NOTE a. Inspect outer coupling cadmium platingfor being discolored (circumferential tan or

If steps 1. through 5. reveal cracks light brown band) or blistered. If cadmiumor distortion indicative of excessive plate discoloration or blistering is found,loads, quill shall be considered replace outer coupling and inner coupling.unserviceable and nonreparable.

b. Inspect gear teeth of outer coupling7. Accomplish Normal Inspection and inner coupling for being discolored(paragraph 65-26). (brown or blue) in the normally bright contact

patterns. If discoloration is found, replaceouter coupling and inner coupling.

65-26. Normal Inspectionc. Inspect outer coupling and inner

1. Inspect parts dimensionally and replace coupling under 5x to 10x magnification forparts that do not fall within inspection limits teeth exhibiting signs of metal smearing or(figure 65-11). tearing in the contact patterns. If smearing or

tearing is found, replace outer coupling andNOTE inner coupling.

Wear limits are provided to show d. Inspect grease from couplings forrequired fit between mating parts. It being very viscous (thick) and having a strongis not intended all dimensions be pungent odor. If grease is found to be viscouschecked as prescribed overhaul (thick) and having a strong pungent odor,procedure. However, parts exhibiting replace outer coupling and inner coupling.evidence of wear or physicaldamage shall be checked NOTEdimensionally.

If TEMP-PLATES are to be replaced,2. Inspect pinion (25, figure 65-10) splines replace "TEMP-PLATES "afterfor chipped, broken or worn teeth. completing entire inspection and

repair procedures and couplings3. Inspect pinion (25) teeth for excessive have been determined serviceablewear, scoring, scuffing, and wear pattern and prior to assembly.(figure 65-12).

4A. Inspect outer coupling (11) temperatureNOTE indicator "TEMP-PLATES" for deterioration,

debonding or discoloration of epoxy coatingOvertemperature indicator dots on that prevents interpretation of indicating dots.temperature indicator "TEMP- If deterioration, debonding, or discoloration ofPLATES" are of a white or light gray epoxy is found, replace "TEMP-PLATES" incolor and turn black when exposed accordance with paragraph 65-9A.to an overtemperature condition.Chemical contamination can also 5. Inspect couplings (10 and 11).

65-00-00Page 30 Rev. 4

BHT-212-CR&0

a. Inspect for chipped, pitted, cracked, or 8. Inspect bearing liners for scoring andexcessively worn teeth. security of mounting in sleeve (18).

b. Check wear patterns (figure 65-13). 9. Inspect bearings for spalling, scoring,pitting, brinelling, flaking, corrosion on rolling

c. Inspect surface of inner couplings elements, and cracked or broken retainerscontacted by seals (14, figure 65-10) for (figure 65-14).excessive wear, nicks, and scratches. Agroove worn by seal is acceptable to a a. Minor nicks, cuts, or scratches areminimum diameter of 1.587 inch (40.3098 acceptable provided they are too small to bemm) provided depth does not exceed 0.002 felt with a probe having an end radius ofinch (0.0508 mm). If groove is smooth, part 0.030 inch (0.762 mm), and provided totalmay be reworked. affected area does not exceed 10% of contact

area at any point.6. Inspect following parts by magneticparticle (Code M) or fluorescent penetrant b. Minor circumferential scoring is(Code F) (BHT-ALL-SPM), as applicable. acceptable on rollers and races provided itDemagnetize parts after magnetic particle cannot be felt with a probe having an endinspection. radius of 0.030 inch (0.762 mm) and provided

affected area does not exceed 10% of contactFigure, Nomenclature Code area at any point.Index No.

65-10, 10 Inner coupling M 10. Inspect sleeve (18, figure 65-10) for65-10, 11 Outer coupling M corrosion damage (figure 65-15).65-10, 25 Pinion M65-10, 2 Bolt M 11. Perform fluorescent penetrant65-10, 4 Retainer F inspection of sleeve (BHT-ALL-SPM).65-10, 8 Plate F65-10, 15 Nut F 12. Inspect shim plate (20, figure 65-10) for65-10, 18 Sleeve F damage and wear.

7. Check bearings (17 and 27) for smoothoperation and indications of excessive wear.Inspect bearing races for roughness.

65-00-00Rev. 4 Page 30A/30B

BHT-212-CR&0

13. Inspect plate (8) for damage seal. 4. Repair minor scratches, nicks, and pitson noncritical surfaces with abrasive cloth or

14. Inspect coupling retaining bolt (2) paper (C-423).visually for damaged threads. Replace boltswhich have malformed threads. 5. Repair minor nicks, scratches, and burrs

on splines and pinion (25) using India stone15. Inspect nut (15) visually for damaged (C-464).threads. Replace nuts which have malformedthreads. 6. Repair inner coupling (10) and outer

coupling (11) as follows:

65-27. Repair a. Repair minor nicks, dents, or scratchesin seal contact area on inner couplings by

MATERIALS REQUIRED polishing with India stone (C-464) to removedamage. Blend into surrounding area. Seal

Refer to BHT-ALL-SPM for specification and groove wear no more than 0.002 inch (5.08deep and minimum diameter of 1.587

inch (40.3098 mm) is acceptable if groove isNUMBER NOMENCLATURE uniform and smooth. More severe damage in

C-100 Chemical Film Material seal contact area may be reworked bygrinding, provided it gives 100% cleanup,

C-103 Chromic Acid when reworked as directed below.

C-108 Brush Cadmium b. Grind coupling OD to a minimumPlating Solution diameter of 1.587 inches (40.3098 mm).

Reground diameter shall not extend moreC-201 Primer than 0.40 inch (10.16 mm) from inner end of

C-309 Methyl-Ethyl-Ketone coupling and blend with original surface.C-309 Methyl-Ethyl-Ketone

(MEK) c. Reground diameter shall be concentricC-317 Adhesive with pitch diameter of internal spline within

0.002 inch (0.0508 mm) TIR.C-334 1.1.1 -Trichloroethane

d. Surface finish on reground diameterC-423 Abrasvie Cloth or shall be 16 RMS or better.

Paper

Tape e. Nital etch couplings after grinding(BHT-ALL-SPM).

C-464 India Stonef. Inspect couplings after nital etch

C-500 Crocus Cloth process by magnetic particle method. Refer toBHT-ALL-SPM.

1. Replace parts which exceed allowable g. Touch-up cadmium plate couplings (10wear limits. and 11, figure 65-10) using brush cadmium

plating solution (C-108). Plating thickness to2. Replace bearings (17 and 27, figure 65- be 0.0001 to 0.0003 inch (0.00254 to 0.0076210) exhibiting evidence of brinelling, spalling, exceed 0.0003 inch (0.00762discoloration from overheating, corrosion on mm) plating thickness in seal contact area.rolling elements, cracked or broken retainers, Do notor rough operation.

3. Replace all seals, packings, standardhardware, and all locking devices at time ofreassembly.

65-00-00Rev. 4 Page 31

BHT-212-CR&O

5 7 8


1 Spline - Outer Coupling *2 Teeth - Inner Coupling Over pins 2.1590 54.8386 2.1740 55.2196(Use 0.1080 IN. (2.7432 mm)

diameter pins)3 Spline - Inner Coupling Between pins 1.1465 29.1211 1.1578 29.40812(Use 0.0960 IN. (2.4384 mm)

diameter pins)4 Spline - Gear Over pins 1.4424 36.63696 1.4465 36.7411(Use 0.0960 IN. (2.4384 mm)

diameter pins)5 Sleeve ID 2.8340 71.9836 2.8347 72.001386 Sleeve OD 4.4097 112.00638 4.4105 112.02677 Sleeve ID 3.1489 79.98206 3.1497 80.002388 GearShaft OD 1.8691 47.47514 1.8696 47.487849 Roller Bearing OD 3.1492 79.98968 3.1496 79.9998410 GearShaft OD 1.3780 35.0012 1.3786 35.0164411 Duplex Bearing ID 1.3777 34.99358 1.3781 35.00374

OD 2.8341 71.98614 2.8346 71.99884

* Maximum allowable depth of wear 0.005 inch (0.127 mm) (measure from unworn face of tooth).

212-R-65-11-1

Figure 65-11. Intermediate gearbox input quill wear limits (sheet 1 of 2)

65-00-00Page 32

BHT-212-CR&O

WIRE FEELER POSITION METALGAGE MAXIMUM STRAIGHT EDGE0.0055 IN. PERPENDICULAR(0.1397 mm) TO FACE OF TOOTH

BEING INSPECTED 7

WEAR AREA GAGE PIN - GEAR

MEASUREMENTMEASUREMENT OVER PINSBETWEEN PINS

DETAIL ADETAIL B

GEAR TEETH AND SPUNE MEASURING PIN212-R-65-11-2

Figure 65-11. Intermediate gearbox input quill wear limits (sheet 2)

plate external spline teeth on inner coupling. (2) Subtract 0.3915 to 0.3910 in.Do not plate internal spline teeth on outer (9.9441 to 9.9314 mm) from dimensionscoupling. Apply tape (C-434) to areas not to etched or stamped on sleeve to give requiredbe plated. (Refer to figure 65-13 for plating shim thickness, after plating.dimensions, and BHT-ALL-SPM for prescribedcadmium plating methods.) (3) Grind new blank shim to required

thickness and apply brush cadmium plating7. If original cadmium plating on sleeve shim solution (C-108). Using etching ink orplate (20, figure 65-10) has worn through, equivalent, identify shim plate by etchingreplate as follows: serial number of applicable sleeve on shim

plate. Also etch thickness on shim plate.Neutralize with water and common baking

a. Cadmium plate sleeve shim plate using soda after etching.brush cadmium plating solution (C-108).Required dimensions shall be met afterplating.8. Repairsleeve (18) as follows:

a. If damaged or loose, replace clinchb. If original sleeve shim plate is missing a damaged or loose, replace clinchor mixed with other shim plates, determine nutsrequired dimensions of replacement shimplate as follows: (1) Use a drift or bolt threaded into nut

to drive clinch nut out; being careful not to(1) Examine sleeve for reference damage hole in sleeve flange.

dimension which is metal stamped or vibro-etched on sleeve adjacent to applicable (2) Clean sleeve by vapor degreasingmounting surface. with 1.1.1-trichloroethane (C-334).

65-00-00Page 33

BHT-212-CR&O

TOP HEEL TOPHEEL TOE

TOE

WEAR PATTERNROOT WEAR PATTERN ROOT

Pinion P/N 212-040-500-7 Gear P/N 212-040-500-6

Desired wear pattern on pinion Desired wear pattern on gearView A View B

0 TO 1/8 INCH 0 TO 1/8 NCH(O.TO 3.175 mm) (0 TO 3.175 mm)

TOP

HEEL TOE

ROOT (CONVEX SIDE)

Gear P/N 212-040-500-6View C

TOP TOE HEEL TOP TOE

HEEL

WEAR PATTERNROOT

ROOT WEAR PATTERN ROOT

Pinion P/N 212-040-500-7 Gear P/N 212-040-500-6

Acceptable wear pattern on pinon Acceptable wear pattern on gearView D View E

212-R-65-12-1C0000

Figure 65-12. Gear and pinion wear patterns (sheet 1 of 3)

65-00-00Page 34 Rev. 3

BHT-212-CR&O

\___ ^OE.__HEEL -OE TOP TOP

WEAR PATTERNROOT WEAR PATTERN ROOT

Pinion P/N 212-040-500-7 Pinion P/N 212-040-500-6

Acceptable wear pattern on pinion Acceptable wear pattern on gear

View F View G

NOTES

1. Wear pattern Inspection: Observe the visible gear contact wear pattern on the concave side ofthe pinion teeth and on the convex side of the gear teeth. The teeth on the pinion have a leftspiral and the teeth of the gear have a right spiral.

2. The desired wear pattern is shown in Views A and B. A speckled or mottled appearance In theflank of the pinion or top of the gear due to dulite removal is permissable. The wide and not toowell defined toe pattern is characteristic of this gear set. The area of the wear pattern In the flankof the gear is very faint and propper lighting must be used in order to see it.

3. Acceptable wear patterns are shown in Views D, E, F, and G. These views show various toe andheel locations, and different severities of the speckled or mottled appearance in the flank of thepinion and top of gear.

4. Pattern limits at toe: The pattern may touch the toe or be a maximim of 1/8 inch (3.175 mm) fromtoe on gear (View C). Usually the pattern will touch the toe in the flank of the pinion and at the topof the gear as shown in Views D and E. If the pattern touches the toe but is more than 1/8 inch(3.175 mm) from heel on gear member, then the pattern is off the toe and is not acceptable. Thismethod of Inspection must be used, due to the wide toe pattern, to determine whether thepattern Is just touching the toe or Is running off the toe. Pattern variation at the toe must notexceed 1/32 inch (0.79375 mm).

5. Pattern limits at heel: The pattern may touch the heel or be a maximum of 1/8 inch (3.175 mm)from heel on gear member (View C). Pattern variation at heel must not exceed 1/32 inch (0.79375mm).

6. Pattern profile: The pattern In the profile direction must touch or extend over the top of thepinion as shown by Views A, D and F. On the gear, the pattern may be 1/32 inch (0.79375 mm)from the top or may extend over the top. Most of the gear patterns will extend over the top asshown by Views B, E and G. A bright Illne occurring at the top of pinion or in flank of the gear iscause for rejection.

212-R-65-12-2C0000

Figure 65-12. Gear and pinion wear patterns (sheet 2)

65-00-00Page 35

BHT-212-CR&O

NOTES

7. Unacceptable defects: In addition to pattern size and location, examine the drive face of all gearteeth for the following defects which are not acceptable If they can be felt with a scribe having a0.002 inch (0.051 mm) radius spherical point.

a. Nonclean up g. Dentsb. Grinding scratches h. Grinding flats or barber polingc. Pitting (evidenced by diagonal streaks In the wear pattern)d. Corrosion I. Scuffinge. Cuts j. Scoringf. Nicks k. Inclusions

212-R-65-12-3C0000

Figure 65-12. Gear and pinion wear patterns (sheet 3)

(3) Clean up surface of sleeve flange to b. Repair mechanical and corrosionremove any raised burrs. damage on sleeve as follows (figure 65-15):

(4) Treat hole and any reworked areas (1) If damage to spot faced surfaces,on sleeve with chromic acid (C-103). area B, exceeds inspection limits, surface

may be reworked by machining off surface toa minimum flange thickness, dimension C, of

(5) If clinch nut was not loose, coat new 0.310 in. (7.874 mm). Machining shall benut with primer (C-201) and drive nut (19) into done with a 0.688 in. (17.4752 mm) diameterplace. Remove any raised burrs on sleeve spotface cutter, with a 0.060 in. (1.524 mm)flange face, and touch up with chromic acid corner radius. After cleanup, pitting is(C-103). acceptable provided it is no more than 0.010

in. (0.254 mm) deep. Surface finish of(6) If nut was loose, remove cadmium unpitted reworked surface shall be 63 RMS or

plating from surfaces of clinch nut contacting better.sleeve, by abrasive paper. Wipe clinch nutand mating surfaces of sleeve clean with MEK (2) Sleeves with corrosion damage(C-309) on clean cheesecloth. Bond clinch within acceptable limits must be reworked bynut in place with adhesive (C-317). Clean smoothing out any sharp edges which mightexcess adhesive from threads and surface of damage packing during assembly. Nicks,sleeve flange and hole. Clinch nut shall be at dents, or pits in area A, figure 65-15, withinleast 0.010 in. (0.254 mm) below surface of allowable limits, shall be reworked to blendsleeve flange. into surrounding area. Minimum radius in

reworked areas is 0.25 in. (6.35 mm) andsurface finish shall be 63 RMS or better.

(7) Verify side of sleeve flangecontacting shim plate is flat and clinch nutdoes not protrude above surface.

65-00-00Page 36

BHT-212-CR&O

A Acceptable pattern typical of low operatingtime.

Acceptable pattern typical of couplings whichhave operated with normal misalignment for alonger period of time than that shown in A.


D Acceptable pattern showing a pitted tooth.This condition is acceptable on all teeth.

E Pattern shows a more severe condition oftooth pitting than that shown In D. There isno metal projecting above the normal face ofthe tooth, indicating that the pitted area ispolishing over. This condition may exist on allteeth. Couplings with pits larger than 1/32Inch (0.79375 mm) diameter should be re-placed. 212-R-65-13

C0000

Figure 65-13. Quill coupling teeth wear patterns

65-00-00Page 37

BHT-212-CR&O

ACCEPTABLE

212-R-65-14UNACCEPTABLE COooo

Figure 65-14. Quill roller bearing wear pattern

(3) Treat sleeves with corrosion c. Cadmium plated steel parts: Treatdamage within acceptable limits by immersion rework areas with brush cadmium platingin a chromic acid bath (BHT-ALL-SPM). solution (C-108) (BHT-ALL-SPM).

11. Replace outer coupling TEMP-PLATES ifc. Perform fluorescent penetrant necessary (Paragraph 65-9A).inspection of sleeve (BHT-ALL-SPM).

65-28. Assembly9. Repair nicks, scratches, and burrs onpinion splines and teeth by dressing withIndia stone (C-464). MATERIALS REQUIRED

10. Refinish parts, after repair (BHT-ALL- NUMBER NOMENCLATURESPM), as outlined below:

C-010 Lubricating Oil

a. Aluminum parts: Touch up with C-015 Lubricant (Tube Pack)chemical film material (C-100).

C-308 Adhesive

b. Magnesium parts: Remove all traces of C-405 Lockwirecorrosion by immersion in chromic acid bath(BHT-ALL-SPM). Touch up parts with chromicacid (C-103) or treat entire part withmagnesium alloy chemical film treatment(BHT-ALL-SPM).

65-00-00Page 38 Rev. 3

BHT-212-CR&O

AREA A

AREA B

DIM.C

NOTES

1. Corrosion pitting or mechanical surface damage in area A, exclusive of area B, is acceptable provided it iswithin the following limits:

a. Maximum acceptable depth is 0.030 inch (0.762 mm).

b. No more than 40 percent of the area within any one inch square, nor 20 percent of the total area of anysurface or diameter may be pitted.

2. Corrosion pitting or mechanical surface damage on the spot faced surface at the attaching holes, area B, isacceptable provided it is within the following limits:

a. Maximum acceptable depth is 0.020 inch (0.508 mm).

b. No more than 20 percent of the total spot faced area at any hole may be pitted.

c. No more than 20 percent of the total area normally contacted by the washer may be pitted.

d. No more than 50 percent of the width of the area normally contacted by the washer may be pitted at anypoint around the hole.

212-R-65-15

Figure 65-15. Quill sleeve damage limits

65-00-00Page 39

BHT-212-CR&O

SPECIAL TOOLS REQUIRED 5. Press pinion (25) into sleeve whilesupporting inner race of duplex ball bearing(17). Avoid damage to teeth of pinion.

NUMBER NOMENCLATURE

T101307 Wrench 6. Apply adhesive (C-308) to faying surfaceof seal (14) and nut (15). Press new seal

T101333 Pressing bar (14) into nut (15) with lip of seal facinginboard. Install new packing (16) on nut (15).

T101334 Pressing bar Position T101564 holding fixture on sleeveT101564 Holding fixture (18) with pins engaged through holes in

sleeve flange. Coat packing and threads ofT101600 Wrench nut (15) with gearbox oil. Install nut in sleeve

and torque 100 to 150 ft.lbs. (135.58 to203.37 Nm) using T101600 wrench. Securenut to sleeve with lockwire (C-405).

CAUTIONNOTE

SAME SHIM PLATE (20, FIGURE A workaid may be fabricated (figure65-10) REMOVED FROM SLEEVE 65-2, detail B) to aid installation ofSHALL BE REINSTALLED OR A seal (13).NEW SHIM PLATE OF SAMETHICKNESS SHALL BE MADE. 7. Install seal (13) into outer coupling (11)

seal groove as follows:1. Coat all parts with gearbox oil prior tostarting reassembly procedure. a. Apply a light coat of lubricant (tube

pack) (C-015) to outer circumference of seal2. Position original shim plate (20, figure 65- (13).10) or new shim plate on sleeve (18) andinstall three screws (21). b. Install seal (13) into outer coupling (11)

seal groove with lip of seal toward internal3. Press duplex ball bearing (17) into sleeve splines of outer coupling (11), as shown in(18) using T101334 pressing bar. Duplex figure 65-10, detail A.bearing shall have matching serial numbers,be installed in pairs, and be installed face-to- NOTEface.

Seal (13) will be partially seated and4. Press roller bearing (27) into sleeve (18) inner coupling (10) will be used as ausing T101333 pressing bar. Install retaining backup, in reverse (see detail A) toring (26). fully seat outer circumference edge

of seal into outer coupling (11) sealgroove.

CAUTION.......**.************* c. Using inner coupling (10) as a backup,

and placed, as shown in detail A, firmly pressWHEN INSTALLING PINION INTO down (hand pressure only) on outer couplingBEARING, USE CARE TO APPLY (11), simultaneously tuck outer circumferencePRESSURE ONLY TO PINION HUB edge of seal (13) with workaid (figure 65-2,AREA. PRESSURE APPLIED AT detail B) into outer coupling (11, figure 65-10)GEAR TEETH CAN RESULT IN seal groove.CRACKS BETWEEN HOLES INWEB, AND POSSIBLE FAILURE OF d. Continue pressing around seal (13)PINION. with workaid until seal (13) is fully seated.

65-00-00Page 40

BHT-212-CR&O

Remove inner coupling (10) from outer alignment. When hole and notch are aligned,coupling (11). install lock spring (6) through hole in rim or

retainer and notch of inner coupling (10).

8. Place small amount of lubricant (tube 15. Extend outer coupling (11) so that sealpack) (C-015) in internal splines of outer (13) is against teeth of inner coupling. Coatcoupling (11) and on inboard side of seal internal splines of outer coupling (11) with(13). Insert inner coupling (10) into outer lubricant (tube pack) (C-015) to 0.12 in.

(11) with small end through seal. (0.3048 mm) depth over top of spline teeth. Acoupling (11) with small end through seal. workaid may be fabricated (figure 65-2, detailworkaid may be fabricated (figure 65-2, detailC) to obtain depth of grease.

NOTE16. Place small end of centering spring (7,

is c figure 65-10) on boss of seal plate (8).Ensure inner coupling (10) is correctfor intermediate and tail rotor 17. Install plate (8), spacer (5), andgearbox, overall length is 1.870 to centering spring (7) into coupling and install1.880 in. (47.498 to 47.752 mm). retainer ring (9).Tail rotor driveshaft hanger couplingoverall length is 2.07 to 2.08 in. 18. Place new packing (24) on plug (23).(52.578 to 52.832 mm). Coat packing and plug with lubricating oil (C-(52.578 to 52.832 mm). 010), and insert plug into pinion (25). Install

retainer ring (22).9. Position couplings (10 and 11) on splinedend of pinion (25). 19. Test quill by holding sleeve and turning

coupling. There should be a very light dragcaused by oil seal and preload of the duplex

10. Coat threads of coupling retaining bolt bearings, but coupling and pinion should turn(2) with lubricating oil (C-010). smoothly.

20. Tag quill with with date of lubrication and11. Place washer (1) on bolt and thread bolt make entry in component historical record ifinto pinion. quill is to be returned to stock.

21. When quill is installed on helicopter, an12. Hold outer coupling (11) with T101307 entry will be made in helicopter log and flexwrench. Use a square extension to torque bolt couplings lubrication log.(2) 80 to 100 ft.lbs. (108.464 to 135.58 Nm).

22. Deleted.

13. Place packing (3) on retainer (4).

14. Coat packing and retainer withlubricating oil (C-010), and insert retainer intobolt (2). If one hole in rim of retainer (4) doesnot align with notch of inner coupling (10),pull retainer free of bolt, rotate 90 degreesand reinstall. Repeat if necessary to obtain

65-00-00Figure 65-16. DELETED Rev. 3 Page 41/42

BHT-212-CR&0

65-29. OUTPUT QUILL. 7. Separate couplings (10 and 11), andremove seal (13) from outer coupling (11).

65-30. Disassembly. 8. Position T101564 holding fixture onsleeve (18) with pins engaged through sleeve

SPECIAL TOOLS REQUIRED flange. Remove nut (15) with T101600wrench.

NUMBER NOMENCLATURE 9. Remove packing (16) and press seal (14)

T101307 Wrench out of nut (15).

T101333 Pressing bar 10. Press gear (24) out of sleeve (18) usingpressing bar (T101333). Remove ring (23)

T101334 Pressing bar and roller bearing (22)..

T101564 Holding fixtureT1 01 564 Holding fixture 11. Press duplex ball bearing (17) out of

T101600 Wrench sleeve using pressing bar (T101334).

NOTENOTE

Duplex bearings shall be retained orIf output quill is being disassembled replaced as a matched serializedfor replacement of part(s) instead of set.overhaul, disassemble only to extentnecessary. 12. Remove ring (29), oil collector sleeve

(28), and oil collector cone (26). I

NOTE13. Remove packings (25 and 27).

For ease of maintenance, blockouter coupling to remain in outboard 14. Remove three screws (21) and shim(extended) position. This will plate (20). Identify shim plate for reinstallationstabilize outer coupling during on same sleeve.disassembly and assembly.

65-31. Cleaning.1. Remove retainer ring (1, figure 65-17),plate (2), centering spring (3), and lock spring(4). MATERIALS REQUIRED

Refer to BHT-ALL-SPM for specification and2. Remove spacer (5).source.

3. Remove retainer (6). A 1/4-20 threadedbolt may be used to facilitate removal of NUMBER NOMENCLATUREretainer (6). Install bolt in center of retainer C-10 Corrosion Preventiveand pull on bolt to withdraw retainer frominner coupling. C-304 Solvent

4. Remove packing (7) from retainer (6). C-334 1.1.1-Trichloroethane

5. Hold outer coupling (11) with T101307 C-436 Paint Removerwrench. Position square adapter throughwrench and seat in coupling retainer bolt (8). 1 Clean quill parts with solvent (C-304)Remove bolt (8) and washer (9). o o

with exception of bearings which are cleaned

6. Remove couplings (10 and 11) from gear with 1.1.1-trichloroethane (C-334).(24).

65-00-00Rev. 4 Page 43

BHT-212-CR&O

2. Use clean, lint-free cloth or low pressure, cause the indicating dots to turnfiltered, compressed air to dry parts. Do not black.allow bearings to spin while drying.

4. Inspect outer coupling (11) temperature3. If not used immediately after cleaning, indicator TEMP-PLATES for evidence ofcoat bearings with gearbox oil. Do not handle overtemperature indicat i o n. Ifunoiled bearings with bare hands. overtemperature indication is noted, perform

coupling overtemperature inspection as4. Remove sealant from quill sleeve withplastic scraper. a. Inspect outer coupling cadmium plating

for being discolored (circumferential tan or5. Remove paint from quill sleeve with paint light brown band) or blistered. If cadmiumremover (C-436) and rinse with clean water. plate discoloration or blistering is found,

replace outer coupling and inner coupling.6. If not used immediately after cleaning,gently agitate parts in corrosion preventive b. Inspect gear teeth of outer coupling(C-105) and air dry. Apply protective coat of and inner coupling for being discoloredgearbox oil. (brown or blue) in the normally bright contact


65-32. Conditional Inspection.c. Inspect outer coupling and inner

NOTE coupling under 5x to 10x magnification forteeth exhibiting signs of metal smearing or

If records and/or physical tearing in the contact patterns. If smearing orappearance of output quill indicate tearing is found, replace outer coupling andassembly has been subjected to an inner coupling.accident or incident outside realm ofnormal usage, perform Conditional d. Inspect grease from couplings for beingInspection as follows. If output quill very viscous (thick) and having a strongdoes not require Conditional pungent odor. If grease is found to be viscousInspection, accomplish Normal (thick) and having a strong pungent odor,Inspection, paragraph 65-33. replace outer coupling and inner coupling.

1. Visually inspect gear (24, figure 65-17) NOTEteeth for damage and evidence of overloadwear pattern (figure 65-12). If TEMP-PLATES are to be replaced,

replace TEMP-PLATES after2. Visually inspect couplings (10 and 11, completing entire inspection andfigure 65-17) for cracked or chipped teeth. repair procedures and couplings

have been determined serviceableand prior to assembly.3. Inspect bearings for roughness or surface and prior

impressions produced by a heavy blow or 4A. Inspect outer coupling (11) temperaturepressure or rollers skidding instead of sliding. indicator TEMP-PLATES for deterioration,indicator TEMP-PLATES for deterioration,debonding or discoloration of epoxy coating

NOTE that prevents interpretation of indicating dots.If deterioration, debonding, or discoloration of

Overtemperature indicator dots on epoxy is found, replace TEMP-PLATES intemperature indicator TEMP- accordance with paragraph 65-9A.PLATES are of a white or light graycolor and turn black when exposedto an overtemperature condition.Chemical contamination can also

65-00-00Page 44 Rev.3

BHT-212-CR&O

22-

2

17. Duplex bearing

I'-S^^^- _ac ^ 4. Lock spring 20. Shim plate

„ _ 21^~ i B -13 5. Spacer 21. Screw

7. Packing 23. Retaining ring8. Bolt 24. Gear

NOTES 9. Washer 25. Packing

A 10. Inner coupling 26. ConeLocation of temperature indicator TEMP-PLATES. 11. Outercoupling 27. Packing

L Apply sealant (C-308) on nut (15) and sleeve (18) 13. Seal 29. Retainer ringafter assembly. 1. Seal15. Nut

16. Packing

212-R-65-17-1

Figure 65-17. Intermediate gearbox output quill (sheet 1 of 2)

65-00-00Rev. 3 Page 45

BHT-212-CR&0

WORKAID

SEAL (13) PARTIALLY SEATED SEAL (13) FULLY SEATED

INTERNAL OUTER COUPLING (11)SPLINES INSTALLED

INNER COUPLING (10) USED INVERTED ON INNERAS BACK-UP TO PUSH LIP COUPLINGOF SEAL (13) UP

DETAIL A212-R-65-17-2212-040-003-17

Figure 65-17. Intermediate gearbox output quill (sheet 2)

5. Inspect couplings (10 and 11). 7. Check bearings (17 and 22, figure 65-17)for smooth operation and indications ofa. Inspect for chipped, pitted, cracked, or excessive wear. Inspect bearing races for

excessively worn teeth. roughness.b. Check wear patterns to criteria shown

on figure 65-18. 8. Inspect bearing liners for scoring andsecurity of mounting in sleeve (28).

c. Inspect surface of inner couplings thatare contacted by seals (14, figure 65-17) for 9. Inspect bearings for evidence of spalling,excessive wear, nicks, and scratches. Aworn by seal is acceptable to a scoring, pitting, brinelling, flaking, corrosiongroove worn by seal is acceptable to aminimum diameter of 1.587 inch (40.3098 on rolling elements, and cracked or brokenminimum diameter of 1.587 inch (40.3098mm) provided depth does not exceed 0.002 retainers (figure 65-14).inch (0.0508 mm). If groove is smooth, partmay be reworked. a. Minor nicks, cuts, or scratches are

acceptable provided they are too small to be6. Inspect following parts by magnetic felt with a probe having an end radius ofparticle (Code M) or fluorescent penetrant 0.030 inch (0.762 mm), and provided total(Code F) (BHT-ALL-SPM), as applicable. affected area does not exceed 10% of contactDemagnetize parts after magnetic inspection

Figure, Nomenclature CodeIndex No. b. Minor circumferential scoring is

acceptable on rollers and races provided it65-17, 10 Inner coupling M cannot be felt with a probe having an end65-17, 11 Outer coupling M radius of 0.030 inch (0.762 mm) and provided65-17, 8 Bolt M affected area does not exceed 10% of contact65-17, 24 Gear M area at any point.65-17, 6 Retainer F65-17, 2 Plate F65-17, 15 Nut F65-17, 18 Sleeve F

65-00-00Page 46 Rev. 4

BHT-212-CR&O

A Acceptable pattern typical of low operating

have operated with normal misalignment for alonger period of time than that shown in A.

C Acceptable pattern denoting operation at

D Acceptable pattern showing a pitted tooth.

E Pattern shows a more severe condition of

^//>/^Y//~~/ no metal projecting above the normal face ofthe tooth, Indicating that the pitted area ispolishing over. This condition may exist on allteeth. Couplings with pits larger than 1/32inch (0.79375 mm) diameter should be re-placed. 212-R-65-18

coooo

Figure 65-18. Intermediate gearbox coupling wear pattern

65-00-00Page 47

BHT-212-CR&0

10. Inspect sleeves (28, figure 65-17) for 65-34. Repair.corrosion as follows:

a. Corrosion pitting or mechanical surface MATERIALS REQUIREDdamage in area A, exclusive of spotface area, Refer to BHT-ALL-SPM for specification andis acceptable for repair if within following source.limits (figure 65-20).

NUMBER NOMENCLATURE(1) Maximum acceptable depth is 0.030

inch (0.762 mm). C-100 Chemical Film Material

(2) No more than 40% of area within C-103 Chromic Acidany 1.0 square inch (25.4 sq mm), nor 20% of 10 Brush Cadmiumtotal area of any surface or diameter may be Plating Solutionpitted.

C-114 Corrosion Treatmentb. Corrosion pitting or mechanical

surface damage on spotfaced surface at C-116 Chromic Acidattaching holes is acceptable provided it iswithin the following limits: C-201 Primer

C-309 Methyl-Ethyl-Ketone(1) Maximum acceptable depth is 0.020 (MEK)

inch (0.508 mm).C-317 Adhesive

(2) No more than 20% of total spotfacedarea at any hole may be pitted. C-334 1.1.1-Trichloroethane

(3) No more than 20% of total area C-500 Crocus Clothnormally contacted by washer may be pitted. C-423 Abrasive Cloth or

Paper(4) No more than 50% of width of area

normally contacted by washer may be pitted C-434 Tapeat any point around hole.

C-464 India Stone11. Perform fluorescent penetrantinspection of sleeve (BHT-ALL-SPM).inspection of sleeve (BHT-ALL-SPM). 1. Replace parts which exceed allowable

12. Inspect shim plate (20, figure 65-17) for wear limits.damage and wear. 2. Replace bearings (17 and 22, figure 65-

13. Inspect plate (2) for damaged seals. 17) exhibiting evidence of brinelling, flaking,spalling, discoloration from overheating,corrosion on rolling elements, cracked or14. Inspect oil collector cone (26) and corrosion on rolling elements, cracked orbroken retainers or do not operate smoothly.sleeve (28) for damage.

3. Replace all seals, packings, standard15. Inspect coupling retaining bolt (8)coupling retaining bolt (8) hardware, and all locking devices at time ofvisually for damaged threads. Replace boltswhich have malformed threads.

16. Inspect nut (15) visually for damaged 4. Repair minor scratches, nicks, and pitsnut (15) visually for damaged on noncritical surfaces with abrasive cloth or

threads. Replace nuts which have malformed paper (C-423).threads.

5. Repair minor nicks, scratches, and burrson splines and gear (24) using India stone (C-464).

65-00-00Page 48 Rev. 4

BHT-212-CR&O


1 Gear shaft OD 1.8691 47.47514 1.8696 47.487842 Sleeve ID 3.1489 79.98206 3.1497 80.002383 Sleeve OD 4.4097 112.00638 4.4105 112.02674 Sleeve ID 2.8340 71.9836 2.8347 72.001385 Spline - gear Over pins 1.4424 36.63696 1.4465 36.7411

(Use 0.0960 IN. (2.4384 mm)diameter pins)

6 Spline - inner coupling Between pins 1.1465 29.1211 1.1578 29.40812(Use 0.0960 IN. (2.4384 mm)diameter pins)

7 Teeth - inner coupling Over pins 2.1590 54.8386 2.1740 55.2196(Use 0.1080 IN. (2.7432 mm)diameter pins)

8 Spline - outer coupling9 Duplex bearing ID 1.3777 34.99358 1.3781 35.00374

OD 2.8341 71.98614 2.8346 71.9988410 Gearshaft OD 1.3780 35.0012 1.3786 35.0164411 Roller bearing OD 3.1492 79.98968 3.1496 79.99984

NOTE

Maximum allowable depth of wear 0.005 inch (0.127 mm) (measure from unworn face of tooth).

212-R-65-19

Figure 65-19. Intermediate gearbox output quill wear limits

65-00-00Page 49

BHT-212-CR&0

6. Repair inner coupling (10) and outer b. If original sleeve shim plate is missingcoupling (11) as follows: or mixed with other shim plates, determine

required dimensions of replacement shima. Repair minor nicks, dents, or scratches plate as follows:

in the seal contact area on the innercouplings by polishing with India stone (C- (1) Examine sleeve for dimension metal464) to remove damage. Blend into stamped or vibro-etched on sleeve, adjacentsurrounding area. Seal groove wear no more to applicable mounting surface.than 0.002 inch (0.0508 mm) deep andminimum diameter of 1.587 inches (40.3098 (2) Subtract 0.3910 to 0.3915 inchmm) is acceptable if groove is uniform and (9.9314 to 9.9441 mm) from etched orsmooth. More severe damage in seal contact stamped dimension on sleeve to give requiredarea may be reworked by grinding, provided it shim thickness, after plating.gives 100% cleanup, when reworked asdirected below. (3) Grind new blank shim to required

thickness and apply brush cadmium platingb. Grind coupling O.D. to a minimum solution (C-108). Using etching ink or

diameter of 1.587 inch (40.3098 mm). equivalent, identify new shim plate by etchingReground diameter shall not extend more serial number of applicable sleeve on shimthan 0.400 inch (10.16 mm) from inner end of plate. Also etch thickness on shim plate.coupling and shall blend with original surface. Neutralize with water and common baking

soda after etching.c. Reground diameter shall be concentric

with pitch diameter of internal spline within 8. Repair sleeve (18) as follows (figure 65-0.002 inch (0.0508 mm) T.I.R. 8):

d. Surface finish on reground diameter a. If damaged or loose replace clinchshall be 16 RMS or better. nuts (19, figure 65-17).

e. Nital etch couplings after grinding (1) Use a drift or bolt threaded into nut(BHT-ALL-SPM). to drive clinch nut out; being careful not to

damage hole in sleeve flange.f. Inspect couplings after inital etch

process by magnetic particle method (BHT- (2) Clean sleeve by vapor degreasingALL-SPM). with 1.1.1-trichloroethane (C-334).

g. Touch-up cadmium plate couplings (10 (3) Clean up surface of sleeve flange toand 11, figure 65-17) using brush cadmium remove any raised burrs.plating solution (C-108). Plating thickness tobe 0.0001 to 0.0003 inch (0.00254 to 0.00762 (4) Treat hole and any reworked areasmm). Do not exceed 0.0003 inch (0.00762 on sleeve with corrosion preventivemm) plating thickness in seal contact area. compound (C-103) (BHT-ALL-SPM).Do not plate external spline teeth on innercoupling. Do not plate internal splines on (5) If clinch nut was not loose, coat newouter coupling. Apply tape (C-434) to areas nut with unreduced primer (C-201) and drivenot to be plated. nut (19) into place. Remove any raised burrs

on sleeve flange face and touch up with7. If original cadmium plating on sleeve chemical film material (C-100) (BHT-ALL-shim plate (20, figure 65-22) has worn SPM).through, replate as follows:

(6) If nut was loose, remove cadmiuma. Cadmium plate sleeve shim plate plating from surfaces of clinch nut contacting

using brush cadmium plating solution (C-108). sleeve, by 600 grit abrasive cloth or paper (C-Required dimensions shall be met after 423). Wipe clinch nut and mating surfaces ofplating. sleeve clean with MEK (C-309) on clean

65-00-00Page 50 Rev. 4

BHT-212-CR&0

cheesecloth. Bond clinch nut in place with 10. Refinish parts, after repair (BHT-ALL-adhesive (C-317). Clean excess adhesive SPM), as outlined below:from threads and surface of sleeve flange andhole. Clinch nut shall be at least 0.010 inch a. Aluminum parts: Touch up with(0.254 mm) below surface of sleeve flange. a. lmim part Touch with it

chemical film material (C-100).

(7) Ensure side of sleeve flangecontacting shim plate is flat and clinch nut b. Magnesium parts: Remove all tracesdoes not protrude above surface. of corrosion by immersion in chromic acid (C-

116). Touch up parts with corrosionb. Repair mechanical and corrosion preventive compound (C-103) or treat entire

damage on sleeve as follows (figure 65-15). part with corrosion treatment (C-114), after

acid bath.(1) If damage to spotfaced surfaces,

area B, exceeds inspection limits, surfacemay be reworked by machining off surface to c. Cadmium plated steel parts: Treata minimum flange thickness, dimension C, of rework areas with brush cadmium plating0.310 inch (7.874 mm). Machining shall be solution (C-108) (BHT-ALL-SPM).done with a 0.688 inch (17.4752 mm)diameter spotface cutter, with a 0.060 inch 11. Replace outer coupling "TEMP-(1.524 mm) corner radius. After cleanup, Paragraph 65pitting is acceptable provided it is no more PLATES" if necessary (Paragraph 65-9A).than 0.010 inch (0.254 mm) deep. Surfacefinish of unpitted reworked surface shall be 63RMS or better. 65-35. Assembly

(2) Sleeves with corrosion damage MATERIALS REQUIREDwithin acceptable limits shall be reworked bysmoothing out any sharp edges which might Refer to BHT-ALL-SPM for specification anddamage packing during assembly. Nicks, source.dents or pits in area A, figure 65-15, withinallowable limits, shall be reworked to blend NUMBER NOMENCLATUREinto surrounding area. Minimum radius inreworked areas is 0.25 inch (6.35 mm) and C-010 Lubricating Oilsurface finish shall be 63 RMS or better. C-015 Lubricating (Tube

Pack)(3) Treat sleeves with corrosiondamage within acceptable limits by immersion C-308 Adhesivein a chromic acid (C-116) for as long ascorrosion is present (BHT-ALL-SPM). It is C-405 Lockwiremandatory that all corrosion products beremoved. Corrosion removal process shall becontrolled to ensure machined dimensions are SPECIAL TOOLS REQUIREDmaintained and cadmium plating is notremoved. After chromic acid bath, rinsesleeve with water to remove chromic acid and NUMBER NOMENCLATUREdry with filtered, compressed air and apply T101307 Wrenchcorrosion treatment (C-114).

T101333 Pressing barc. Perform fluorescent penetrant

inspection of sleeve. Refer to BHT-ALL-SPM. T101334 Pressing bar

9. Repair minor nicks, scratches, and burrs T101564 Holding fixtureon gear (24, figure 65-17) splines and teeth T101600 Wrenchby dressing with India stone (C-464).

65-00-00Rev. 4 Page 51

BHT-212-CR&0

203.37 Nm) using T101600 wrench. SecureCAUTION nut to sleeve with lockwire (C-405).

SAME SHIM PLATE (20, FIGURE NOTE65-17) REMOVED FROM SLEEVE A workaid may be fabricated (figureSHALL BE REINSTALLED OR A

W SHALL BE REINSTALLED 65-2, detail B) to aid installation ofNEW SHIM PLATE OF SAME seal (13, figure 65-17).THICKNESS SHALL BE MADE.

7. Install seal (13) into outer coupling (11)1. Coat all parts with gearbox oil prior to seal groove as follows:starting reassembly procedure.

a. Apply a light coat of lubricant (tube2. Position original shim plate (20) or new pack) (C-015) to outer circumference of sealshim plate on sleeve (18) and install three (13).screws (21).

b. Install seal (13) into outer coupling3. Press duplex ball bearing (17) into (11) seal groove with lip of seal towardsleeve (18) using T101333 pressing bar. The internal splines of outer coupling (11), asduplex bearing shall have matching serial shown in figure 65-17, detail A.numbers, be installed in pairs and be installedface-to-face. NOTE

4. Press roller bearing (22) into sleeve (18) Seal (13) will be partially seated andusing T101333 pressing bar. Install retaining inner coupling (10) will be used as aring (23). backup, in reverse (see detail A) to

fully seat outer circumference edgeof seal into outer coupling (11) seal

CAUTION groove.

c. Using inner coupling (10) as a backup,WHEN INSTALLING GEAR INTO and placed, as shown in detail A, firmly pressBEARING, USE CARE TO APPLY down (hand pressure only) on outer couplingPRESSURE ONLY TO GEAR HUB (11), simultaneously tuck outer circumferenceAREA. PRESSURE APPLIED AT edge of seal (13) with workaid into outerGEAR TEETH CAN RESULT IN coupling (11) seal groove.CRACKS BETWEEN HOLES INWEB AND POSSIBLE FAILURE OF d. Continue pressing around seal (13)GEAR. with workaid until seal (13) is fully seated.

Remove inner coupling (10) from outer5. Press gear (24) into sleeve while coupling (11).supporting inner race of duplex ball bearing

8. Place small amount of lubricant (tubepack) (C-015) in internal splines of outercoupling (11) and inboard side of seal (13).

6. Apply adhesive (C-308) to faying Insert inner coupling (10) into outer couplingsurfaces of seal (14) and nut (15). Press new (11) with small end through seal.seal (14) into nut (15) with lip of seal facinginboard. Install new packing (16) on nut (15).Position T101564 holding fixture on sleeve NOTE(18) with pins engaged through holes insleeve flange. Coat packing and threads of Ensure inner coupling (10) is correctnut (15) with gearbox oil. Install nut in sleeve for intermediate and tail rotorand torque 100 to 150 ft.lbs. (135.58 to gearbox, overall length is 1.870 to

65-00-00Page 52 Rev. 4

BHT-212-CR&0

1.880 inch (47.498 to 47.752 mm). 16. Extend outer coupling (11) so seal (13)Tail rotor driveshaft hanger coupling is against teeth of inner coupling. Coatoverall length is 2.07 to 2.08 inch internal splines of outer coupling (11) with(52.578 to 52.832 mm). lubricant (tube pack) (C-015) to 0.12 inch

(3.048 mm) depth over top of spline teeth. A9. Place small amount of lubricant (tube workaid may be fabricated (figure 65-2, detailpack) (C-015) on internal splines of outer C) to obtain depth of grease.coupling (11). Insert coupling (10) into outercoupling (11) with small end through seal. 17. Place small end of centering spring (3)

on boss of seal plate.10. Position couplings (10 and 11) onsplined end of gear (24). 18. Install plate (2), spacer (5), and

centering spring (3) into coupling and install11. Coat threads of coupling retaining bolt retainer ring (1).(8) with lubricating oil (C-010).

19. Place new packing (25) on cone (26).12. Place washer (9) on bolt and thread bolt Coat packing and cone with approved oil andinto gear. insert cone into gear (24). Install retainer ring

(29).13. Hold outer coupling (11) with T101307wrench. Use a square extension to torque bolt 20. Test quill by holding sleeve and turning(8) 80 to 100 ft.lbs. (108.464 to 135.58 Nm). coupling. There should be a very light drag

caused by oil seal and preload of duplex14. Place packing (7) on retainer (6). bearings, but coupling and pinion should turn

smoothly.15. Coat packing and retainer withapproved oil and insert retainer into bolt (8). If 21. Tag quill with date of lubrication andone hole in rim of retainer (6) does not align make an entry in component historical record,with notch of inner coupling (10), pull retainer if quill is to be returned to stock.free of bolt, rotate 90° and reinstall. Repeat ifnecessary to obtain alignment. When hole 22. When quill is installed on helicopter,and notch are aligned, install lock spring (4) make an entry in helicopter log and flexthrough hole in rim of retainer and notch of couplings lubrication log.inner coupling (10).

65-00-00Rev. 4 Page 53/54

BHT-212-CR&O

TAIL ROTOR (90° ) GEARBOX

65-36. TAIL ROTOR GEARBOX. 3. Remove retainer ring (23), glass (22), andindicator (20). Remove packing (21) from

65-37. OVERHAUL. glass.

4. Remove nuts (35) and spacers (34). Cut65-38. Disassembly. sealant between case (9) and quill (33).

Remove sealant from three jackscrew holes.SPECIAL TOOLS REQU D Install three T101308 jackscrews. Turn

jackscrews equally to pull quill from case.Remove packing (32) from quill.

NUMBER NOMENCLATURE

T101305 Wrench NOTE

T101308 Jackscrew set Overtemperature indicator dots ontemperature indicator TEMP-

T101350 Backlash clamp PLATES are of a white or light graycolor and turn black when exposed

T101561 Wrench to an overtemperature condition.

T101563 Holding fixture cause the indicating dots to turnT103263 Bearing holding bar black.

T101599 Pressing tool 5. Inspect outer coupling (36) temperatureindicator TEMP-PLATES for evidence of

T101872 Backlash arm overtemperature indication. Ifovertemperature indication is noted, performcoupling overtemperature inspection as

NOTE follows:

If records and/or physical a. Inspect outer coupling cadmium platingappearance of gearbox indicate for being discolored (circumferential tan orassembly has been subjected to an light brown band) or blistered. If cadmiumaccident or incident outside realm of plate discoloration or blistering is found,normal usage, perform Conditional replace outer coupling and inner coupling.Inspection, paragraph 65-40.

b. Inspect gear teeth of outer coupling1. Remove chip detector (24, figure 65-21) and inner coupling for being discoloredand gasket (19). Drain oil from gearbox. (brown or blue) in the normally bright contact

patterns. If discoloration is found, replace2. Release pin (7) and remove oil cap (4). p n. ico

outer coupling and inner coupling.Remove packing (8) from cap.

c. Inspect outer coupling and innerNOTE coupling under 5x to 10x magnification for

teeth exhibiting signs of metal smearing orFor ease of maintenance, block tearing in the contact patterns. If smearing orouter coupling to remain in outboard tearing is found, replace outer coupling and(extended) position. This will inner coupling.stabilize outer coupling duringdisassembly and assembly. d. Inspect grease from couplings for being

very viscous (thick) and having a strongpungent odor. If grease is found to be viscous

65-00-00Rev.3 Page 55

BHT-212-CR&O

(thick) and having a strong pungent odor, 13. Remove seal (45) from sleeve (38).replace outer coupling and inner coupling. Remove retaining ring (44). Heat case and

remove bearing (43).

NOTE14. Remove retaining ring (31). Heat case

If TEMP-PLATES are to be replaced, and remove bearing (30).replace TEMP-PLATES aftercompleting entire inspection and 15. Remove screws (15) and shim plate (17)repair procedures and couplings from case.have been determined serviceableand prior to assembly.

NOTE

5A. Inspect outer coupling (36) temperature Duplex bearings are a matched setindicator TEMP-PLATES for deterioration, Both bearings aredebonding or discoloration of epoxy coatingthat prevents interpretation of indicating dots. number. Keep together as a set.If deterioration, debonding, or discoloration ofepoxy is found, replace TEMP-PLATES in Remove shim plate fluorescentaccordance with paragraph 65-9A. penetrant inspection of case. Identify

shim plate to ensure installation on6. Overhaul input quill as required same case from which removed.(paragraph 65-46)

7. Remove nuts (42) and washers (40 and 65-39. Cleaning.41, figure 65-21). Cut sealant between case(9) and sleeve (38). Remove sealant from MATERIALS REQUIREDthree jackscrew holes and install threeT101308 jackscrews. Turn jackscrews evenlyto pull quill from case. Carefully remove NOMENCLATUREsleeve (38) from shaft to avoid damage to C-105 Corrosion Preventiveroller bearing (43). Remove packing (37) fromsleeve (38). C-304 Solvent

C-427 Barrier Material8. Remove clips (27 and 29). Install C-427T101563 holding fixture. Remove nut (28) C-436 Paint Removerusing T101561 wrench. Remove nut (26)using T101305 wrench. Remove holdingfixture. 1. Clean parts with solvent (C-304). Dry

parts with clean, lint-free cloths or filtered,9. Support case (9) in flat areas between compressed air. Do not allow bearings to spinstuds (13) and press shaft (1) out of case. when drying.

10. Remove bolts (2) and gear (3) from 2. Protect cleaned bearings with corrosionshaft. preventive corrosion preventive (C-105) and

wrap with barrier material (C-427) or coat with11. Support case (9) in flat areas between gearbox oil. Do not handle unoiled bearingstuds (11) and press duplex bearings (25) out with bare hands.of case using T103263 bearing holding bar.

3. Inspect case (9, figure 65-21) for12. Remove shim (18) from case with snap corrosion damage to threads. No structuralring pliers. damage to threads is acceptable.

65-00-00Page 56 Rev. 3

BHT-212-CR&O

4. Remove sealant from gearbox case with 65-40. Conditional Inspection.plastic scraper.

NOTE5. Remove paint with paint remover (C-436).Rinse with clean water. If records or physical appearance of

gearbox indicates assembly has6. Apply corrosion preventive to ferrous been subjected to an accident orparts after cleaning as follows: incident outside realm of normal

usage, perform ConditionalNOTE Inspection as follows. If Conditional

Inspection is not required,Normally, parts treated by this accomplish Normal Inspectionmethod may be left covered in (paragraph 65-41).indoor storage for approximately 150hours without being affected. 1. Check gearbox for freedom of rotation

and for proper backlash of gears. Backlasha. If parts are processed for inspection should not vary more than 0.002 in. (0.0508

prior to applying corrosion preventive mm) when checked at different points aroundtreatment, wash ferrous parts in a clean rinse gear.of solvent (C-304) and drain on rack,otherwise proceed with step b. 2. Inspect gearbox output shaft for yielding.

With gearbox still assembled, rotate outputb. Gently agitate ferrous parts in corrosion shaft and check runout of pitch diameter of

preventive (C-105) and drain on rack. splines by indicating on a 0.0600 in. (1.524mm) diameter pin laid in spline. Maximum

c. Apply protective coat of gearbox oil. acceptable runout is 0.012 in. T.I.R. (0.3048

65-00-00Rev. 3 Page 56A/56B

BH

T-212-C

R&

OE

Fig

ure 65-21.

Tail ro

tor g

earbo

x (sheet

1 of 2)

65-00-00R

ev.3 P

age

57

BHT-212-CR&O

1. Shaft 13. Stud 25. Duplex bearing 37. Packing2. Bolt 14. Washer seat 26. Nut 38. Sleeve3. Gear 15. Screw 27. Clip 39. Clinch nut4. Cap 16. Stud 28. Nut 40. Washer5. Pin 17. Shim plate 29. Clip 41. Washer6. Safety chain 18. Shim 30. Bearing 42. Nut7. Pin 19. Gasket 31. Retaining ring 43. Bearing8. Packing 20. Indicator 32. Packing 44. Retaining ring9. Case 21. Packing 33. Input quill 45. Seal

10. Oil cap adapter 22. Sight glass 34. Spacer 46. Data plate11. Stud 23. Retaining ring 35. Nut12. Bushing 24. Chip detector 36. Coupling

212-R-65-21-1212-040-004

Figure 65-21. Tail rotor gearbox (sheet 2)

mm) on small diameter spline or 0.010 in. 2. Inspect input quill (paragraph 65-49).T.I.R. (0.254 mm) on larger spline.

3. Inspect gears and splines for chipped,3. Visually inspect couplings for cracked or broken, or worn teeth. Check bearings forchipped teeth. Refer to paragraph 65-49. smooth operation and for indications of

excessive wear. Inspect bearing liners for4. Inspect bearings for roughness or scoring, and security of mounting in case andbrinelling. sleeve. Inspect studs and washer seats for

looseness, damage, and corrosion.5. Inspect case, couplings, gears and sleeveby magnetic particle or fluorescent penetrantmethods (BHT-ALL-SPM) (paragraph 65-41).

Overtemperature indicator dots on6. If any of above steps reveals cracks or temperature indicator TEMP-distortion indicative of excessive loads, entire PLATES are of a white or light graycomponent shall be considered unserviceable color and turn black when exposedand nonreparable. to an overtemperature condition.

Chemical contamination can also7. Accomplish Normal Inspection (paragraph cause the indicating dots to turn65-41). black.

65-41. Normal Inspection. 4. Inspect outer coupling (36, figure 65-21)temperature indicator TEMP-PLATES for

1. Inspect all parts of gearbox for obvious evidence of overtemperature indication. Ifdamage which would make part nonreparable overtemperature indication is noted, performand unserviceable. coupling overtemperature inspection as

follows:

65-00-00Page 58 Rev. 3

BHT-212-CR&O

a. Inspect outer coupling cadmium plating NOTEfor being discolored (circumferential tan orlight brown band) or blistered. If cadmium If TEMP-PLATES are to be replaced,plate discoloration or blistering is found, replace TEMP-PLATES afterreplace outer coupling and inner coupling. completing entire inspection and

repair procedures and couplingshave been determined serviceable

and inner coupling for being discolored and por to assembly.(brown or blue) in the normally bright contactpatterns. If discoloration is found, replace 4A. Inspect outer coupling (36) temperatureouter coupling and inner coupling. indicator TEMP-PLATES for deterioration,

debonding or discoloration of epoxy coatingthat prevents interpretation of indicating dots.

c. Inspect outer coupling and inner If deterioration, debonding, or discoloration ofcoupling under 5x to 10x magnification for epoxy is found, replace TEMP-PLATES inteeth exhibiting signs of metal smearing or accordance with paragraph 65-9A.tearing in the contact patterns. If smearing ortearing is found, replace outer coupling andinner coupling. 5. Inspect bearings for smooth operation

and for indications of excessive wear. Inspectbearing liners for scoring, and for security of

d. Inspect grease from couplings for being mounting in case and sleevevery viscous (thick) and having a strongpungent odor. If grease is found to be viscous(thick) and having a strong pungent odor, Inspect studs and washer seats forreplace outer coupling and inner coupling. looseness, damage, and corrosion.

65-00-00Rev. 3 Page 58A/58B

BHT-212-CR&O

7. Inspect following parts by magnetic 13. Inspect shim plate (17) for damage andparticle (Code M) or fluorescent penetrant wear.(Code F) (BHT-ALL-SPM), as applicable.Demagnetize parts after magnetic particle 14. Inspect bearings (25, 30 and 43) forinspection. roughness, spalling, scoring, pitting.

brinelling, and flaking as follows:Figure, Nomenclature CodeIndex No. a. Corrosion on rolling element or races

65-21, 1 Shaft M and for cracked or broken retainers (figure65-21, 3 Gear M 65-25).65-21, 9 Case F65-21, 26 Nut M b. Minor nicks, cuts, or scratches are65-21, 28 Nut F acceptable provided they are too small to be65-21, 38 Sleeve F felt with a probe having and end radius of

0.030 in. (0.762 mm), and provided totalaffected area does not exceed 10% of contactarea at any point.

8. Inspect parts for wear in excess ofallowable limits (figure 65-22). Refer to c. Minor circumferential scoring isparagraph 65-49 for wear limits applicable to acceptable on rollers and races provided itinput quill. cannot be felt with a probe having an end

radius of 0.030 in. (0.762 mm) and providedaffected area does not exceed 10% of contact

NOTE area at any point.

It is not intended all dimensions be 15. Inspect output shaft (1) visually forchecked as prescribed overhaul damaged threads. Replace shaft if threadsprocedure. Check parts are malformed. If shaft is suspected of beingdimensionally that show evidence of damaged, perform runout inspection. Inspectwear or physical damage. output shaft for nicks, dents, scratches, pits,

and wear (figure 65-22).9. Inspect teeth on gear (3, figure 65-21) forexcessive wear, scoring, spalling, and 16. Inspect indicator (20, figure 65-21) forscuffing. Check wear pattern (figure 65-22). discoloration and paint peeling.

10. Inspect case (9, figure 65-21) and 17. Inspect oil level sight glass (22) foroutput quill sleeve (38) for corrosion damage cracks, crazing, scratches, and discoloration.(figure 65-24).

18. Inspect chip detector (24) for obviousa. Maximum permissible depth of pitting damage.

in all areas is 0.030 in. (0.762 mm) and nomore than 40% of area within 1.0 sq.in. 19. Inspect studs (11, 13, and 16) for bent(645.2 mm2) or more than 20% of total area or damaged threads.of any surface or diameter.

20. Inspect nuts (26 and 28) visually forb. Structural damage to threaded holes damaged threads. Replace nuts which have

for studs is acceptable provided damage does malformed threads.not extend past first thread.

11. Inspect oil filler cap adapter (10, figure NOTE65-21) for damage and wear.

Apply corrosion preventive treatment12. Inspect oil filler cap (4) for damage. if parts are not processed

immediately after inspection(paragraph 65-39).

65-00-00Rev. 4 Page 59

BHT-212-CR&O

65-42. Repair. 10. Replace oil level sight glass (22, figure65-21) if cracked, crazed, scratched or

MATERIALS REQUIRED discolored. Replace indicator (20) if paint isMATERIALS REQUIRED peeled.

NUMBER NOMENCLATURE 11. Replace bearings which are spalled,scored, brinelled, pitted, discolored from

C-005 Solid Film Lubricant overheating, or which have damaged orC-100 Chemical Film Material broken retainers, or roughness.

C-100 Chemical Film Material

C-108 Brush Cadmium 12. Repair damaged stud holes by drillingPlating Solution out damaged thread. Clean out diameter

shall not exceed major thread diameter ofC-114 Corrosion Treatment internal threads. Break all sharp edges,

except in thread areas, clean out small ventC-116 Chromic Acid hole in bottom of threaded hole. Treat

repaired surfaces with chemical film materialC-500 Crocus Cloth (C-100)(C-100).C-423 Abrasive Cloth or

Paper 13. Repair damaged studs (BHT-ALL-SPM).Stud height, prior to installation of shim plate

C-464 India Stone on input quill port, shall be 1.450 in. (36.83mm) (minimum). Stud height on output portshall be 0.850 in. (21.59 mm) (minimum).

1. Replace parts exceeding allowable limits. Stud height on pitch change port shall be0.785 in. (19.939 mm) (minimum).

2. Replace all seals, gaskets, preformedpackings, and standard hardware on 14. Repair case (9, figure 65-21), which hasreassembly. corrosion within allowable limits (figure 65-

24), as follows:3. Replace parts which are cracked, broken,warped, distorted, have malformed threads or a. Polish out, within acceptable depthfail to pass inspection. limits, any sharp edges which might damage

packings upon installation.4. Replace all parts which exceed allowabletolerances (figure 65-22). b. Immerse corroded case in chromic acid

(C-116) bath to completely remove corrosion5. Replace cases and output sleeves having products (BHT-ALL-SPM).loose liners or corrosion between steel linerand magnesium case or sleeve.

6. Replace gearbox cases which have CAUTIONcorrosion damage in excess of limits (figure ....65-24).65-24). CORROSION REMOVAL PROCESS

7. Replace cases with structural damage in SHALL BE MONITORED TOthreads exceeding repair limits (figure 65-24). ENSURE MACHINED DIMENSIONS

ARE MAINTAINED AND CADMIUM

8. Repair minor scratches, nicks, and pits on PLATING IS NOT REMOVED FROMnon-critical surfaces with crocus cloth (C- STUDS.500).

c. Immediately after corrosion removal,9. Repair minor nicks, scratches, and burrs apply corrosion treatment (C-114).on splines and gear teeth by dressing withIndia stone (C-464).

65-00-00Page 60

BHT-212-CR&O

4 5

10

18

17 13


1 Spline, Shaft Over pins 1.1530 29.2862 1.1560 29.3624(Use 0.060 IN. (1.524 mm)diameter pins)

2 Spline, Shaft Over pins 1.3370 33.9598 1.3401 34.03954(Use 0.060 IN. (1.524 mm)diameter pins)

3 Shaft (Seal Contact Area) OD 1.4320 36.3728 1.4400 36.5764 Shaft (Bearing Contact Area) OD 1.4748 37.45992 1.4756 37.480245 Roller Bearing OD 2.4404 61.98616 2.4409 61.998866 Sleeve, Shaft OD 7.7489* 196.82206* 7.7510 196.87547 Shaft (Gear Contact Area) OD 4.1255 104.7877 4.1263 104.808028 Duplex Bearing OD 3.1491 79.98714 3.1496 79.999849 Duplex Bearing ID 1.5745 39.9923 1.5749 40.00246

10 Shaft (Bearing Contact Area) OD 1.5751 40.00754 1.5757 40.0227811 Case ID 3.5000 88.9000 3.5020 88.950812 Roller Bearing OD 2.0467 51.98618 2.0472 51.9988813 Case ID 3.5600 90.4240 3.5615* 90.4621*14 Liner, Gearbox Case ID 3.1490 79.9846 3.1497 80.0023815 Liner, Gearbox Case ID 2.0464 51.97856 2.0473 52.0014216 Gear ID 4.1250 104.7750 4.1255 104.787717 Case ID 7.7500 196.8500 7.7541* 196.95414*18 Liner, Output Sleeve ID 2.4402 61.98108 2.4410 62.0014

Average 212-R-65-22Figure 65-22. Tail rotor gearbox wear limits

65-00-00Page 61

BHT-212-CR&O

Desired wear pattern on pinion Desired wear pattern on gear

View A View B

NOTES

1. Wear Pattern Inspection: Observe the visible gear contact wear pattern on the concave side ofthe pinion theeth and on the convex side of the gear teeth.

2. The desired wear pattern is shown in views A and B. A slight bright line at top of pattern ongear and In flank of position Is permissible.

90 GEARBOX

0 TO 0.156 INCH 0 TO 0.156 INCH(0 TO 3.962 mm) (0 TO 3.962 mm)

TOP

HEEL TOE

ROOT

Pattern tolerances at toe and heel on gear and pinion

View C

3. Acceptable wear patterns are shown in views D, E, F, G, H and I. View C is furnished to futherdefine wear limits.

4. Pattern Limits at Toe: The wear pattern may touch the toe or may be a maximum of 0.156 inch(3.962 mm) from the toe (see views C, D, G and I). Pattern variation at the toe must not exceed0.156 inch (3.962 mm). Normally, the pattern will touch the toe on the pinion but will not touchthe toe on the gear (views D and E). It Is permissible for the pattern to touch the toe on the gearIf the pattern does not go off the toe of the pinion.

5. Pattern Limits at Heel: The wear pattern may touch the heel or may be a maximum of 0.156 inch(3.962 mm) from heel. Pattern variation at the heel must not exceed 0.031 Inch (0.787 mm). Theheel positions shown in views A, B, D, E, F, G, H and I are within these limits.

212-R-65-23-1C0000

Figure 65-23. Gear and pinion wear pattern (sheet 1 of 2)

65-00-00Page 62

BHT-212-CR&0

ACCEPTABLE WEAR PATTERN ON PINION ACCEPTABLE WEAR PATTERN ON GEAR

(TOUCHING TOE)VIEW D VIEW

NOTES

6. Pattern Profile: The pattern must be positioned on the tooth in a profile direction such that the pattern

extends over the top of the pinion and is 0.031 to 0.063 inch (0.787 to 1.600 mm) from the top of the

gear (views A, B, D, E, F, G, H and I). A pattern which does not extend over the top of the pinion or

touches the top of the gear shall be rejected. A bright line occurring at the top of the pinion or in the

flank of the gear is also cause for rejection.

7. Unacceptable Defects: In addition to pattern size and location, examine the drive face of all gear teeth

for the following defects which are not acceptable if they can be felt with a scribe having a 0.002 inch

(0.051 mm) spherical point.

a. Non-clean up h. Grinding flats or barber poling

b. Grinding scratches (evidenced by diagonal streaks

c. Pitting in the wear pattern)

d. Corrosion i. Scuffing

e. Cuts j. Scoringf. Nicks k. Inclusions

g. Dents

ACCEPTABLE WEAR PATTERN ON GEAR

ACCEPTABLE WEAR PATTERN ON PINION (0.156 INCH (3.962 mm) FROM TOE)

VIEW F VIEW G

ACCEPTABLE WEAR PATTERN ON PINION ACCEPTABLE WEAR PATTERN ON GEAR(TOUCHING HEEL AND 0.156 INCH (3.962 mm) FROM TOE)

VIEW H VIEW I

212-R-65-23-2

Figure 65-23. Gear and pinion wear pattern (sheet 2)

65-00-00Rev. 4 Page 63

BHT-212-CR&O

AREA AAREA B

~ AREA D

NOTES

1. The maximum permissible depth of pitting in areas A,B, C. and D is 0.030 inch (0.762 mm) and no morethan forty percent of the area within one inch square ormore than twenty percent of the total area of anysurface or diameter may be pitted.

2. Structural damage to the threaded holes for the studsis acceptable provided the damage does not extendpast the first thread.

212-R-65-24

Figure 65-24. Tail rotor gearbox corrosion damage limits

65-00-00Page 64

BHT-212-CR&0

15. Repair or replace shim plate (17, figure b. Replace sleeves which have excessive65-21) and shim (18) as follows: corrosion damage (figure 65-24).

a. If original plating on shim plate (17) c. Repair sleeves, which do not exceedhas worn through, apply brush cadmium allowable corrosion damage limits, as follows:plating solution (C-108). Required dimensionsshall be met after plating (figure 65-27). (1) Polish out (within acceptable limits)

any sharp edges which might damageb. Examine gearbox case (9) for packings using abrasive cloth or paper (C-

reference dimension etched on shim and shim 423). Finish smooth with crocus (C-500).plate adjacent to applicable mounting surface.Record reference dimensions. (2) Immerse corroded sleeve in chromic

acid (C-116) bath to completely removec. Subtract 0.3542 to 0.3546 in. (8.99668 corrosion products (BHT-ALL-SPM).

to 9.00684 mm) from referenced dimensionon case (9) to give required thickness forshim (18). CAUTION

d. If a shim (18) of correct thickness isnot on hand, grind a new blank shim torequired thickness determined in step c. CORROSION REMOVAL PROCESSSides of shim shall be parallel within 0.0002 SHALL BE MONITORED TOin. (0.00508 mm). Do not cadmium plate ERE MA CHINED DIMENSIONS

ARE MAINTAINED AND CADMIUMPLATING IS NOT REMOVED FROM

e. Subtract 5.2498 to 5.2503 in. STUDS.(133.34492 to 133.35762 mm) fromreferenced dimension on case (9) to give (3) Immediately after corrosion removalrequired thickness for shim plate (17). apply chemical film treatment to magnesium

alloy (refer to BHT-ALL-SPM).f. If a shim plate (17) of correct thickness

is not on hand, grind a new blank shim plate 17. Repair output shaft (1) as follows:to required thickness determined in step e.After grinding, countersink three holes 100° X a. Polish out mechanical and corrosion0.250 to 0.260 in. (6.35 to 6.604 mm) damage (within allowable limits specified indiameter. Cadmium plate shim plate (17) figure 65-26) with 400 grit abrasive cloth orusing brush cadmium plating solution (C-108). paper (C-423) to blend with surrounding areaAfter plating, sides of shim plate shall be and to effect a bottom radius of 1/2 in. (12.7parallel within 0.0002 in. (0.00508 mm) on mm).inside 4.600 in. (116.84 mm) diameter, butplate may taper 0.0000 to 0.0005 in. (0.0 to b. No rework is required in oil seal0.0127 mm) on either or both sides outside contact area if depth of wear does not exceed4.600 in. (116.84 mm) diameter. Identify new 0.002 in. (0.0508 mm) and groove is uniformshim plate by serial number of case (9) on and smooth. More severe damage may bewhich it is to be installed and shim plate reworked as follows providing such repairthickness. Use etching ink or equivalent. gives 100% cleanup: Grind seal diameter toNeutralize acid, after marking, with water and a minimum diameter of 1.430 in. (36.322 mm)baking soda. (figure 65-26). Reground area shall not

extend into existing 0.062 in. (1.5748 mm)16. Repair sleeve (38) as follows: radius and blend into existing diameter with a

minimum radius of 0.062 in. (1.5748 mm).a. Replace clinch nuts (39) if damaged or Finished diameter shall be concentric with

loose (BHT-ALL-SPM). diameter for roller bearings within 0.0015 in.(0.0381 mm) T.I.R. and surface finish shall be16 RMS or better.

65-00-00Rev. 4 Page 65

BHT-212-CR&O

0

ACCEPTABLE

UNACCEPTABLE

212-R-65-25Coooo

Figure 65-25. Roller bearing inspection

65-00-00Page 66

BHT-212-CR&O

DIAMETER A DIAMETER B(SEAL CONTACT AREA) (ROLLER BEARING SURFACE)

SPLINE N --\ \

\\ - ----- AREA D -

AREA E E

TAIL ROTOR GEARBOX OUTPUT SHAFT212-040-462-001

NOTES

1. Run-Out Inspection:

a. Mount shaft on 60 ° centers.

b. Indicate run-out on diameter B. Maximum acceptable run-out is 0.001 inch (0.0254 mm) T.I.R.

2. Damage limit for area C, the outer diameter of the portion of the shaft outside the gearbox between thediameter for the oil seal and the shoulder adjacent to the splines, is 0.005 inch (0.127 mm).

3. Damage limit for area D, the outer diameter of the portion of the shaft inside the gearbox between the twodiameters for the bearings, is 0.010 inch (0.254 mm).

4. Damage limit for diameter A, the shaft oil seal diameter, is 0.002 inch (0.0508 mm) or to a minimum diameterof 1.430 inch (36.322 mm).

5. Damage limit for area E, not to exceed 1/3 length of any spline tooth, no more than 2 teeth on spline M or N.Depth not to exceed 0.002 inch (0.0508 mm) after clean-up.

212-R-65-26

Figure 65-26. Tail rotor gearbox output shaft damage limits

65-00-00Page 67

BHT-212-CR&O

0.850 IN. | 0.3542 TO 0.3546 IN.

(21.59 mm}) - (8.99668 TO 9.00684 mm)

iS -| -- 0.785 IN.

SHIM

5.2498 TO 5.2503 IN.(133.34492 TO 133.35762 mm)

1.450 IN. /(36.83 mm) /

SHIM 212-R-65-27

Figure 65-27. Tail rotor gearbox shims and studs dimensions

c. Nital etch shaft (BHT-ALL-SPM). 65-43. Assembly.

d. Inspect shaft by magnetic particle MATERIALS REQUIREDinspection (BHT-ALL-SPM). Demagnetizeshaft after magnetic particle inspection.

NUMBER NOMENCLATUREe. Apply brush cadmium plating solution

(C-108) (BHT-ALL-SPM) to reworked areas C-304 Solventon portion of shaft between diameter for rollerbearing and shoulder adjacent to splines.405Lckwir

f. Apply solid film lubricant (C-005) (BHT-ALL-SPM) to shaft in area E (figure 65-26). SPECIAL TOOLS REQUIREDMinimum thickness of film shall be 0.0002 in.(0.00508 mm). Bake shaft in an oven at a NUMBERNOMENCLATUREtemperature of 265°F (130°C) for two hours.

T101305 Wrench18. Replace outer coupling TEMP-PLATES if

Inecessary. (Paragraph 65-9A). T101350 Backlash clamp

T101561 Wrench

T101563 Holding fixture

T103263 Bearing holding Bar

65-00-00Page 68 Rev.3

BHT-212-CR&O

SPECIAL TOOLS REQUIRED (CONT) 9. Install nut (28) and use T101561 wrenchto torque nut 1800 to 2400 in.lbs. (203.364 to

NUMBER NOMENCLATURE271.152 Nm).

T101599 Pressing tool 10. Install clip (29). Remove T101563holding fixture.

T101872 Backlash arm11. Turn shaft and check bearings roll

1. Clean all parts with solvent (C-304) and preload of bearingscoat with gearbox oil. Do not handle drybearings with bare hands. 12. Heat sleeve (38), install roller bearing

(43), and secure with retaining ring (44).2. Heat gear (3, figure 65-21)with heat lampand position gear on shaft (1) and install 13. Press seal (45) into sleeve with lip ofbolts (2). Torque bolts 80 to 100 in.lbs. (9.04 seal facing inboard (figure 65-22).seal facing inboard (figure 65-22).to 11.30 Nm). Secure bolts with lockwire (C-

~14. Install new packing (37, figure 65-21).

NOTE 15. Coat packing (37), lip of oil seal (45) andmounting port of case (9) with gearbox oil.

The same shim plate (17) which wasremoved from the case shall be 16. Heat mounting port of case with a heatreinstalled or a new shim plate of lamp. Install sleeve (38) on case and securesame thickness shall be made with aluminum washers (40) next to(paragraph 65-42). magnesium case and steel washers (41)

under nuts (42). Torque nuts 50 to 70 in.lbs.3. Ensure all six washer seats (14) are (5.649 to 7.9086 Nm).properly installed on gearbox case. Positionshim plate (17) on case (9) and secure with 17. Turn shaft (1) by hand and check forthree screws (15). light drag caused by oil seal and preload in

duplex bearings.4. Install shim (18) in case (9).

18. Install new packings (32) on input quill5. Heat case (9) and press bearing (30) into (33). Lubricate packing and mating surface ofcase (9) and install retaining ring (31). input quill with gearbox oil.

NOTE 19. Heat input quill port in case (9) with heatlamp.

Duplex bearings have matchingserial numbers and must be installed 20. Install quill in gearbox. Exercise care toin pairs, face-to-face. keep quill aligned as it is installed so nose of

pinion enters roller bearing and gear teeth6. Press duplex bearing (25), using T103263 mesh properly.bearing removal bar, into case.

21. Align quill on studs so flats on gearbox7. Support inner race of bearings (25), with case and quill sleeve flange are aligned.T103263 bearing removal bar, and pressshaft (1) into case (9). 22. Install spacers (34) and nuts (35).

8. Position case (9) in T101563 holding 23. Verify gearbox turns smoothly by turningfixture and install nut (26). Use T101305 input pinion by hand. Check backlashwrench to torque nut 360 to 480 in.lbs. between input quill pinion and gear in three(40.6728 to 54.2304 Nm). Install clip (27). places 120 ° apart. Use T101350 backlash

65-00-00Page 69

BHT-212-CR&O

clamp and T101872 backlash arm (using 31. Seal and paint tail rotor gearboxoutboard dowel). Backlash shall be 0.005 to (paragraph 65-44).0.011 in. (0.127 to 0.2794 mm). Recordbacklash. 32. Perform run-in and test (paragraph 65-

45).

|CAUTION 65-44. Sealing and painting.

DO NOT ALTER SHIM PLATE (17) MATERIALS REQUIREDOR SHIM (18) TO OBTAINREQUIRED BACKLASH. IF

BACKLASH IS NOT WITHIN NUMBER NOMENCLATURE

LIMITS, PARTS ARE NOT C-202 PrimerDIMENSIONALLY CORRECT ORARE NOT CORRECTLY C-203 LacquerASSEMBLED.

C-210 Paint

24. Install oil level indicator (20) in case (9). C-308 Adhesive

25. Place packing (21) on sight glass (22). C-309 Methyl-Ethyl-KetoneLubricate packing and case port with gearbox (MEK)oil and insert sight glass into case.

26. Install retaining ring (23). NOTE

If tail rotor gearbox is to be run-in onrun-in stand, skip painting and

Only use M83248-1 packing on chip sealing, until after run-in inspectiondetector. (paragraph 65-45).

27. Place new gasket (19) on chip detector 1. Clean external surfaces of case and quill(24) and install in case. Torque 120 to 150 sleeve with MEK (C-309) and clean cloths.in.lbs. (13.5576 to 16.947 Nm) and secure Do not allow cleaning agent to contact seals.with lockwire (C-405).

2. Fill groove between gearbox case andquill sleeves and around bearing retaining nut

~~~NOTE with adhesive (C-308). Allow to cure for 72

A 0.5 in. (12.7 mm) diameter white hours at room temperature.dot on cap denotes vented cap. If avented cap is installed, apply a 0.5 NOTEin. diameter white dot on case(paragraph 65-44). Mix adhesive (C-308) according to

directions on container and apply to28. Place new packing (8) on oil cap (4) and gearbox with pressure gun or woodinstall oil cap on case. Attach pin (7) to case. spatula. If necessary, smooth

sealant with bare finger wetted with29. Install 0.5 in. (12.7 mm) thick plywood water.block and cork gasket on pitch change quillmounting port. 3. Remove plywood block and gasket from

pitch change quill port. Remove oil filler cap.30. Prepare data plate (46) for installation Mask the following areas to prepare forand bond to sleeve (BHT-ALL-SPM). painting.

65-00-00Page 70

BHT-212-CR&O

a. Cap adapter (10, figure 65-21). 65-45. Run-in and test.

b. Chip detector (24). It is recommended after overhaul that gearboxbe test run and inspected in accordance with

c. Input quill (33). Bell Helicopter Textron BHT-PUB 77-003(publication furnished with run-in stand) for

d. Oil level sight glass (22). qualification for flight. In the event a run-instand is not available, the functional testspecified in BHT-212-MM, may beaccomplished as minimum acceptablealternate test.

f. Data plate (46).

g. Bushings (12). 65-46. INPUT QUILL.

h. Case port adjacent to studs (11). 65-47. Disassembly.

i. Seals (45, figure 65-21 and 13, figure SPECIAL TOOLS65-28) at outboard end of sleeve and quill.

4. Spray paint gearbox with primer (C-202). NUMBER NOMENCLATURECoat 0.4 to 0.9 mils thickness.

T101307 Wrench

NOTE T101560 Holding fixture

Apply aluminized lacquer coat not T101566 Barless than thirty minutes and notmore than four hours after epoxy T101599 Pressing toolprime is applied. T101600 Wrench

5. Spray on first coat of color No. 17178 T101880 Sleeve toollacquer (C-203) 4 to 6 mil thickness. Allow todry for thirty minutes to one hour and applysecond coat. 1. Remove retaining ring (1, figure 65-28),

plate (2), centering spring (3), and spacer (5).Thread a 1/4-20 bolt into center of retainer (6)

NOTE and pull retainer with lockspring (4) andpacking (7) from inner coupling (10). RemoveIf second coat of lacquer cannot be lockspring and packing from retainer.

applied within time limits noted instep 6, second coat may be delayedfor up to seventy-two hours, but NOTEsurface to be painted shall becleaned with a tack rag prior to For ease of maintenance, blockapplying second coat. outer coupling so it will remain in

outboard (extended) position. This6. Allow last coat of lacquer to dry for 48 will stabilize outer coupling duringhours and remove masking tape. disassembly and assembly.

7. Use brush to apply 0.5 in. (12.7 mm) 2. Hold outer coupling (11) with T101307diameter dot of white catalyzed paint (C-210) wrench and use square adapter throughto oil cap and to gearbox case boss below oil wrench to remove coupling retaining bolt (8).cap adapter. Remove washer (9).

65-00-00Page 71

BHT-212-CR&O

3. Remove inner and outer couplings (10 4. Remove paint with paint remover (C-436).and 11) from pinion. Rinse with clean water.

4. Separate couplings and remove seal (13) 5. Apply corrosion preventive to ferrousfrom outer coupling. parts after cleaning as follows:

5. Hold sleeve (20) with T101560 holding NOTEfixture and use T101600 wrench to removenut (15). Remove seal (14) and packing (16) Normally, parts treated by thisfrom nut. method may be left covered in

indoor storage for approximately six~~~~~NOTE days without being affected.

Wear sleeve (18) should be relaced a. If parts are processed for inspectionWear sleeve (18) should be replaced

otherwise, proceed with step b.6. Remove spacer (17) and press pinion(21) out of sleeve (20). Use suitable plug to b. Gently agitate ferrous parts in corrosionpress on outer race of bearings (19) to preventive (C-105) and drain on rack.remove bearings from sleeve. Tap wearsleeve (18) with a mallet to loosen bonding. c. Apply protective coat of gearbox oil.Press wear sleeve (18) from spacer (17) withT101880 sleeve tool.

65-49. Inspection.

65-48. Cleaning. 1. Inspect all parts of input quill for obviousdamage which would make part nonreparable

MATERIALS REQUIRED or non-serviceable.

2. Inspect gears and splines for chipped,NUMBER NOMENCLATURE broken or worn teeth. Check bearings for

smooth operation and indications of excessiveC-105 Corrosion Preventive wear.

C-304 Solvent304 Solvent 3. Inspect the inner coupling (10, figure 65-C-407 Abrasive Pad 28), outer coupling (11), sleeve (20), pinion

(21), bolt (8), and nut (14) by magneticC-427 Barrier Material particle method (BHT-ALL-SPM).

C-436 Paint RemoverNOTE

1. Clean parts with solvent (C-304). Dry Remove cork plug before performingparts with clean, lint-free cloths or filtered, inspection.compressed air. Protect cleaned bearingswith corrosion preventive (C-105) and wrap 4. Inspect parts as required for wear inwith barrier material (C-427). excess of allowable limits (figure 65-29).

2. Remove sealant from quill with plastic 5. Inspect teeth on pinion (21, figure 65-28)scraper for excessive wear, scoring, spalling, and

scuffing (figure 65-23).

3. Clean primer from spacer (6) with aplastic scraper and abrasive pad (C-407).

65-00-00Page 72

BHT-212-CR&O

SEE DETAIL B

13

17 87 20

INSTALL WEAR SLEEVE WITH 6ROUNDED END AS SHOWN

2.l. Plate Coupling, inner 18. Sleevewear211. Ring retaining 9. Washer 17. Spacer2. Plate 10. Coupling, inner 18. Sleeve, wear3. Spring centering 11. Coupling, outer 19. Bearing duplex4. Spring lock 12. Deleted 20. Sleeve5. Spacer 13. Seal 21. Pinion6. Retainer 14. Seal 22. Cork plug7. Packing 15. Nut8. Bolt 16. Packing

NOTES

A Location of temperature indicator TEMP-PLATE.

A Apply adhesive sealant (C-308) on nut (15) and sleeve (20) after assembly.

212-R-65-28-1212-040-004-11

Figure 65-28. Tail rotor gearbox input quill (sheet 1 of 2)

65-00-00Rev. 3 Page 73

BHT-212-CR&O

SEAL (13) PARTIALLY SEATED SEAL (13) FULLY SEATED

INTERNAL OUTER COUPLING (11)SPLINES (12) INSTALLED

INNER COUPLING (10) USED INVERTED ON INNERAS BACK-UP TO PUSH LIP COUPLINGOF SEAL (13) UP

DETAIL B212-R-65-28-2212-040-003-17

Figure 65-28. Tail rotor gearbox input quill (sheet 2)

6. Inspect inner and outer couplings (10 and b. Inspect gear teeth of outer coupling11, figure 65-28) for chipped, pitted, cracked, and inner coupling for being discoloredand excessively worn teeth (figure 65-29). (brown or blue) in the normally bright contact


NOTE

Overtemperature indicator dots on c. Inspect outer coupling and innertemperature indicator TEMP- coupling under 5x to 10x magnification forPLATES are of a white or light gray teeth exhibiting signs of metal smearing orcolor and turn black when exposed tearing is found, replace outer coupling andto an overtemperature condition. inner coupling.Chemical contamination can alsocause the indicating dots to turn d. Inspect grease from coupling for beingblack. very viscous (thick) and having a strong

pungent odor. If grease is found to be viscous7. Inspect outer coupling (11, figure 65-28) (thick) and having a strong pungent odor,temperature indicator TEMP-PLATES for replace outer coupling and inner coupling.evidence of overtemperature indication. Ifovertemperature indication is noted, perform NOTEcoupling overtemperature inspection asfollows: If TEMP-PLATES are to be replaced,

replace TEMP-PLATES aftera. Inspect outer coupling cadmium plating completing entire inspection and

for being discolored (circumferential tan or repair procedures and couplingslight brown band) or blistered. If cadmium have been determined serviceableplate discoloration or blistering is found, and prior to assembly.replace outer coupling and inner coupling.

65-00-00Page 74 Rev. 3

BHT-212-CR&O

7A. Inspect outer coupling (11) temperature 10. Inspect sleeve (20) for corrosionindicator TEMP-PLATES for deterioration, damage to threads. No structural damage todebonding or discoloration of epoxy coating threads is acceptable.that prevents interpretation of indicating dots. 11. Apply corrosion preventive treatment, if11. Apply corrosion preventive treatment, ifIf deterioration, debonding, or discoloration of parts are not processed immediately afterepoxy is found, replace TEMP-PLATES in inspection (paragraph 65-39).accordance with paragraph 65-9A.

65-50. Repair.8. Inspect duplex bearing (19) for roughnessand spalling, scoring, pitting, brinelling, MATERIALS REQUIREDflaking, and corrosion on rolling element orraces and for cracked or broken retainers NUMBER NOMENCLATURE(figure 65-30). Minor nicks, cuts, or scratchesare acceptable provided they are too small to C-108 Bru s h Cad m i u mbe felt with a probe having an end radius of Plating Solution0.030 in. (0.762 mm), and provided total C-500 Crocus Clothaffected area does not exceed 10% of contactarea at any point. Minor circumferential C-434 Tapescoring is acceptable on rollers and races C-464 India Stoneprovided it cannot be felt with a probe, havingan end radius of 0.030 in. (0.762 mm) andprovided affected area does not exceed 10%of contact area at any point.

9. Inspect coupling retaining bolt (8, figure65-28) visually for damaged threads. Replacebolts with malformed threads.

65-00-00Rev. 3 Page 74A/74B

BHT-212-CR&0

18. Inspect outer coupling (11) temperatureindicator TEMP-PLATES for deterioration, Figure, Nomenclature Codedebonding or discoloration of epoxy coating Index No.that prevents interpretation of indicating dots. 65-28, 2 PLATE FIf deterioration, debonding, or discoloration of 65-28, 6 Fepoxy is found, replace TEMP-PLATES in 65-28, 8 Bolt Maccordance with paragraph 65-9A. 65-28, 10 Inner coupling M

65-28, 10 Inner coupling M. nspect duplex bearing (19) for 65-28, 11 Outer coupling M

roughness and spalling, scoring, pitting, 65-28, 17 Spacer65-28, 17 Spacer Mbrinelling, flaking, and corrosion on rolling 65-28, Selement or races and for cracked or broken 65

65-28, 21 Pinion Fretainers (figure 65-30). Minor nicks, cuts, or 65 , 21 nionscratches are acceptable provided they aretoo small to be felt with a probe having anend radius of 0.030 in. (0.762 mm), and 13. Apply corrosion preventive treatment, ifprovided total affected area does not exceed parts are not processed immediately after10% of contact area at any point. Minor inspection (paragraph 65-39).circumferential scoring is acceptable onrollers and races provided it cannot be feltwith a probe, having an end radius of 0.030 65-50. Repair.in. (0.762 mm) and provided affected areadoes not exceed 10% of contact area at any MATERIALS REQUIREDpoint.

Refer to BHT-ALL-SPM for specification andI10. Inspect coupling retaining bolt (8, figure source.65-28) visually for damaged threads. Replacebolts with malformed threads. NUMBER NOMENCLATURE

11. Inspect sleeve (20) for corrosion C-108 Brush Cadmiumdamage to threads. No structural damage to Plating Solutionthreads is acceptable. C-500 Crocus Cloth

12. Inspect following parts by magnetic C-434 Tapeparticle (Code M) or fluorescent penetrant(Code F) (BHT-ALL-SPM), as applicable. C-464 India StoneDemagnetize parts after magnetic particleinspection.

65-00-00Rev. 4 Page 74A/74B

BHT-212-CR&O

5

12 11 10 9 8


1 Pinion (Bearing Contact Area - OD 1.2395 31.4833 1.2399 31.49346Diameter must not vary more than0.0001 (0.00254 mm) over entirelength)

2 Pinion (Bearing Contact Areas) OD 1.5751 40.00754 1.5758 40.025323 Duplex Bearing OD 3.1491 79.98714 3.1496 79.999844 Sleeve, Input OD 3.5597 90.41638 3.5605 90.4367

Average5 Spline, Pinion Over pins 1.4424 36.63696 1.4465 36.7411

(Use 0.0960 IN. (2.4384 mm)diameter pins)

6 Spline, Inner Coupling Between pins 1.1465 29.1211 1.1578 29.40812(Use 0.0960 IN. (2.4384 mm)diameter pins)

7 Teeth, Inner Coupling Over pins 2.1590 54.8386 2.1740 55.2196(Use 0.1080 IN. (2.7432 mm)diameter pins)

8 Spline, Outer Coupling Between pins 1.8290 46.4566 1.8360 46.6344(Use 0.1309 IN. (3.32486 mm)diameter pins)

9 Spline, Spacer Between pins 1.1780 29.9212 1.1810 29.9974(Use 0.0864 IN. (2.19456 mm)diameter pins)

10 Spacer, Splined 1.7470 44.3738 1.7510 44.4754(Seal Contact Area)

11 Sleeve, Input ID 3.1492 79.98968 3.1499 80.0074612 Duplex Bearing ID 1.5745 39.9923 1.5749 40.00246

NOTE

1 Maximum allowable depth of wear 0.005 inch (0.127 mm) (measure from unworn face of tooth).212-R-65-29

Figure 65-29. Tail rotor gearbox input quill wear limits

65-00-00Page 75

BHT-212-CR&0

A Acceptable pattern typical of low operatingtime.

B Acceptable pattern typical of couplings whichhave operated with normal misalignment for alonger period of time than that shown in A.


D Acceptable pattern showing a pitted tooth.This condition Is acceptable on all teeth.

E Pattern shows a more severe condition oftooth pitting than that shown in D. There isno metal projecting above the normal face ofthe tooth, Indicating that the pitted area ispolishing over. This condition may exist on allteeth. Couplings with pits larger than 1/32inch (0.79375 mm) diameter should be re-placed. 212-R-65-30

Figure 65-30. Input quill coupling teeth wear pattern

65-00-00Page 76

BHT-212-CR&O

1. Replace parts which are not within MATERIALS REQUIRED (CONT)allowable wear limits.

NUMBER NOMENCLATURE2. Replace all seals, gaskets, and preformedpackings on reassembly.

C-211 Shellac3. Replace parts which are cracked, broken,warped, distorted, have malformed threads, or C-304 Solvenfail to pass inspection. C-308 Adhesive

4. Repair minor scratches, nicks, and pits on C-405 Lockwirenoncritical surfaces with crocus cloth (C-500).

C-490 Cork Stopper

5. Repair minor nicks, scratches, and burrson splines and gear teeth by dressing with SPECIAL TOOLS REQUIRED

SPECIAL TOOLS REQUIREDIndia stone (C-464).

6. Replace wear sleeve (18, figure 65-28) on NUMBER NOMENCLATUREreassembly or when seal is replaced.

T101307 Wrench7. Replace bearings which are spalled, T101560 Holding fixturescored, brinelled, pitted, discolored fromoverheating, have damaged or broken T101566 Barretainers, or do not roll smoothly.

T101599 Pressing tool8. Plate couplings (10 and 11) using brush T101600 Wrenchcadmium plating solution (C-108). Platingthickness to be 0.0001 to 0.0003 in. (0.00254 T101880 Sleeve toolto 0.00762 mm). Do not exceed 0.0003 in.(0.00762 mm) plating-thickness in sealcontact area. Do not plate external spline 1. Clean all parts with solvent (C-304) andteeth on inner coupling (10) and do not plate coat with gearbox oil. Do not handle dryinternal spline teeth on outer coupling (11). bearings with bare hands.Tape area not to be plated with tape (C-434)(BHT-ALL-SPM). 2. Install new No.9 short cork stopper (C-

490) (22, figure 65-28) in pinion (21) with9. Repair pinion (21) by dressing out minor shellac (C-211) (figure 65-29).nicks, scratches, and burrs with India stone(C-464). 3. Press duplex bearing (19, figure 65-28)

into sleeve (20) using T101566 Bar. Duplex110. Replace outer coupling temperature bearings shall have matching serial numbers,

indicator TEMP-PLATES if necessary face.indicator TEMP-PLATES if necessary be installed in pairs and be installed face-to-(Paragraph 65-9A).

65-51. Assembly.

MATERIALS REQUIRED

NUMBER NOMENCLATURE

C-015 Lubricant (Tube Pack)

C-201 Primer

65-00-00Rev.3 Page 77

BHT-212-CR&O

splines of outer coupling (11), as shown inCAUTION figure 65-28, detail B.

WHEN INSTALLING PINION INTO NOTEBEARING, USE CARE TO ONLYAPPLY PRESSURE TO PINION Seal (13) will be partially seated andHUB AREA. PRESSURE APPLIED inner coupling (10) will be used as aAT GEAR TEETH CAN RESULT IN backup, in reverse (detail B) to fullyCRACKS BETWEEN HOLES IN seat outer circumference edge ofWEB AND POSSIBLE FAILURE OF seal into outer coupling (11) sealPINION. groove.

4. Support inner race of duplex bearings c. Using inner coupling (10) as a backupwith T101599 pressing tool and press pinion (placed as shown in detail B) firmly press(21, figure 65-28) into sleeve (20). Exercise down (hand pressure only) on outer couplingcare to avoid damage to teeth of pinion. (11), simultaneously tuck outer circumference

edge of seal (13) with workaid into outer

5. Coat mating surfaces of wear sleeve (18) coupling (11) seal groove.and spacer (17) with primer (C-201). Place d. Continue pressing around seal (13)wear sleeve on spacer, with unchamfered end i orid u seal (13)toward shouldered end of spacer. Press wear wth orkaid unter seal (13) fully seatedsleeve onto spacer (detail A, figure 65-28) Remove inner coupling (10) from outerusing T101880 sleeve tool. Remove excess coupling (11).primer. Coat wear sleeve with gearbox oiland install spacer on pinion (21).

pack) (C-015) in internal spline of outer6. Apply adhesive (C-308) to faying surfaces coupling (11, figure 65-28) and inboard sideof seal (14) and nut (15). Press new seal of seal (13). Insert coupling (10) into outer(14) into nut (15) with lip of seal facing coupling (11) with small end through seal.inboard. Install new packing (16) on nut. (See figure 65-29 for cutaway view ofLubricate seal lip, packing, and threads of nut installed components.)with gearbox oil. Position T101560 holdingfixture on sleeve (20) and install nut (15). NOTEUse T101600 wrench to torque nut 100 to 150ft.lbs. (135.58 to 203.37 Nm) and secure with Ensure inner coupling (10) is correctlockwire (C-405). for intermediate and tail rotor

gearbox, overall length is 1.870 to1.880 in. (47.498 to 47.752 mm).

NOTE Tail rotor driveshaft hanger coupling

A workaid may be fabricated overall length is 2.070 to 2.080 in.(Chapter 65) to aid installation of (52.578 to 52.832 mm).seal (13, figure 65-28).

9. Position assembled couplings (10 and 11)7. Install seal (13) into outer coupling (11) on Splined end of pinion. Coat threads ofseal groove as follows: coupling retaining bolt (8) with gearbox oil.

Place washer (9) on bolt and thread bolt intoa. Apply a light coat of lubricant (tube pinion. Hold outer coupling (11) with

pack) (C-015) to outer circumference of seal T101307 wrench. Position square adapterp13). through wrench and torque bolt (8) 80 to 100

ft.lbs. (108.464 to 135.580 Nm).b. Install seal (13) into outer coupling (11)

seal groove with lip of seal toward internal 10 Place packing (7) on retainer (6). Coatpacking and retainer with gearbox oil andinsert retainer into bolt (8). If one hole in rim

65-00-00Page 78

BHT-212-CR&0

of retainer does not align with notch of inner 15. When tail rotor drive quill is installed oncoupling, pull retainer out, rotate it 90 ° and helicopter make an entry in helicopter log andreinstall. Repeat if necessary to obtain flex couplings lubrication log (BHT-212-MM)alignment. Install lock spring (4). with date of lubrication.

11. Extend outer coupling (11) so seal (13)aintinis against teeth of inner coupling (10). Coat ninternal splines of outer coupling withlubricant (tube pack) (C-015) to 0.12 in. MATERIALS REQUIRED(3.048 mm) depth over top of spline teeth. A Refer toworkaid may be fabricated (figure 65-6) toobtain depth of grease.

12. Place small end of centering spring (3) NUMBER NOMENCLATUREon boss of plate (2). Install plate (2), spacer C-309 Methyl-Ethyl-Ketone(5), and spring (3) into coupling and install (MEK)retaining ring (1) (figure 65-28).

13. Test quill as follows: Hold sleeve and 1. Clean external surfaces of input quillturn coupling. There should be a very light sleeve with MEK (C-309) and clean cloths. Dodrag caused by preload of oil seal and duplex not allow MEK to contact seals.bearings. Coupling and pinion should turnsmoothly. 2. Mask seal (14, figure 65-28) at outboard

end of quill.14. Tag tail rotor drive quill with date oflubrication and make an entry made in 3. Refer to paragraph 65-44 for paintingcomponent historical record, if quill is to be instructions applicable to input quill.returned to stock.

65-00-00 IRev. 4 Page 79 1

BHT-212-CR&0

Table 65-1. Magnetic Particle Inspection

NOTES: 1. Magnetization currents given in the following table are applicable tomagnetic particle inspection apparatus using DIRECT CURRENT (D.C.). Ifan ALTERNATING CURRENT (A.C.) apparatus is used adjust the current asfollows: ALTERNATING CURRENT (A.C.) = .667 x DIRECT CURRENT(D.C.)

2. Ferrous parts requiring magnetic particle inspection that are not addressed in theattached material are to be inspected in accordance with the general proceduresoutlined in MIL-STD-1949.

3. Part numbers listed applies to all successive dash numbers for that componentunless otherwise specified.

SET-UP AND MAGNETIZATIONNUMBER NOMENCLATURE CURRENT REQUIREMENTS

212-040-600-001 & -005 HANGER ASSEMBLY COMPONENTS

204-040-603-009 COUPLING SET-UP: PLACE PART OVER 1 IN. DIAMETER7, FIGURE 65-2 CENTRAL CONDUCTOR.

CURRENT FOR PRIMARY DIAMETERS:MAGNETIZE AT 1180 AMPS.

(OMIT COIL SHOT).


CURRENT FOR PRIMARY DIAMETERS:MAGNETIZE AT 3030 AMPS. OPTIONALCURRENT FOR SECONDARY DIAMETERS:MAGNETIZE AT 1700 AMPS.

(OMIT COIL SHOT).

212-040-602-001, SHAFT SET-UP: PLACE PART OVER 0.7 IN.-003 11, FIGURE 65-2 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).



(OMIT COIL SHOT).

65-00-00Page 80 Rev. 4

BHT-212-CR&O

Table 65-1. Magnetic Particle Inspection (Cont)

SET-UP AND MAGNETIZATIONPART NUMBER NOMENCLATURE CURRENT REQUIREMENTS

212-003-007 INTERMEDIATE GEARBOX COMPONENTS

212-040-500-005, PINION SET-UP: PLACE PART OVER 7 IN. DIAMETER-009 25, FIGURE 65-2 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).



(OMIT COIL SHOT).

204-040-612-001 BOLT SET-UP: PLACE PART OVER .375 IN.2, FIGURE 65-10 DIAMETER CENTRAL CONDUCTOR.


**CAUTION - CENTRAL CONDUCTOR MAYGET VERY HOT**.

(OMIT COIL SHOT).

204-040-604-005 COUPLING SET-UP: PLACE PARTS OVER 2 IN.11, FIGURE 65-10 DIAMETER CENTRAL CONDUCTOR.

CURRENT FOR PRIMARY DIAMETERS:MAGNETIZE AT 3030 AMPS. OPTIONALCURRENT FOR SECONDARY DIAMETERS:MAGNETIZE AT 1700 AMPS.(OMIT COIL SHOT).

65-00-00Rev. 4 Page 81

BHT-212-CR&0



212-040-004-005 TAIL ROTOR GEARBOX COMPONENTS

212-040-451-001 GEAR SET-UP: PLACE PART OVER 2 IN. DIAMETER3, FIGURE 65-21 CENTRAL CONDUCTOR.


SET-UP: 5 TURN COIL SHOT.

DISK-SHAPED PORTION OF PART: LAY PARTFLAT IN BOTTOM OF COIL. SHOOT AT 3000AMPS.

ROTATE PART ONE-QUARTER TURN ANDREPEAT.

212-040-462-001 SHAFT SET-UP: PLACE PART OVER 0.7 IN.1, FIGURE 65-21 DIAMETER CENTRAL CONDUCTOR.


**CAUTION - CENTRAL CONDUCTOR MAYGET VERY HOT**.

SET-UP: 5 TURN COIL.

HOLD PART IN BOTTOM OF COIL WITHLONGITUDINAL AXIS PARALLEL TO COILAXIS. MAGNETIZE AT 3240 AMPS. (LONGPART, SHOOT AT 15 INCH INTERVALS).



(OMIT COIL SHOT).



(OMIT COIL SHOT).

65-00-00Page 82 Rev. 4

BHT-212-CR&0



212-040-458-001 NUT SET-UP: PART OVER 2 IN. DIAMETER15, FIGURE 65-28 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-459-001 SLEEVE SET-UP: PLACE PART OVER 2 IN. DIAMETER20, FIGURE 65-28 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

212-040-450-001 PINION SET-UP: PLACE PART OVER 0.7 IN.21, FIGURE 65-28 DIAMETER CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

204-040-612-001 BOLT SET-UP: PLACE PART OVER .375 IN.8, FIGURE 65-28 DIAMETER CENTRAL CONDUCTOR.


**CAUTION - CENTRAL CONDUCTOR MAYGET VERY HOT.**

(OMIT COIL SHOT).

204-040-412-001 NUT SET-UP: PLACE PART OVER 1 IN. DIAMETER26, FIGURE 65-27 CENTRAL CONDUCTOR.


(OMIT COIL SHOT).

(TABLE I.D. 922004)

65-00-00Rev. 4 Page 83/84

Documents

BHT-212-CRO-4[1].PDF Rapair Manual Tail Rotor